Draft SOW RFI W909MY-20-R-A024 3kW Tactical Quiet Generator.pdf

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STATEMENT OF WORK

FOR THE

3 KILOWATT (kW) TACTICAL QUIET GENERATOR (TQG) SETS

January 28, 2019

Prepared By:

Product Director-Small Expeditionary Power Sources

SFAE-CSS-E2-S

Fort Belvoir, VA 22060 ii

TABLE OF CONTENTS

3 KILOWATT (kW) TACTICAL QUIET GENERATOR (TQG) SETS

STATEMENT OF WORK

1.0 SCOPE ----------------------------------------------------------------------------------------- 1

1.1 Government 3 kW TQG Set Program Office ----------------------------------- 1

1.2 Contract Data Requirements Lists (CDRL) ------------------------------------- 1

2.0 APPLICABLE DOCUMENTS ----------------------------------------------------------- 1

2.1 Department of Defense Specifications -------------------------------------------- 1

2.2 Department of Defense Standards ------------------------------------------------- 1

2.3 Department of Defense Handbooks ----------------------------------------------- 1

2.4 Purchase Description and Drawings ---------------------------------------------- 1

2.5 Availability of DOD Documents --------------------------------------------------- 1

2.6 Non-Government Standards and Other Publications ------------------------- 2

2.7 Availability of Non-Government Standards and Other Publications ------ 2

3.0 REQUIREMENTS -------------------------------------------------------------------------- 2

3.1 Order of Precedence ------------------------------------------------------------------ 2

3.2 Government Furnished Equipment (GFE) -------------------------------------- 2

3.3 Program Management --------------------------------------------------------------- 3

3.3.1 Conferences and In Progress Reviews -------------------------------------------- 3

3.4 DATA Submissions ------------------------------------------------------------------- 3

3.4.1 Digital Media -------------------------------------------------------------------------- 3

3.4.2 Electronic Mail ------------------------------------------------------------------------ 4

3.4.3 Access to Technical Data ------------------------------------------------------------ 4

3.5 Configuration Control --------------------------------------------------------------- 4

3.5.1 Configuration Baseline--------------------------------------------------------------- 4

3.5.2 Configuration Management System ---------------------------------------------- 4

3.5.3 Configuration Management Plan -------------------------------------------------- 5

3.5.4 Documentation Procedures --------------------------------------------------------- 5

3.5.5 Configuration Control Documentation ------------------------------------------- 5

3.6 System Test and Evaluation -------------------------------------------------------- 6

3.6.1 Test Concept --------------------------------------------------------------------------- 6

3.6.2 Test Plan First Article Production Test (PT) ------------------------------------ 7

3.6.3 First Article Pre Production Qualification Test (PPT) ------------------------ 7

3.6.4 First Article Production Qualification Test (PT) ------------------------------- 7

3.6.5 Inspection /Test Reports ------------------------------------------------------------- 7

3.6.6 Test Incident Reports (TIR) -------------------------------------------------------- 8

3.6.7 Failed Item Analysis Reports (FIAR) -------------------------------------------- 9

3.6.8 Physical Configuration Audit (PCA) --------------------------------------------- 9

3.7 Quality Assurance --------------------------------------------------------------------- 10

3.7.1 Requirements for Quality Assurance 10

3.7.2 Conformance Inspection/Test----------------------------------------------------- 12 ii

3.7.2.2 Conformance Inspection/Test Documentation -------------------------------- 13

3.8 Unique Item Identification (UID)133.8.1 Requirements of Unique Item Identification (UID)

3.8.2 Unique Item Identification (UID) Coding -------------------------------------- 13

3.8.3 Correction of Non-Compliant Equipment & Technical Data -------------- 14

3.8.4 Pricing of UID Requirements ----------------------------------------------------- 14

3.8.5 UID Data Submittals --------------------------------------------------------------- 14

3.9 Production Surge Requirement -------------------------------------------------- 14

3.9.1 Content -------------------------------------------------------------------------------- 15

3.10 Pollution Prevention Program ---------------------------------------------------- 15

3.10.1 Contractors Pollution Prevention Program ----------------------------------- 15

3.10.2 Environmental Law Non-Compliance ------------------------------------------ 16

3.11 Warranty (flow-through) ---------------------------------------------------------- 16

3.12 Integrated Logistics Support ------------------------------------------------------ 16

3.12.1 Preservation and Packaging ------------------------------------------------------ 16

3.12.2 Design Change Notice (DCN) ----------------------------------------------------- 17

3.12.3 Repair Parts and Special Tools List (RPSTL) --------------------------------- 21

3.12.4 Electronic Technical Manual Revision/Changes ------------------------------ 24

3.12.5 Family Tree --------------------------------------------------------------------------- 29

3.12.6 Training Materials ------------------------------------------------------------------ 29

APPENDIX A PROVISIONING REQUIREMENTS----------------------------------- 31

APPENDIX B DATA REQUIREMENTS FORM --------------------------------------- 33

APPENDIX C PROVISIONING DATA ELEMENT DEFINITIONS --------------- 35

TABLE A-II REQUIREMENTS FOR TECHNICAL MANUALS ----------------- 56

TABLE A-VI REQUIREMENTS FOR TECHNICAL MANUALS ---------------- 68

TABLE A-XV REQUIREMENTS FOR TECHNICAL MANUALS ---------------- 69

TABLE A-XVI REQUIREMENTS FOR TECHNICAL MANUALS ---------------- 71

ATTACHMENT A CONTRACT DATA REQUIREMENTS LISTS (CDRL)

