BKNO3_PWS_v8.pdf

MANUFACTURING OF BORON/POTASSIUM NITRATE (BKNO3) PELLETS USING

SPECIFICATIONS

PERFORMANCE WORK STATEMENT

1.0 Scope of Work

The requirements in this document contain the information necessary to manufacture MIL-P-

46994 Type IIB BKNO3 for use in fleet deliverables at Naval Surface Warfare Center Indian

Head Division (NSWC IHD). Purchase of this material is part of Government First Article and production tests and deliveries of a rocket motor ignition device. The Contractor shall manufacture, test, and deliver First Article materials to the Government for test and acceptance.

Upon First Article material acceptance and invoice payment the Government will use these First

Article deliverables in a First Article Test (FAT) of ignition device assemblies, which may take as long as 6-9 months. It is recommended the Contractor not start manufacturing production deliverables until the Government has informed the Contractor of successful ignition device

FAT.

2.0 Applicable Documents

2.1 General Specifications

American National Standards Institute (ANSI)/National Conference of Standards

Laboratories (NCSL) Standards:

ANSI/NCSL Z540.3 Requirements for the Calibration of Measuring and Test Equipment

Department of Defense Military Specification

MIL-P-46994 Pellets/Granules Boron/Potassium Nitrate

International Organization for Standardization (ISO)/International Electrotechnical

Commission (IEC) Standards:

ISO 9001 Quality Management Systems

ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration

Laboratories

Society of Automotive Engineers (SAE) Standards:

SAE AS6174 Counterfeit Material; Assuring Acquisition of Authentic and

Conforming Material

2.2 Conflicting Document Requirements

If there are any conflicts between specifications, drawings, or requirements listed herein, the contractor shall notify the Contracting Officer (KO) and the Technical Point of Contact (TPOC), in writing for interpretation, clarification, and resolution.

3.0 Requirements

3.1 General

The Contractor shall fabricate, inspect, test, and deliver material in accordance with the applicable specifications. Material shall be packaged by part number and ready for use. The

Contractor shall provide, design, and fabricate all necessary tooling to manufacture and dimensionally inspect the material, and provide data as detailed herein.

3.1.1 Subcontractor and Supplier Performance

The Prime Contractor shall bear the ultimate responsibility for all deliveries and performance of all requirements under this contract. The Prime Contractor shall monitor and maintain all subcontractor relationships. At the Government’s sole discretion, the Government may apply quality and/or on-time delivery issues stemming from the work of a subcontractor to the Prime

Contractor’s quality performance metrics.

3.1.2 Kickoff Meeting

The shall be a Government/Contractor Kickoff Meeting to establish Government/Contractor interfaces within 15 workings days after contract award, or as mutually agreed to by the

Government and the Contractor. The anticipated meeting objectives shall include team introduction, general program discussions, as well as more specific information in regards to the supported program.

3.1.3 Safety Data Sheet

The Contractor shall provide a SDS in accordance with DI-SAFT-82112 per CDRL A001 for each deliverable lot.

3.1.4 Deliverable Lot Homogeneity

Deliverables for each line item shall be manufactured in one continuous production run or in one batch, under essentially identical conditions, from the same raw materials, and to be offered for acceptance at one time. A single continuous production run or batch may be used to meet several deliverable line items.

3.2 Test and Inspection

The Contractor shall maintain and control processes to inspect and test the material as described in this PWS. These processes should cover all phases from the ordering of the material to the

Government acceptance of the finished product.

3.2.1 First Article Testing

The Contractor shall complete First Article Tests in accordance with MIL-P-46994, Section 3.6, as well as submit First Article Test (FAT) samples to the Government.

The Contractor shall submit a first article sample prior to the first delivery of any production material. The first article sample shall be fully representative of the material proposed for production, and demonstrate the adequacy and suitability of the Contractor's processes and procedures in complying with the requirements set forth by the drawings and specifications.

Any production by the Contractor before formal acceptance of the First Article sample shall be at the Contractor’s cost risk. To ensure timely payment for the production lot deliverables the

Contractor should wait to start manufacturing production deliverables until after the Government has completed ignition device FAT.

3.2.2 Product Certification

The Contractor shall submit a Certificates of Compliance in accordance with DI-MISC-81356 per CDRL A002 to accompany the shipment of each lot, as required in Table 1. The certificate shall state compliance of the material with its respective drawing or specification, and the contract/order requirements. The certificate shall as a minimum state the company name, contract/order number, drawing or specification number, and date.

The Contractor shall submit a Certificates of Analysis in accordance with DI-MISC-80678 per

CDRL A003, showing the material has been sampled and/or tested and found to be within the minimum requirements of the specification/drawing, and as required in Table 1 below. The certificate shall be forwarded to the Government; one (1) copy to accompany the shipment (in the packing list envelope), and one (1) copy mailed to arrive at time of receipt of the shipment

(mark the certificate to the attention of the designated POC above). Each certificate must be traceable to the material covered by the certificate.

