Attachment 01 - IBCS LRIP FRP Statement of Work.docx

Statement of Work for the Integrated Battle Command System (IBCS) Low Rate Initial Production/Full Rate Production (LRIP/FRP)

12 May 2020

PREPARED BY:

IAMD Project Office

ATTN: SFAE-MSL-IA

Redstone Arsenal, AL 35898-5710

Table of Contents

W31P4Q-08-C-0418 Attachment 0001-IBCS SOW

FOR OFFICIAL USE ONLY

W31P4Q-20-R-0015 LRIP/FRP

Attachment 01

1. INTRODUCTION

This Statement of Work (SOW), referred to herein as the Integrated Battle Command System (IBCS) Hardware Low Rate Initial Production/Full Rate Production (HW LRIP/FRP) SOW, is the primary document to support the IBCS hardware end item production for the Production and Deployment phase of the IAMD program.

Non-Personal Services: The Government will neither supervise contractor employees nor control the method by which the contractor performs the required tasks. Under no circumstances will the Government assign tasks to, or prepare work schedules for, individual contractor employees. It shall be the responsibility of the contractor to manage its employees and to guard against actions that are of the nature of personal services, or give the perception of personal services. If the contractor believes that actions constitute, or are perceived to constitute personal services, it shall be the contractor's responsibility to notify the Contracting Officer (KO) immediately.

Applicable top level documents cited in this SOW are identified by number, version, title, date, and category in the Document Summary List (DSL). The document versions specified on the DSL take precedence over the generic references (without revision letters) cited in the SOW.

Intellectual Property: To the extent this contract requires the delivery of technical data relating to this SOW, such technical data shall be provided with unlimited rights.

Flow Down To Subcontracts: All requirements of this SOW are required to be flowed down to the applicable subcontract level.

SCOPE

This requirement is a Hardware production effort, but also requires maintaining approved software & firmware updates, cybersecurity, Authority to Operate, etc. on existing hardware components; as well as, any engineering changes executed in the performance period of this effort. This IBCS HW LRIP/FRP segment is to produce the IBCS hardware end items in accordance with (IAW) the supplied Technical Data Packages and the Critical Item Development Specification (CIDS). Engineering changes may be required for obsolescence, new capabilities, and export considerations. In addition, discrete efforts to include new interface and integration efforts may be added by the Government and negotiated on a case-by-case basis and may cover program management, systems engineering, IBCS hardware and software end items modifications, integration, manufacturing readiness, test, logistics, cybersecurity, or any other effort required to support program objectives.

Additionally, the IBCS HW LRIP/FRP requirements incorporate a collaborative approach to integration/test at the SoS level where IBCS Hardware and Software must integrate and perform in a cohesive and synchronous manner; the Government will provide oversight on this collaborative approach at the SoS level.

The current IBCS System Unit Configurations are as follows (reference only):

Quantity per Echelon

IBCS Battalion (BN)

IBCS BN Totals

IBCS Composite BN

IBCS Composite BN Totals

IBCS IFPC BN

IBCS IFPC BN Totals

Table 1: IBCS System Unit Configurations

BACKGROUND

The AIAMD SoS program provides the capability to enable IBCS, sensors, and weapons on an Integrated Fire Control Network (IFCN). The program supports Air and Missile Defense (AMD) operations (e.g., air defense, airspace management, fire control, identification, surveillance, weapons control, and IFCN operations) across all Air Defense Artillery (ADA) echelons, and with Unified Action Partners (UAP). AIAMD SoS provides several new additional capabilities: the IFCN relays, and Plug and Fight (P&F) kits that integrate legacy systems Major End Items (MEI). Network enabled IBCS allows ADA command nodes the ability to use data from organic and non-organic sensors to support engagements by ADA systems. The Integrated Defense Design allows commanders and staff at all echelons to develop, evaluate, store, and implement plans that integrate all ADA components while P & F allows dynamic tailoring of IBCS, sensors, and weapons within the network as changes occur during operations. This ability to integrate multiple data sources in real time enables the development and utilization of advanced engagement concepts which expand the footprints and capability of systems which historically operated independently and potentially enable engagements of tracks that are not held by the interceptor's organic sensor. A key enabler for maneuver forces is the integration of IBCS into Air Defense Airspace Management (ADAM) Cells at Brigade Combat Team (BCT), Corps, and Division.