1.0 SCOPE.

The objective of this effort is to procure 3 kW Tactical Quiet Generator (TQG) sets, through the use of the Government’s Build-To-Print Technical Data Package (TDP) to meet the requirements delineated in the Purchase Description (PD).

1.1 Government 3 kW TQG Set Program Office

DOD Product Director-Small Expeditionary Power Sources

ATTN: SFAE-CSS-E2-S

5850 Delafield Road, Bldg 324 Ft. Belvoir, VA 22060-5809

1.2 Contract Data Requirements Lists (CDRLs, DD Form 1423-1) See Attachment A.

2.0 APPLICABLE DOCUMENTS

The following documents are applicable to this Statement of Work and attached appendices to the extent specified herein.

2.1 Department of Defense Specifications

GEIA-STD-0007 -Logistics Product Data MIL-PRF-63010B -Performance Specification Manuals DoDM 4100.39 -Federal Logistics Information System (FLIS) Procedures Manual

2.2 Department of Defense Standards

MIL-STD-129R -Military Marking For Shipment and Storage MIL-STD-40051-2C -Preparation of Digital Technical Information for Page-Based

Technical Manuals MIL-STD-130 -Identification Marking of U.S. Military Property MIL-STD-2073-IE -Standard Practice for Military Packaging MIL-STD-2361 -DoD Interface Standard Digital Publications Development MIL-STD-3018 -Parts Management MIL-STD-1686C -Electrostatic Discharge Control Program For Protection of Electrical and Electronic

Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices

2.3 Department of Defense Handbooks

MIL-HDBK-1222F -Guide to the General Style and Format of U.S. Army Work

Package Technical Manuals DoD Handbook H6 -Federal Item Name Directory (FIND) (No document No.) -Department of Defense Guide to Uniquely Identifying Items

2.4 Purchase Description and Drawings

PD 6115-0076D -Purchase Description Generator Sets, Military, Tactical, Skid

Mounted, Diesel Engine Driven, 60 Hz TA 30554-98-831 -Generator Set, 3 kW, 60 Hz

2.5 Availability of DOD Documents

Unless otherwise indicated, copies of above specifications, standards, and handbooks are available on the ASSIST-QuickSearch website at quicksearch.dla.mil.

Handbook H6 is available at www.data.gov.

DoD Guide to Uniquely Identifying Items is available at www.dau.mil.

2.6 Non-Government Standards and Other Publications

ANSI/IEEE 200 -Electrical and Electronics Parts and Equipment, Reference

Designations for (w/Correction Sheet) ASTM D 3951-18 -Standard Practice for Commercial Packaging EIA Standard 632 -Processes for Engineering a System EIA Standard 649 -National Consensus Standard for Configuration

Management TECHAMERICA-STD-0016 -Standard for Preparing a Diminishing Manufacturing Sources and Material Shortages (DMSMS) Management Plan SD-22 -Diminishing Manufacturing Sources and Material Shortages GIDEP Manual -Government Industry Data Exchange Program (GIDEP) IAW GIDEP Operations Manual

2.7 Availability of Non-Government Standards and Other Publications ANSI documents are available from the American National Standards Institute, 25 West 43nd Street, 4th Floor, New York, NY 10036.

ASQ documents are available from the American Society for Quality, P.O. Box 3005, 611 E.

Wisconsin Ave., Milwaukee, WI 53201-3005.

ASTM documents are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, Pennsylvania 19428-2959, .

EIA documents are available from the Electronic Components Industry Association, 310 Maxwell Road, Suite 200, Alpharetta, GA 30009 and www.ecianow.org.

IEEE documents are available from the Institute of Electrical and Electronics Engineers, Inc., 3 Park Avenue, 17th Floor, New York, New York 10016-5997..

3.0 REQUIREMENTS

Unless otherwise specified herein, the contractor shall provide the facilities, services, personnel, parts, supplies, materials and equipment required to fabricate, assemble, manufacture, paint, inspect, test, and deliver the ordered quantities of 3kW Tactical Quiet Generator (TQG) sets, in accordance with the terms and quantities set forth in this contract and its Attachments and Appendices. The contractor shall deliver the 3kW TQG set IAW the delivery order, the Purchase Description (PD 6115-0076D), this statement of work, and the Government Top Assembly (TA) Drawings 30554-98-831.