Both Certificates of Analysis and Compliance shall state, above the signature of a legally authorized representative of the company, the following:

“This certification concerns a matter within the jurisdiction of an agency of the United States and making a false, fictitious, or fraudulent certification may render the maker subject to prosecution under Title 18, United States Code 1001.”

Test Requirement

Certificate Specification Note

Material MIL-P-46994 3.1.1 Analysis

Formulation MIL-P-46994 3.1.2 Analysis

Binder MIL-P-46994 3.1.3 Analysis

Boron MIL-P-46994 3.1.4 Analysis

Dimensions MIL-P-46994 3.2 Analysis

Physical Properties MIL-P-46994 3.3 Analysis

Ballistic Properties MIL-P-46994 3.3 Analysis

Cracks or Laminations MIL-P-46994 3.4 Compliance

Workmanship MIL-P-46994 3.7 Compliance

Table 1: Certification Requirements

3.3 Quality Control

3.3.1 Quality System and Quality Control Processes

The Contractor shall maintain a quality system in compliance with ISO 9001:2015 standards, or equivalent, for the duration of the contract. The Contractor shall provide the Government a compliance certificate in accordance with DI-MISC-80678 per CDRL A004 within 15 working days of contract award. The Contractor shall submit a new compliance certificate to the

Government within 15 working days of any subsequent certification changes.

The Contractor shall maintain quality control processes to ensure products are in compliance with the applicable drawings, specifications, and contract. The Contractor shall maintain documentation to identify, record, and disposition nonconforming material or other characteristic discrepancies for the entire duration of this contract.

3.3.2 Acceptance of Product

Final acceptance of first article samples and production deliverables will be determined by

Government sample testing and certification verification at Government destination for each deliverable line item. Samples shall be tested in accordance with MIL-P-46994. The

Government shall complete FAT sample testing within 6-9 months of receipt of all documentation and deliverables associated with the relevant line item. The Government shall complete production sample testing within 60 days of receipt of all documentation and deliverables associated with the relevant line item

The Government reserves the right to perform additional inspection and testing to verify acceptability, which may include testing at other facilities.

3.3.3 Calibration System

Calibration of measuring and testing equipment shall, as a minimum, adhere to the requirements of either ANSI/NCSL Z540.3 or ISO/IEC 17025. The Contractor shall provide the Government a compliance certificate in accordance with DI-MISC-80678 per CDRL A004 within 15 working days of contract award. The Contractor shall submit a new compliance certificate to the

Government within 15 working days of any subsequent certification changes.

3.3.4 Government-Identified Nonconformity Reporting Procedures

The Government shall alert the Contractor to any nonconforming deliverables within one working day of identifying the nonconformity. The Contractor shall respond to with their recommended disposition on the deliverables within one working day. The Government reserves the right to deviate from the Contractor’s recommended disposition.

3.4 Preservation

The Contractor shall pack the BKNO3 in accordance with either Paragraph 5.2.1 or 5.2.2 of

MIL-P-46994B. The contractor shall package the BKNO3 in accordance with Paragraph 5.1.1 of

MIL-P-46994B. Completed lot packaging shall be labeled IAW MIL-P-46994B Paragraph 5.3.

The Contractor shall label completed outer packaging to include at least:

Component name

Drawing number and revision

Contract number

Manufacturer name and date

Quantity

3.5 Counterfeit Material

The Contractor shall maintain a counterfeit material prevention program in accordance with SAE

AS6174, or comparable. The Contractor shall notify the KO within five working days if material cannot be obtained from an authorized supplier.

4.0 Deliverables

The Technical Point of Contact and Contracting Officer (KO) for this contract will approve all deliverables as specified. The following Certificates shall include the signature of the

Contractor’s representative authorized to make such certification.

CDRL Data Item Description Section Title

A001 DI-SAFT-82112 3.1.3 Safety Data Sheet (SDS) Report

A002 DI-MISC-81356 3.2.2 Certificate of Compliance

A003 DI-MISC-80678 3.2.2 Certificate of Analysis

A004 DI-MISC-80678 3.3.1 /

3.3.3

Qualification Certification

4.1 Material Delivery

The Contractor shall notify the Contracting Officer 30 days in advance if the Contractor cannot meet the contract delivery schedule.

The Contractor shall be responsible for coordinating and shipping all the units below to the required destination. Lead times listed below represent the maximum allowable delivery timeframe; early deliveries are permitted.

Item Year Specification Rev AMD Nomenclature Qty UOI Lead [wks]

1 FAT MIL-P-46994, Type IIB B 4 BKNO3 Pellets 6 LB 22 ARO

2 Base MIL-P-46994, Type IIB B 4 BKNO3 Pellets 30 LB 12 AIFA

3 Option 1 MIL-P-46994, Type IIB B 4 BKNO3 Pellets 30 LB 22 ARO

4 Option 2 MIL-P-46994, Type IIB B 4 BKNO3 Pellets 30 LB 22 ARO

ARO – After receipt of order

AIFA – After igniter first article

Delivery address provided below:

NSWC Indian Head Division

5021 Safe Haven Way

Explosive Scales Facility, Building 1104

Indian Head, MD 20640-1525