NOTE: Radio Frequency Set is also known as Integrated Fire Control Network (IFCN) Relay

The IBCS SoS is made up of four components:

1. Engagement Operations Center (EOC), the Army AMD integrated fire control center provides AIAMD command, staff and engagement functions;

2. Integrated Fire Control Network (IFCN) Relay, IFC network with Tactical Mast Trailers equipped with IBCS B-side adaptation kits;

3. IBCS Software, Common Warfighter Machine Interface (CWMI);

4. Adaptation Kits (A-Kits), Adapts legacy sensors/shooters to the IFCN (Sentinel, PATRIOT, IFPC/Avenger etc.).

General Requirements The Government is will provide the most current IBCS software to the contractor. The Government is responsible that the IBCS software provided to the contractor is qualified. The Government will provide all IBCS software related products and inputs required by the contractor to satisfy the requirement of this contract.

The contractor shall provide the necessary services, personnel, labor, facilities, materials, supplies, and equipment necessary to perform the requirements of this SOW which include the following:

a. Procuring, building, fabricating, integrating, testing and delivering CIDS and IBCS Technical Data Package (TDP). IBCS systems IAW Army Integrated Air and Missile Defense (AIAMD) System of Systems (SoS) (MIS-PRF-56500) (Attachment 02) is provided as a reference only.

b. End item interoperability with all other IBCS System or foreign end items as required.

c. Each supplier/vendor materials procured for IBCS shall be reviewed/inspected to meet TDP specification and CIDS requirements. The contractor shall provide a continuous improvement plan which addresses Pre-Planned Product Improvements (P3I) and Unplanned Product Improvements. The contractor shall provide recommendations to take advantage of new technology and maximizes the use of Army or DoD standard components to deliver increased capability, supportability, and survivability of the IBCS System.

d. The contractor shall deliver deltas (new or modified TDP elements developed as a result of this contract) to the Government provided TDP for all variants of the IBCS System, and provide such data with unlimited rights. The delta (new or modified TDP elements developed as a result of this contract) drawing package shall include all drawings necessary to integrate the IBCS System into design and manufacturing.

e. The Contractor shall provide the engineering, production (including facilities, tools/tooling, fabrication, and manufacturing equipment), and test engineering support; touch labor to support the requirements of the program office. This will include, but not limited to, support to logistics, test, quality, production, systems engineering, hardware, program management, obsolescence, cyber security, software and export control.

f. The contractor shall manufacture IBCS System components to support Army echelon from Platoon through Corps. The manufacture will include procuring, fabricating, and integrating the various components and subsystems, to satisfy the requirement for the IBCS System capability.

PRODUCTION (Fixed Price Incentive Fee) The contractor shall provide engineering support for production, integration, test, environmental stress screening, and software load test activities, including maintenance of automation and tools used in these activities. The contractor shall provide engineering subject matter expertise to isolate, analyze and fix hardware defects.

Engagement Operations Center (EOC) The Contractor shall fabricate, assemble, integrate, test and deliver EOCs, Part Number ALH-216012-001, IAW the provided product TDP included as part of the data library. Testing shall include execution of the attached Acceptance Test Procedures (ATP) IAW Attachment 04. The contractor will notify the Government no less than 5 days before the ATP testing begins. The contractor will include a copy of all inspection and test results as a part of the DD250 and maintain all inspection and test records associated with the end item and subassemblies.

Engagement Center Trailer (ECT) The contractor shall use Tobyhanna Army Depot via a Public/Private Partnership subcontract to build ECTs. The contractor shall utilize Part Number ALH-215170-001, IAW the provided product TDP included as part of the data library. The government will provide the Environmental Control Unit (ECU), Generator, and Trailer as shown in Attachment 03 (GFE List). The contractor shall notify the Government no less than 5 days before ECT final inspection at Tobyhanna. Testing will be conducted IAW the ATP in Attachment 04. The contractor will include a copy of all inspection and test results as a part of the EOC DD250 and maintain all inspection and test records associated with the end item and subassemblies.