3.0.1 TQG Requirements

The Contractor shall be responsible for providing the battery (PD 3.30.7.2.1), ground rods (PD 3.24), and the auxiliary fuel lines (PD 3.31.6) for each TQG in accordance with the requirements stated in PD 6115-0076D

3.1. Order of Precedence. The Order of Precedence for all requirements of this contract shall be 1) Purchase Description PD 6115-0076D 2) this statement of work, and 3) the Government Top Assembly (TA) Drawings 30554-98-831.

3.2 Government Furnished Equipment (GFE)

As GFE, 1 60Hz 3kW TQG will be provided FOB: Origin (freight on board). The Contractor is responsible for shipment from Fort Belvoir, VA and for the return shipping at the close of the contract.

3.3 Program Management

The contractor shall be responsible for establishing and maintaining an effective internal management and control system to ensure that the terms of this contract are met, resources are safeguarded, laws and regulations are followed, and reliable data are obtained, maintained, and disclosed through applicable contract data requirements. The management system utilized by the contractor shall provide for the capability to plan and control organization, schedule, cost, technical performance, accurate progress reporting procedures, and forecast potential results of alternate program actions.

3.3.1 Conference and In-Progress Reviews

The contractor shall ensure that appropriate personnel, including sub-contractors, are available to address order and resolve agenda items for In-Progress Reviews (IPRs). The Government reserves the right to IPRs to discuss contract issues on an as-needed basis. The IPRs will take place at either the Government or contractor’s facility at the discretion of the Government.

Frequency of IPRs held at the Government facility shall not exceed two times per calendar year.

3.3.1.1 Post Award Orientation Conference

The contractor shall convene a Post Award Orientation Conference at the contractor’s facility no later than 30 days after contract award. The Government will provide the agenda to the contractor five working days prior to the start of the Post Award Conference. The Guidance for changes to the existing electronic technical manual, including the Repair Parts and Special Tools List (RPSTL), and provisioning, shall take place at the Post-Award Conference. The contractor shall be prepared to discuss all technical manual, RPSTL and provisioning requirements. No more than 15 Government personnel will attend. The conference shall be no more than two days in duration. An exact date shall be coordinated with the Contracting Officer’s Representative (COR) after contract award.

3.3.1.2 Program Reviews & Meetings

Program reviews shall be conducted by the contractor as requested by the Contracting Officer’s Representative (COR) when needed. All program reviews will be held at the contractor’s facility or via teleconference, at the Government’s discretion. The contractor shall provide provisions, reports, and documentation to accommodate up to 15 Government attendees. Specific dates for all reviews shall be determined by agreement between the Contractor and COR to avoid scheduling reviews on weekends and holidays. In the event a meeting or program review is scheduled via teleconference, the Contractor shall provide scheduling coordination and a teleconference bridge with up to 10 lines.

3.3.1.3 Meeting Minutes

For all meetings and program reviews held, the Contractor shall submit meeting minutes via email to the Government. The meeting minutes shall contain all action items, and the status of all open action items from previous meetings. The submission shall be prepared and delivered in Microsoft Office file format (MS Word, MS Excel), reference CDRL A019, Conference Minutes.

3.4 DATA Submissions

Unless otherwise specified data deliverables required under this contract (as set forth on the CDRLs), upon Government approval and to the maximum extent practical, shall be submitted via e-mail to the COR.

3.4.1 Digital Media

Unless otherwise specified the digital file format for data deliverables shall be “Microsoft Word” word processor format. Spreadsheet data shall be in “Microsoft Excel” format.

Presentations shall be prepared and delivered in “Microsoft PowerPoint” AND PDF format.

3.4.2 E-Mail

The Government will provide the contractor an e–mail or file transfer address for submission of data subsequent to contract award. Data transmitted in this manner shall conform to requisite file formats. Classified information shall not be transmitted via electronic mail.

3.4.3 Access to Technical Data

The contractor shall provide in-plant access to Government personnel for all Technical and Logistics Data used in support of the 3 kW TQG set contract efforts. The contractor shall provide copies of all documents generated through the course of the contract when requested.

3.5 Configuration Control

3.5.1 Configuration Baseline (CB)

The Configuration Baseline for this contract will be:

Top Assembly 30554-98-831 (60 Hz) 3kW TQG Purchase Description (PD 6115-0076D)

The contractor shall be required to submit Configuration Control Documents in accordance with Paragraph 3.5.5 for Government approval for any changes to the baseline.

3.5.2 Configuration Management System

The Contractor shall establish and maintain an in-house documented procedure which ensures all of the Contractor’s activities have access to and use of the contractually specified CB, approved changes and departures, and affectivity data. The documented procedures and the data in use shall be available for Government review and use. No changes or departures from the CB are acceptable except for changes or departures which are submitted in accordance with the SOW, Scientific and Technical Reports, Configuration Control Documents (CCDs), and are approved by the Government and which are incorporated into the contract by the PCO.