Integrated Collaborative Environment (ICE) The Contractor shall fabricate, assemble, integrate, test and deliver ICEs, Part Number ALH-216012-003, IAW the provided product TDP included as part of the data library. The ICE shall be accepted and delivered as part of the EOC. Testing shall include execution of the attached ATP IAW Attachment 04. It shall be tested IAW the attached ATP Attachment 04. The contractor shall notify the Government no less than 5 days before ATP begins. The contractor will include a copy of all inspection and test results as a part of the EOC DD250 and maintain all inspection and test records associated with the end item and subassemblies

Integrated Fire Control Network (IFCN) Relay The Contractor shall fabricate, assemble, integrate, test and deliver IFCN Relays, ALH-216012-005, IAW the provided product TDP included as part the data library. Testing will include execution of the attached ATP Attachment 04. The contractor will notify the Government no less than 5 days before ATP testing begins. The contractor will include a copy of all test results as a part of the DD250 and maintain all records associated with the delivered end item and subassemblies

B-Kit The Contractor shall fabricate, assemble, integrate, test and deliver the B-Kit, Part Number 13758530, IAW the provided product TDP included as part the data library or as modified for an exportable configuration. The contractor will notify the Government no less than 5 days before the Final Acceptance Testing IAW Attachment 04. The contractor will include a copy of all test results as a part of the DD250 package and maintain all records associated with the delivered end item and subassemblies.

First Article Inspection (FAI) The contractor shall conduct a FAI on the first deliveries of deliveries made to the government. The contractor shall implement and maintain an FAI Plan IAW DI-NDTI-81307 (CDRL A001) IAW SAE AS9102. The contractor shall notify the Government at least fifteen days prior to conducting any FAI, so the Government may participate in the activity. The contractor shall prepare an FAI Report IAW DI-MISC-80508 (CDRL A002). The FAI Report shall include AS9102 referenced forms stamped by the supplier quality engineer and address the results and findings of the inspection.

For a lapse in production of 12 months or more, the contractor shall conduct an FAI. The contractor shall conduct an FAI on all new or modified HW not previously represented in the IBCS TDP IAW the Government Approved FAI Plan. The contractor shall notify the Government at least fifteen days prior to conducting any FAI, so the Government may participate in the activity.

Production Meetings, Reviews and Metrics Startup Meeting The contractor shall conduct a program start up meeting NLT 60 days ACA IAW DID DI-ADMN-81249B, Conference Agenda, (CDRL A003), using existing start up procedures and policies for the contractor. No policies or procedures shall be waived without government approval. The startup meeting shall establish the baseline for the program. Special emphasis shall be placed on RAID (Risks, Assumptions, Issues and Dependencies) log, and review milestones. The contractor shall provide a conference report to include all artifacts NLT 5 days after the conclusion of the startup meeting IAW DI-ADMN-81308A, (CDRL A004).

System Metrics The contractor shall develop and implement a plan for managing this contract using quantifiable metrics. All reporting of metrics will be shown as trends with planned versus actual data points. All metrics will be updated as a minimum monthly. All metrics required in the SOW shall also be included in the plan. The plan shall have metrics for both production and new development efforts. The plan shall contain sample presentations of all metrics. The plan shall also contain a matrix showing the metric, the source of all data, the owner of the metric, frequency and level of review by the contractor IAW DI-MISC-80508 (CDRL A005). For a 12 month moving window forward and a 6 month moving window into the past, production metrics shall include schedule and quality metrics to monitor the effectiveness of the contractor’s manufacturing, quality, and subcontractor/supplier management programs. As a minimum, production metrics shall include the following:

· IBCS Hardware System Line of Balance (LOB)

· IBCS Hardware System second order LOB

· Touch Labor

· Support to touch labor

· GFE delivery LOB

· ATP discrepancies and resolution

· Production and Quality Metrics

· Waivers and deviations

· SCARS and CARS by vendor

· Contractors internal metrics for production

Manufacturing Management Program (MMP) The contractor shall develop and implement a MMP that meets the requirements of Society of Automotive Engineers (SAE) standard AS6500. The contractor shall document this program as part of their MMP and deliver IAW DI-MGMT-81889 (CDRL A006). The contractor shall include its plan for Manufacturing Readiness Assessments (MRAs) in the MMP. In accordance with AS6500, the contractor shall maintain a manufacturing surveillance process.

Integrated Program Reviews (IPRs) The contractor shall conduct IPRs with Government program personnel on a quarterly basis. The reviews shall cover the latest status of overall contract effort with emphasis on problems and achievements in all program areas to include the following: program metrics, costs, schedules, and risk. The contractor shall provide Review Packages IAW DI-ADMN-81373 (CDRL A007) and Meeting Minutes IAW DI-ADMN-81505 (CDRL A008) for all reviews.