3.5.3 Configuration Management Plan

The Contractor shall develop a Configuration Management Plan in accordance with CDRL A001, Configuration Management Plan. It shall describe the Contractor’s configuration management program; how it is organized and how it will be conducted. It shall also describe the methods, procedures, and controls used to ensure effective configuration identification, change control, status accounting, and audits of the total configuration, including hardware, software, and firmware.

3.5.4 Documentation Procedures

The contractor shall establish and maintain an in-house documented procedure which ensures all of the contractor’s activities have access to and use of the contractually specified configuration baseline(s), approved changes and variances, and effectivity data. The documented procedures and the data in use shall be available for Government review and use.

3.5.5 Configuration Control Documentation

Contractor initiated change proposals (Engineering Change Proposal (ECP), Value Engineering Change Proposal (VECP), Request For Variance (RFV), Notice of Revision (NOR), and Specification Change Notice (SCN) shall be prepared in accordance with the formats and requirements specified in the applicable paragraphs of EIA Standard 649, this SOW, and CDRL A002, Configuration Control Document. Contractors shall not implement any change proposal until a contract modification is issued to implement the CCD, unless otherwise stated herein.

3.5.5.1 Documentation Content

Proposals shall identify any cost increases or cost savings and shall set forth a “not to exceed” price should negotiations be necessary. Proposals shall include sufficient technical data to describe the change from the current baseline, a justification for the change, and an impact if the change is not approved. Proposals shall address all logistics elements as required on the ECP Long Form.

3.5.5.2. Documentation Identification

Each ECP, NOR, RFV, drawing change or DA Form 2028 (Recommended Changes to Publications and Blank Forms), shall be uniquely and sequentially identified by the contractor.

Unique contractor forms are not to be used.

3.5.5.3 Documentation Submittal

The contractor shall submit the CCD to the Administrative Contracting Officer (ACO) and COR to confirm compliance with this statement of work. Within five working days of receipt, the ACO will provide a response stating whether or not the proposal is in compliance. Any unresolved differences between the ACO and the contractor shall be elevated to the Procuring Contracting Officer (PCO) for resolution. For proposals which the ACO has determined to be in compliance with this statement of work, the Contractor shall forward the original and copies per CDRL A002, Configuration Control Document.

Submittal of a preliminary ECP informally to the COR is permitted, however the Government is not obligated to provide a comprehensive review.

3.5.5.4 Contract Incorporation

Government acceptance of a proposal shall be accomplished by the issuance of a written contract change order or execution of a supplemental agreement incorporating said proposal. The Government will notify the contractor in writing regarding proposals determined to be unacceptable, with supporting rationale.

3.5.5.5 Configuration Control Identifications

The contractor shall identify to the Procuring Contracting Officer (PCO), Administrative Contracting Officer (ACO), and the technical office identified on the CDRL A002 Configuration Control Document, the name(s) of the official(s) of its organization who are authorized to sign Contractor change proposals within 30 DAC.

3.6 System Test and Evaluation

3.6.1 Test Concept

The purpose of this contract is to acquire 3 kW TQG sets through the use of the Government’s Build-To-Print Technical Data Packages (TDPs) with Purchase Description (PD). Production Qualification Testing (PQT) will be conducted as described in paragraph 3.2.2 of the 3kW TQG Purchase Description (PD 6115-0076D) prior to initiating full-rate production. The contractor shall notify the Government a minimum of 10 working days prior to start of any testing in order for the Government to have representation present, if desired. The contractor shall retain all test records for the duration of the contract and for three (3) years afterward. These records shall be available for review by the Government. At the conclusion of PQT the contractor shall contact the Government for disposition instructions for the sets.

The Contractor is authorized to utilize Major Range Test Facility Base (MRTFB) test facilities (such as Aberdeen Test Center) at DoD rates.

3.6.2 Test Plan

The contractor shall submit a Test Plan in accordance with CDRL A003, Production Qualification Test Plan, for the required PQT as defined in the PD 6115-0076D and this SOW. The test plan shall contain:

a. The delineation and allocation of tests to be performed on each unit and the order of such tests (this may be prescribed in applicable technical data).

b. Step-by-step test procedures for each test and the applicable data sheets to be employed to document the results of testing. (Test reports, TIRs, FIARs).

c. Identification of test facilities, equipment, and personnel.

d. Test milestones scheduled and the contractor’s test readiness posture.

e. A table which cross-references the paragraph number of the specification requirement and the associated paragraph number of the test plan.

3.6.3 Production Qualification Test (PQT)

The contractor shall conduct the Production Qualification Test (PQT) required by paragraph

3.2.2 of the 3 kW TQG Set PD 6115-0076D and this SOW. In support of PQT, the contractor shall provide Inspection & Test Reports in accordance with the SOW Paragraph 3.6.5.

3.6.4 Inspection /Test Reports

The contractor shall prepare Inspection and Test Reports in accordance with the SOW and the CDRL A004, Production Qualification Test Report, for the required Inspection/Test.