Quality Quality Assurance (QA) Program The contractor shall maintain a quality system IAW current versions of ISO 9001, AS 9100, or equivalent system as agreed between the contractor and the Government. Any exclusion to the contractor’s quality management system shall be agreed to between the contractor and the Government. The contractor shall make available, for review by the Government, quality system procedures, planning, and all other documentation and data that comprise the contractor's quality system. The Government may perform any necessary inspections, audits, or evaluations to confirm conformance to requirements and adequacy of the quality system. Quality system procedures, planning, and all other documentation and data that comprise the contractor's quality system shall be made available to the Government via the contractor’s CSA system.

Program Product Assurance Plan The Contractor shall develop and implement a Government approved Program Product Assurance Plan (PPAP) IAW DI-QCIC-81722 (CDRL A009), that provides for effective application and integration of Quality Assurance, Reliability, and Parts Management principles and integration with other disciplines such as configuration and data management, systems engineering, design, test and logistics, to maintain the integrity of SoS Products. The PPAP shall describe the methodology used throughout all phases of the program (development, fabrication, test, delivery, and post-delivery support) to meet the quality requirements for this program. The contractor shall provide a quality program, and all inspections/tests required by the contract requirements are contained in the contractor’s production planning and manufacturing methods.

Corrosion Prevention and Control The contractor shall implement a Corrosion Prevention and Control Plan (CPCP) as a part of the PPAP (CDRL A009), using the DOD Corrosion Prevention and Control Planning Guidebook (https://www.corrdefense.org/Default.aspx) as guidance to ensure Corrosion Prevention and Control is addressed as part of the design of MEI improvements.

GFE Management Government Furnished Property (GFP) Accountability and Reporting The contractor shall manage the integration of GFE onto the production line and identify any potential GFE shortages 90 days before the need date on the production line. The contractor shall identify work arounds for any late or deficient GFE that will still allow for delivery of the MEI.

Property Records The contractor shall create and maintain records of all property accountable to the contract, clearly identifying between Government Furnished Materiel (GFM) and Contractor Acquired Property (CAP).

Property Accountability The contractor shall perform property administration IAW FAR 52.245-1, Government Property, to manage and account for Government property accountability. The contractor shall identify and inventory Government property accountable to the contract IAW DI-MGMT-80441 (CDRL A010).

Disposition of Property The contractor shall account for all excess or shortages of GFM and request disposition instructions via the Plant Clearance Automated Reutilization Screening System (PCARSS) IAW DFARS 252.245.7004. During the associated IPT’s as reference in SOW paragraph 5.7, the contractor shall provide status of excess or shortage of Government Furnished Materiel (GFM) and Government Furnished Equipment (GFE).

Configuration Management System & Audits

CM Program The contractor shall establish and implement a CM program IAW EIA-649-1 to manage the configurations provided under this contract. The program shall consist of configuration identification, configuration change control, configuration audits and reviews, configuration status accounting and data management. The contractor shall prepare and deliver CM Plan (CMP) IAW DI-SESS-80858 (CDRL A011).

Configuration Change Management The contractor shall only change the Government-controlled CD as a result of a Government approved Engineering Change Proposal (ECP). ECPs apply to hardware and firmware changes. The contractor shall prepare an ECP only after the Government has authorized preparation by an approved Change Request or by Government direction. The contractor shall prepare and deliver ECPs IAW DI-SESS-80639 (CDRL A012) with Notices of Revision (NORs) prepared IAW DI-SESS-80642 (CDRL A013). The contractor shall document all revised Government-controlled CD on an Engineering Release Records approved by the Government. The contractor shall prepare and deliver ERRs IAW DI-SESS-80463 (CDRL A014). The contractor shall update and deliver any TDP updates IAW DI-SESS-80776 (CDRL A015) and the associated TDP Selection Option Worksheet.

Request for Variance (RFV) The contractor shall prepare an RFV IAW DI-SESS-80640 (CDRL A016) against Government controlled documentation for any deviations.