3.6.5 Test Incident Reports (TIR)

a. The contractor shall issue a TIR for each incident of failure (relevant, non-relevant, pattern or critical as defined in PD 6115-0076D, paragraph 6.3.7), and maintenance action (scheduled and unscheduled except PMCS checks for reliability and endurance testing, unless a failure has been discovered) that occurs during contractor testing.

b. TIRs shall be issued for all testing.

c. The TIR shall contain sufficient information to determine the cause of the test incident and any initial corrective action taken. Information on the TIR shall be documented in accordance with the SOW and the CDRL A005, Test Incident Reports. dates and a summary of the incident

d. The contractor shall inform the COR (via e-mail) within twenty-four (24) Hours upon occurrence of any incident.

e. TIRs shall contain the following minimum information:

1. Report Release Date.

2. Test Title.

3. Report Number.

4. Testing Agency.

5. System being tested.

6. Contract Number.

7. Item # (Serial #).

8. Type of Test being performed.

9. Number of hours accumulated during the particular test.

10. Total accumulated hours on system.

11. Date/Time of incident.

12. Testing Environment: Includes test environment and weather conditions (i.e.

environmental chamber and snow).

13. Part/Assembly Name: Name of part or assembly described on the TIR.

14. Part/Assembly Serial Number.

15. Manufacturer: Name of manufacturer for the Part/Assembly.

16. Part Life: Hours since part was last replaced/installed/adjusted.

17. Active Maintenance Clock-hours/Man-hours: Enter clock-hours and man-hours required to perform all maintenance for all tasks or actions being described in this TIR regardless of maintenance level. This will also include the number of personnel performing maintenance.

18. Type of maintenance performed (i.e. scheduled, unscheduled).

19. Level of Maintenance Used: name of highest level used to perform any of the maintenance being described on this TIR.

20. Incident/Maintenance Description: fully describe the incident or event and any resultant maintenance tasks.

3.6.6 Failed Item Analysis Reports (FIAR)

a. The contractor shall perform an investigation and analysis of each failure that occurs during contractor testing. Investigation and analysis shall be conducted to the hardware level necessary to identify the root causes, mechanism, and potential effects of the failures. Methods such as microscopic analysis, x-ray, thermal analysis, spectrographic analysis, etc., shall be used when appropriate to determine the failure cause.

b. The report (as a minimum) shall include the following: a) date of failure, b) date of report, c) name of engineer responsible for failure analysis, d) part number(s) of failed item(s), e) operational and environmental conditions under which failure occurred, f) description of the failure,g) the mode of failure, h) failure history of the item, i) complete details of the failure analysis, j) immediate corrective action taken, and k) recommendation for final corrective action (if different from immediate). The FIAR shall be prepared in accordance with the SOW and the CDRL A006, Failed Item Analysis Reports.

c. All hardware failures from system level down to the part level shall be subject to these requirements. Reports shall be issued for all failures occurring during all testing conducted under this contract, both contractor and Government testing including contractor prototype examination).

d. For purposes of this report, a failure shall be as defined in PD 6115-0076D paragraph 6.3.7.

e. Based on the corrective action the contractor shall retest all failed items.

f. Result of the FIAR shall be summarized and documented as part of the final test report.

3.6.7 Physical Configuration Audit (PCA)

The contractor in the presence of the Government and upon successful completion of the PQT will subject the initial production item(s) to a Physical Configuration Audit as defined below.

The Contractor shall conduct a Physical Configuration Audit (PCA) at the contractor’s facility within 30 days of conducting PQT. A Government team of not more than 5 personnel will observe the PCA and verify that the 3kW TQG hardware and TA 30554-98-831 (and all lower level drawings) are in agreement. The Contractor shall provide all current drawings, configuration documents, and other resources required for the Government team’s review.

Sufficient quantities of drawings, documents and resources shall be available to allow each member of the Government team to work independently or simultaneously in the observation of the PCA. Such resources shall include:

A. full sets of the current drawings;

B. isolation of the item(s) and detail parts to be reviewed (fully assembled hardware that cannot be broken down to parts that can be audited is unacceptable);

C. tools and inspection equipment necessary for evaluation and verification;

D. adequate space, desks, and tables for all Government personnel to perform the review;

E. appropriate personnel from each engineering, quality, test and manufacturing department to discuss specific issues, as requested;

F. access to the incoming inspection, fabrication, production, and testing facilities; and G. copies of any inspection reports, process sheets, data sheets, and any other documentation as deemed necessary and as requested by the Government team.

H. At least one 3kW TQG from the Contractor’s production line

Through this PCA, the Contractor shall show that each item and assembly accurately matches its drawing. When verifying dimensions, no more than two decimal places shall be verified. For example, if a dimension is “5.1234,” only up to 5.12 needs to be verified, with an applicable two-decimal place tolerance. The result of the audit shall be reported in accordance with CDRL A007, PCA Report.

3.7 Quality Assurance

Once production has begun, the contractor will be required to perform quality conformance inspections as per paragraph 4.6 Quality Conformance Inspection of the 3kW TQG Purchase Description (PD 6115-0076D). The Government, at its discretion during the contract production period, may select sets and subject them to examination as described in paragraph

4.9 Inspection Comparison of the 3kW TQG Purchase Description (PD 6115-0076D).

3.7.1 Requirements for Quality Assurance.

The contractor shall implement and maintain a Quality Assurance Approach that meets or exceeds the requirements established below. These requirements are commonly accepted practices employed by industry in both national and international manufacturing environments.

A Quality Assurance Plan shall be prepared and submitted for Government review and approval IAW the CDRL A008, Quality Assurance Plan. The plan shall include the contractor’s planned approach to quality control, and will include the following quality planning and achievement elements in addition to others already a part of their Quality control for manufacturing:

3.7.1.1 Quality Approach. The contractor shall establish/maintain a quality approach to satisfy contract and order requirements.

3.7.1.2 Initial Quality Planning. During the earliest practical phase of the contract, the contractor shall conduct a complete review of the contract requirements to identify all the resources necessary for assuring product integrity.

3.7.1.3 Design. The contractor shall establish/maintain controls over the design process, when applicable, to ensure that contract requirements are satisfied.

3.7.1.4 Document Control. The contractor shall establish/maintain procedures that control the adequacy, completeness, correctness, and changes of all documents (work instructions, drawings, specifications, etc.).

3.7.1.5 Records. The contractor shall maintain and utilize all records required for effective operation of the quality approach. The quality approach shall ensure that these records are complete (including subcontractor records) and reliable.

3.7.1.6 Control of Purchases. The contractor shall ensure that all supplies and services purchased from suppliers conform to contract requirements. The contractor shall require that their subcontractors control the product integrity of their services and supplies.

3.7.1.7 Government Furnished Material (GFM). The contractor shall be responsible for such GFM received under this contract, and shall be responsible for conducting all necessary inspections, maintenance, and tests. The contractor shall be responsible for reporting all inspection results, maintenance actions, losses, and damage to the Government.

3.7.1.8 Materials Control. The contractor shall maintain controls over all materials and products throughout the manufacturing process. These controls shall enable the identification of materials which have passed inspection from those which have not. The contractor shall maintain records identifying the status and final destination of all materials/products.

3.7.1.9 Nonconforming Material. The contractor shall establish and maintain a system for controlling any material which does not satisfy contract requirements, including procedures for its identification, segregation, and disposition (rework/repair, scrap, etc.).

3.7.1.10 Corrective Action. The contractor shall promptly detect nonconforming material and conditions adverse to product integrity, and shall then initiate the corrective actions required to satisfy contract requirements.

3.7.1.11 Manufacturing Operations/Process Controls. The contractor is responsible for assuring/monitoring that all manufacturing operations/processes are accomplished under controlled conditions. Controlled conditions include documented work instructions (including workmanship), production equipment, special work environments, inspections/tests, work specifications, and approval/rejection criteria.

3.7.1.12 Inspection and Testing. The quality approach shall ensure that all inspections and tests required to satisfy contract or order requirements are conducted.

3.7.1.13 Measuring, Testing, and Inspection Equipment. The contractor shall provide and maintain gages (including production tooling used for inspection purposes) and other measuring and testing equipment to ensure that products conform to contract requirements. These devices shall be calibrated against certified measurement standards which are traceable back to national/international standards.

3.7.1.14 Inspection and Test Status. The contractor shall maintain a system for the identification of the inspection and test status of all products throughout all stages of the manufacturing cycle.

3.7.1.15 Quality Audits. The contractor shall perform internal quality audits to verify the effectiveness of their quality approach.

3.7.1.16 Training Requirements. The contractor shall provide appropriate training for their personnel performing quality functions.

3.7.1.17 Statistical Quality Control and Analysis. The contractor shall establish/utilize statistical methods whenever appropriate to satisfy the contract or order requirements.

3.7.1.18 Continuous Process Improvement. The contractor shall monitor the effectiveness of their quality approach and continually improve quality processes.

3.7.1.19 Handling, Storage, Preservation, Packaging, and Shipping. As part of the internal quality process, the contractor shall establish and maintain procedures for handling, storage, preservation, packaging, and shipping to protect the quality of products and prevent damage, loss, deterioration, degradation or substitution of products.

3.7.2 Conformance Inspection/Test

The contractor shall conduct the Conformance Inspection/Test required by paragraph 4.6 of the 3 kW TQG Set PD 6115-0076D and this SOW. The contractor shall utilize test procedures from the First Article PT when similar tests are involved. In support of the Conformance Inspection/Test the contractor shall be responsible to provide the following:

3.7.2.1 Conformance Inspection/Test Failure Reporting.

The contractor shall provide written notification to the Government’s Quality Assurance Representative (QAR) within twenty-four hours of occurrence and corrective action taken. The contractor shall use their own format when providing written notification documentation. In addition the contractor shall notify the COR via e-mail and telephone within twenty-four hours of failure occurrence and corrective action taken.