Serialization, Lot and Block Control The contractor shall develop and implement a system for serialization and lot control IAW the approved IBCS CMP (CDRL A011). The contractor shall use this program for manufacturing, identification of required hardware, and lot and block control of hardware to be delivered under this contract. Furthermore, the contractor shall develop and register DoD Item Unique Identification (IUID) data IAW MIL-STD-130, and deliver via Wide Area Workflow by submitting an XML file or flat file through the Global Exchange Service or manually via the IUID Web Entry Site at http://www.bpn.gov/iuid.

Configuration Audits and Reviews Physical Configuration Audit (PCA) The contractor shall conduct PCAs / Delta PCAs for all major subassemblies at the time of the first article inspection to validate the PBL documentation. The contractor shall conduct an IBCS system level PCA to validate the final PBL documentation for each end product. The contractor shall prepare an IBCS PCA Plan IAW DI-SESS-81646 (CDRL A017).The contractor shall prepare a PCA Report IAW DI-SESS-81022 (CDRL A018). The Government may choose to co-chair all audits as a voting member.

Configuration Status Accounting (CSA) The contractor shall perform a CSA function IAW the contractor's Government approved IBCS CMP. The CSA data and information shall be recorded and reported for all CD. The CSA system shall depict the as-designed, as-built, and as-modified configurations and shall be indexed for ready reporting and retrieval. The contractor shall provide the Government with on-line access to the CSA system.

Data Management The contractor shall implement a data management program to control and track the delivery of data items required by the CDRL, DD Form 1423. The contractor shall host a Government accessible website to use for the on-line delivery of all CDRL items and deliver CDRLs formally to the Government via a Government hosted website.

Data Accession List The contractor shall prepare a Data Accession List (DAL) IAW DI-MGMT-81453 (CDRL A019) of all documentation developed as part of the effort. The contractor’s CM office shall provide individual documents listed on the DAL at the Government’s request. Upon notification from the Procuring Contracting Officer, the contractor shall furnish a copy of any DAL Requested Documentation IAW DI-MISC-80508 (CDRL A020).

Data Item Master Schedule The contractor shall provide a Schedule for Data Items IAW DI-MISC-80508 (CDRL A021). The schedule shall detail the previous month's submittals and data items forecasted to be delivered for the following month.

Manufacturing The contractor shall maintain production facilities and tooling necessary to meet a minimum production capacity of 12 EOC/ECT, 12 ICE, and 24 Relays per year on a 1/8/5 basis. The contractor shall provide a Production Capacity Plan to surge up to a maximum production capacity of 68 EOC/ECT, 43 ICE, and 58 Relays per year IAW Table 1. Contractor generated, maintained, or implemented producibility analysis documentation conducted during the IBCS program shall be available for Government review.

Parts, Materials and Processes (PMP) The contractor shall implement, and maintain, or comply with and maintain, a program that defines the criteria, procedures, and processes for the management and control of PMP.

PMP Plan The contractor shall develop and execute PMP Plan IAW DI-STDZ-81993 (CDRL A022). The PMP Plan shall address the requirements of MIL-STD-11991 and describe the parts and materials selection process, responsibilities for the evaluation, documentation and notification of part changes, manufacturing processes, and material changes. This process shall address allocation of system performance requirements to parts and materials requirements, consideration for performance tolerances, and define parts and materials qualification requirements that assure meeting system performance and reliability requirements. In addition, the Plan shall include flow-down requirements for parts and materials to suppliers for assemblies procured. The use of any of the problem PMPs listed in MIL-STD-11991, Appendix C, shall require Government approval.

PMP Program The PMP program shall ensure that the following: Parts performance, reliability, quality, and safety meet system performance requirements for the worst case system non-operating and operating environments over the system life cycle IAW the applicable CIDS found in the data library. Parts shall not be used outside vendor specifications without prior Government approval. Materials used shall produce equipment that meets system hardware performance requirements IAW the applicable CIDS for each respective delivered end item found in the data library. The PMP program shall include the necessary design effort, selection of materials, delineation of applicable finishes, techniques for deterioration prevention, and appropriate test programs to verify deterioration control. Finishes and coatings shall be applied as necessary to provide corrosion/deterioration protection. The paint system shall provide Chemical Agent Resistant Coating (CARC) characteristics. Manufacturing processes used to manufacture electronic hardware shall yield assemblies and equipment that meet system performance requirements of the CIDS. The PMP program shall describe the materials, methods, and verification criteria for producing quality electrical interconnections and assemblies and shall use process control methodologies for the planning, implementation, and evaluation of the manufacturing processes. Soldering shall comply with J-STD-001, class 3, and IPC-A-610, class 3. Cable and wire harness assembly workmanship shall meet the IPC/WHMA-A-620, class 3 standard, at a minimum.