3.7.2.2 Conformance Inspection/Test Documentation. The contractor shall prepare a Failed Item Analysis Report for any non-conformance in the Quality Assurance Discipline. The report shall be prepared IAW CDRL A006, Failed Item Analysis Reports.

The contractor shall be responsible for maintaining a complete record of all FIARs for the life of the contract and three years after its completion.

3.8 Unique Item Identification (UID)

3.8.1 Requirements for Unique Item Identification (UID). The contractor shall provide UID, or DoD recognized equivalent, for all items delivered. UID markings shall be IAW MIL-STD-130N. Placement and code assignment have been established for the 3kW sets incorporated into the Technical Data Package for the systems. Placement is found in drawing No. 98-831 and code assignment is in drawing No. 88-22842.

3.8.1.1 Commercial Markings. All other items shall have acceptable commercial markings that meet the guidelines in Department of Defense (DoD) Guide to Uniquely Identifying Items.

3.8.1.2 Permanency and Legibility. The UID marking and identification plates, tags, etching, or labels when used on equipment, parts, assemblies, subassemblies, units, sets, groups, or kits shall be as permanent as the normal life expectancy of the item and be capable of withstanding the environment, test, cleaning, repair, and rebuild procedures specified for the item. Legibility shall be as required and verified for ready readability per MIL-STD-130N.

3.8.1.3 Deleterious Effect. Marking of items shall be accomplished in a manner that will not adversely affect the life and utility of the item. Marking materials creating hazardous conditions shall not be used.

Placement and choice of the marking shall not create hazardous conditions.

3.8.2 UID Coding. UID markings and readability requirements shall comply with MIL-STD-130N.

3.8.2.1 UID Priority. The human readable characters and the machine readable UID symbol will be marked on the hardware. The order of priority when there are space limitations shall be in accordance with MIL-STD- 130N. The 2D machine readable UID is the minimum requirement when there are severe space limitations.

3.8.2.2 UID Location. If the technical data has not specified the marking location, markings shall be located such that they are visible during item use, provided that sufficient space is available, and does not interfere with equipment operations.

3.8.2.3 Serial Numbers. The contractor shall meet the requirements of MIL-STD-130N to establish the UID. The contractor shall insure that the UID is unique for that item from all other items forever.

3.8.2.3.1 UID List. The contractor shall maintain an accurate, current list of UIDs for all manufactured items on this contract. Dates of manufacture, substitutions, shop changes, etc. shall be included on this list. The list shall be available for inspection by the Procuring Contracting Officer

(PCO) or other Government representative at any time during the life of the contract.

3.8.3 Correction of Noncompliant Equipment and Technical Data.

3.8.3.1 Marking Requirement Corrections. The contract contains configuration control requirements.

The contractor shall initiate the appropriate configuration control document to correct all affected drawings/specifications which conflict with or omit the marking requirements stipulated above.

3.8.3.2 If the technical documentation of the item on order is in conflict with the requirements of this SOW, production of equipment with revised markings shall not proceed until Government approval is received.

3.8.4 Pricing of UID Requirements. All efforts required by this SOW, including the preparation of and the actual marking of hardware will be included in the base contract price.

3.8.5 UID Data Submittals: The contractor shall enter the UID data submittals into the Wide Area Work Flow (WAWF) system. See the DoD website for the latest information https://www.acq.osd.mil/dpap/pdi/eb/WAWFeBusinessSuite.html

3.9 Production Surge Requirements

The contractor shall submit a Production Surge Plan in accordance with this SOW and the CDRL DD Form 1423 for CDRL A009, Production Surge Plan.

3.9.1 Content. The Production Surge Plan shall consist of the following:

3.9.1.1 Rate. The maximum sustainable rate of production, to include a production buildup schedule by month until the maximum sustainable production rate is achieved. When applicable, a subcontractor’s or vendor’s capability to accelerate production/delivery of components must be taken into consideration and a statement shall be included in the plan verifying that this vertical planning has been done.

3.9.1.2 List of items. List the identifying subcontracted and non-subcontracted items/components, by nomenclature, part number, lead-time, and production buildup of long lead-time, critical, or pacing items/components which could adversely impact production rates.

Subcontractors and vendors shall be identified by name, address, and cage code (if available) for each item. This requirement shall flow down to whichever subcontractor tier (level) is necessary to adequately identify the long lead-time, critical, and pacing items/components.

3.9.1.3 List of contracts. A list of Government contracts being performed at the contractor’s facility that have a production surge provision or could reasonably be presumed to be surged or accelerated. The list shall identify the contract number, the item(s), and the Defense Priorities Allocation Systems priorities rating assigned to each contract.

3.9.1.4 Impact. Describe what impact surging this contract would have on the performance of any other Government contract that might be currently surged with this contract, or what impact surging of the other Government contract(s) would have on the ability to surge this contract.