Commercial Off-the-Shelf (COTS) Management Plan The contractor shall prepare, or update an existing, Commercial Off-the-Shelf (COTS) Management Plan for submittal and approval as a portion of the PMP Plan. The Plan shall meet the requirements of EIA-933.

Lead Free Control Plan (LFCP) The contractor shall prepare, or update an existing, Lead Free Control Plan (LFCP) for submittal and approval as a portion of the PMP Plan. The requirement for a Lead Free Control Plan shall be flowed down to suppliers of equipment that may include lead-free materials. The LFCP shall be IAW GEIA-STD-0005-1, “Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder” or its equivalent. In addition, the LFCP shall also include tin whisker mitigation plans in accordance with GEIA-STD-0005-2, “Standard for Mitigating the Effects of Tin Whiskers in Aerospace and High Performance Electronic Systems” or its equivalent, at control level 2C or equivalent. The contractor shall include in the LFCP any special design considerations, manufacturing process controls, test and qualification requirements, quality inspection and screening, marking and identification, maintenance and repair processes, and other steps taken to mitigate risks.

Non-Conforming Material The contractor shall notify and request approval from the Government via the Procuring Contracting Officer (PCO) for acceptance or use of nonconforming material (variances from contractor drawings and specifications). The contractor shall use a Material Review Board (MRB) process to document, evaluate, and recommend disposition of nonconforming material. The contractor shall prepare Standard Repair Procedures if so desired with approval by the Government IAMD Performance Management Directorate (PMD) Director prior to use. The non-conformance process shall include analyses of nonconforming material to determine root cause, recommendations for and preventive/corrective actions through implementation, and the tracking of nonconforming material dispositions that require a Request for Variance (RFV). The contractor shall include IAMD Project Office (PO) or designee representation on the MRB and shall notify the Government five (5) working days prior to the scheduled MRB. The contractor shall not give a disposition of “use as is” or “repair” through contractor action without Government approval of a RFV. The contractor shall control the identification, documentation, evaluation, disposition, and segregation requirements of non-conforming products. The contractor shall upon discovery, immediately notify the PCO and IAMD PO of any nonconforming material that exists in previously delivered products. Notification shall include a description of the suspected nonconforming material, potential risk or product impact, contract number, Part Number, National Stock Number (NSN), affected serial numbers, and/or lot numbers when applicable.

Counterfeit Parts Prevention The contractor shall prepare, or update an existing, Counterfeit Risk Management Plan IAW DI-MISC-81832 (CDRL A023). The Counterfeit Risk Management Plan shall meet the requirements of SAE AS5553 for electronic items and SAE AS6174 for non-electronic items. The contractor shall procure parts from original manufacturers or the original manufacturers’ franchised distributors. The contractor shall report counterfeits and suspected counterfeits to the Government and in the Government Industry Data Exchange Program (GIDEP), in accordance with the GIDEP Operations Manual, SO300-BT-PRO-010 and track using a risk mitigation plan or countermeasure to eliminate the problem.

Environmental Stress Screening (ESS) The contractor shall implement and maintain a manufacturing ESS program to include electrical and electronic components, circuit card assemblies (CCAs), Line Replaceable Units (LRUs), and MEI level. Screens shall include temperature cycling, vibration/shock, and power on/off cycling. The ESS program shall define, as a minimum, hardware indenture levels of ESS, selected screening profiles and rationale, and metrics used for evaluating ESS effectiveness. The contractor shall identify LRUs for ESS to include high failure rate items. The contractor may request Government approval to discontinue ESS on an item that the contractor deems ineffective. All requests to discontinue ESS on an item shall include objective data and rationale. ESS for COTS hardware may be performed at the original equipment manufacturer production facility. GFE, at the standalone level, is not required to receive ESS. The Government may recommend performing ESS at the MEI level. The ESS Plan shall be included as part of the PPAP (CDRL A009).

Manufacturing Readiness Assessments The contractor shall conduct assessments of manufacturing readiness in accordance with AS6500 with the Manufacturing Readiness Level (MRL) 9 evaluation criteria to take place approximately 120 days prior to Full Rate Production Decision at the contractor’s facility. The contractor shall provide all required resources to demonstrate that they meet the criteria of an MRL 9. The contractor shall lead the assessments at subcontractors/suppliers to include government participants. The contractor shall notify the Government at least 15 working days prior to the activity at each of the subcontractors/suppliers. The contractor shall identify high risk sources of supply, long-lead items, obsolescence issues, as well as other manufacturing risks. The selection of subcontractors/suppliers to be reviewed will be approved by the Government. The contractor shall develop and implement manufacturing maturation plans or their equivalent for areas in which the MRL is lower than the target MRL 9 for full rate decision. The contractor shall monitor and provide status at all program reviews for in-house and supplier MRLs and shall re-assess MRLs in areas for which design, process, source of supply, or facility location changes have occurred that could impact the MRL. The contractor shall be responsible for the closure of all issues identified during the MRAs at their facility and the subcontractor/supplier facilities. The contractor shall document findings of the MRAs in the Assessment of Manufacturing Risk and Readiness IAW DI-SESS-81974 (CDRL A024). All MRA findings shall be closed by the Production IPT, or accepted as a risk by the Government NLT 30 days prior to full rate production decision

Production Line Validation (PLV) Planning The contractor shall prepare and deliver a Production Line Validation Plan IAW DI-MISC-80508 (CDRL A025). The PLV plan shall be used to verify and demonstrate manufacturing planning and prove out the manufacturing processes, tooling, test equipment, work instructions, and test procedures. The PLV Plan shall include a procedure and associated criteria for the conduct of prime/subcontractor/vendor PLVs. The contractor shall correct manufacturing issues identified in order to reduce the risk. These corrections are defined as either improving upon the existing processes, implementing an alternate process, or identifying the issue as an acceptable risk per the contractor’s analysis to proceed forward without changing. This plan shall include any portion of the supply chain, including the prime contractor, meeting the conditions for PLV, which are defined as significant changes that effect personnel, facilities, equipment, tooling, and test equipment used for fabrication of the hardware, or a lapse in production of 12 months or more. In the event of a significant change occurring subsequent to the initial PLV Plan submittal, the contractor shall provide a recommendation to address the change, and the Government/contractor team will mutually agree to a path forward. The contractor shall prepare a report with the detailed manufacturing and process data supporting the PLV and submit IAW DI-MISC-80508 (CDRL A026).

Production Line Validation (PLV) Execution The contractor shall conduct PLVs using the production hardware to record the processes, documentation, tooling, and test equipment used during fabrication of the production hardware. The contractor shall notify the Government at least 15 business days in advance when major production line validation, demonstration, and prove out activities are scheduled so the Government may participate. The contractor shall conduct PLV activities at critical vendor facilities and prime contractor’s facilities. The contractor shall maintain PLV documentation as baseline documentation and it shall be available for Government review upon request. PLV criteria shall be defined and governed by the PLV procedure documented in the PLV Plan.

Vendor and Subcontractor Control The contractor shall develop, implement, and maintain a supplier quality control program to include supplier scorecard and describe subcontractor and vendor quality provisions as part of the PPAP (CDRL A009). The contractor shall assure the qualification of all suppliers and maintain an Approved Vendor List (AVL), or equivalent, with the procedures for additions to the AVL described in the PPAP (CDRL A009).

Qualification The contractor shall verify all hardware and firmware items are fully qualified and suitable for production and fielding to requirements IAW the applicable CIDS for each respective delivered end item found in the data library. The Government will deliver qualified IBCS software for the contractor to use in the hardware qualification. For changes to the qualified baseline, the contractor shall notify the Government as a part of the ECP process. The contractor shall prepare and deliver a qualification test plan and report IAW DI-NDTI-80566 (CDRL A027) and DI-NDTI-80809 (CDRL A028) that defines the contractor’s plan to qualify hardware at the LRU and MEI level. New designs or redesigns (hardware), process changes, a break in production of greater than 12 months, the move of the production line, or new vendor constitute a change to the qualified baseline.

Product Acceptance

Configuration Acceptance Prior to conducting the acceptance test for any hardware, the hardware end items configuration has been validated on the HCS by meeting all the requirements of the ATP Attachment 04 and Software Installation Instructions Attachment 05.

Acceptance Test Plan & Procedures The ATPs are included as Attachment 04. The contractor shall update and deliver the ATP IAW DI-NDTI-80603 (CDRL A029). The contractor shall develop and maintain Acceptance Test equipment for each MEI and include this approach in the ATP to be delivered IAW DI-QCIC-80553 (CDRL A030). The contractor shall perform acceptance testing on all hardware end items using the Acceptance Test Equipment, ATP, and Acceptance Test Plan prior to delivery to the Government. For vendor/subcontractor supplied COTS items that are to be used as spares, Certificates of Conformance and test reports/records from the supplier are acceptable to satisfy acceptance test requirements. The contractor shall request Government approval for changes to the Acceptance Test Plans, ATP, and associated equipment, to include SIE/STE. The contractor shall notify the Government at least five (5) working days prior to conduct of each Acceptance Test event in order for the Government to witness the testing.

The MEI Acceptance Test event shall:

The Acceptance Test Procedure results/reports, including supporting documentation and data that comprise the report, shall be made available to the Government via the CSA system.

SIE/STE Validation All SIE/STE and associated software and documentation will be validated by the Government prior to use for accepting End items and LRUs. The contractor shall verify the SIE/STE is ready for validation and notify the IAMD Performance Management Directorate a minimum of five (5) working days prior to scheduled validation. If SIE/STE is used by the contractor, the contractor shall develop an SIE/STE Validation Plan IAW DI-MISC-80759 (CDRL A031).

Hardware Risk Management The contractor shall implement a Risk Management Program that addresses hardware, cost/affordability, schedule, technical, performance, and reliability risk management IAW the IAMD Risk Management Plan Attachment 12, and develop and deliver Risk Reports IAW with DI-MGMT-81809 (CDRL A032).

PRODUCT ENGINEERING SERVICES (Cost Plus Incentive Fee) The contractor shall execute product engineering services by direction of a TO/DO and negotiated on a case-by-case basis based on the information contained in the contractor’s CLASS 1 Engineering Change Proposal (ECP) response prior to production. ECPs shall include program management, systems engineering, operations and support labor, IBCS hardware end items modifications, integration, component replacement, manufacturing readiness, test, logistics, and IBCS support in response to changes deemed necessary to achieving a LRIP and FRP decision or an exportable configuration

Production Engineering Support The contractor shall provide engineering support for production, integration, test, environmental stress screening, and software load test activities, including maintenance of automation and tools used in these activities. The contractor shall provide engineering subject matter expertise to isolate, analyze and fix hardware defects. The contractor shall provide in contractor format a monthly technical metrics report, to include analysis and recommendations.

ECP Process Preliminary ECP Preliminary ECPs shall be prepared and submitted to the Government in accordance with DI-SESS-80639 (CDRL A012).Preliminary ECPs must be dispositioned (approved or disapproved) before development of a Formal Class I ECP by a properly constituted Government Configuration Control Board (CCB) chaired by the IFMC Chief Technical Officer or their designated Government representative. Preliminary ECPs shall at a minimum address all applicable “Effects on Engineering, Support, and Other Product Attributes” as identified on page 3 of the ECP DD Form 1692 and also include, but not limited to: the resourced loaded IMS, cost estimate, and design concept.

Class I ECPs The contractor shall use the instructions in “DD Form 1692” or equivalent for assigning a Major (Class I) or Minor (Class II) classification to an ECP. Class I ECPs shall be prepared and submitted to the Government in accordance with the configuration management requirements of the SOW paragraph 5.10.2. Class I ECPs must be dispositioned (approved or disapproved) for implementation by a properly constituted Government Configuration Control Board (CCB) chaired by the IFMC Project Manager or their designated Government representative.

Class I ECPs shall at a minimum address all applicable “Effects on Engineering, Support, and Other Product Attributes” as identified on page 3 of the ECP DD Form 1692 to include, but not limited to: recommended design, recommended material, recommended supply source, recommended configuration documentation updates, recommended logistics documentation update, training device updates, recommended logistics package and support, IP associated with design, delivery schedule, tests, tests documentation, evaluation and operational advantages of design, non-reoccurring engineering cost, labor mix and cost, material cost, unit cost and design reviews.

Upon auditing, fact-finding, and/or negotiating the final price associated with the ECP, the Government will issue a separate TO/DO by which the contractor shall implement the proposed change.