Describe what impact surging this contract would have on the contractor’s commercial business.

3.9.1.5 Labor. Identify all additional skilled labor requirements, i.e., technicians, engineers, quality assurance, etc., necessary to support the maximum sustainable production rate.

3.9.1.6 List of materials. A list identifying strategic or critical materials and/or precious metals, by type, quantity and cost, required to produce the item on contract or the subcontracted/non-subcontracted long lead-time, critical or pacing items/components. This list should include rolling inventory to attain and maintain surge production within six months. Additionally, a list identifying any substitute materials that could be utilized in place of the strategic or critical materials and/or precious metals. Any components which use rare-earth magnets shall be identified to the COR.

3.9.1.7 List of production/test equipment and other resources. A list of tooling, equipment, other resources and costs down to the lowest tier subcontractor that, if acquired, would increase surge production rate capability and/or reduce lead-time by at least 10 percent, or as specified in the contract within current facilities limitations. The estimated increase in the surge production rate and/or decrease in lead-time shall be included. Data obtained under this paragraph will not be used in the preparation of the basic plan but may be used by the Government for developing additional surge capability if deemed essential.

3.10 Pollution Prevention

3.10.1 Contractor’s Pollution Prevention Program (PPP). The contractor shall establish a PPP IAW the Pollution Prevention Act of 1990. The purpose of the PPP is to eliminate or reduce (where elimination is not feasible) hazardous and environmentally unacceptable materials throughout the system life cycle, thus incurring the lowest possible cost required to ensure protection of human health and the environment.

3.10.2 Environmental Law Non-Compliance. Upon determination of any non-compliance of the contractor, subcontractor or suppliers, to any Federal, State, or local environmental laws, the Government will be notified immediately. This notification will include the following detailed information concerning:

(1) Nature and circumstances of the non-compliance

(2) Actions planned or taken to correct the situation, including milestones

(3) Approval of corrective actions by the responsible environmental regulatory agency.

(4) Actual or potential adverse impact(s) of such non-compliance on the program/product, if any.

3.11 Warranty (Flow-Through)

The contractor shall provide the Government the same component, manufacturer, and latent defects commercial warranties that are agreed to between the Prime Contractor and the Subcontractors/Vendors without supplementary cost to the Government. The contractor shall provide to the Government a list of components identified by CAGE code and Contractor Part Numbers that are under warranty with the duration of that warranty (in months from delivery of the end item to the Government), and provide updates of any changes to that listing as they occur. The listing shall be in contractor format and delivered IAW CDRL A010, Component Warranty List – 60 Hz.

3.12 Integrated Logistics Support (ILS)

This section contains the requirements for Integrated Logistics Support (ILS) products updates when program changes occur which impact the logistics support profile of the 3kW TQG sets.

Such changes may be necessary due to Government-approved Change Proposals which cause the logistics profiles to change.

3.12.1 Preservation and Packaging

Except when indicated otherwise, all items shall be packaged IAW ASTM D 3951-18.

3.12.1.1 Packaging. The level of Packaging shall be “commercial” as described in ASTM D 3951-18. This Commercial packaging with no preservation will be the default process. The commercial packaging price will be broken out in a CLIN and will be added to the set by default when no special packaging option is called out. Options for Military Packaging and/or preservation shall be IAW MIL-STD-2073-1E. Separate CLINs for the A/A type and C/B type Military packaging or preservation will provide the pricing for these options to be added to each set when used in lieu of commercial packaging.

3.12.1.2 Marking. All packages in this contract shall be marked IAW MIL-STD-129R.

3.12.1.3 PHYTOSANITARY MEASURES FOR WOOD PACKAGING MATERIAL (WPM)

TRANSITING INTERNATIONAL BORDERS 5 July 2006

3.12.1.3.1 This section is to invoke DoD requirement, Implementation of United Nations (UN) Food and Agriculture Organization (FAO) protocol on International Standards for Phytosanitary Measures (ISPM) 15. ISPM 15 is a protocol designed to block movement of pests that can destroy forests from one nation to another.

3.12.1.3.2 For all contracts that use bulk lumber that includes pallets, crates, boxes, and reels and dunnage composed of non-manufactured wood that will be used for packaging or the transportation of items, materials, etc. or for all contracts that require materiel to be packaged by the manufacturer, the following applies:

3.12.1.3.3 Non-manufactured soft and hard wood materials identified as intended for use in the construction of wooden pallets, wood containers, and blocking and bracing shall be heat treated (HT) to a core temperature of 56 degrees Centigrade for 30 minutes, certified, and marked by an accredited agency recognized by the American Lumber Standards Committee (ALSC) in accordance with their Non-manufactured Wood Packaging Policy and Non-manufactured Wood Packaging Enforcement Regulations, both dated 30 May 2001.

3.12.1.3.4 Interim Policy on Phytosanitary Measures for Wood Packaging Material (WPM) Transiting International Borders.

3.12.1.3.5 New WPM acquired by the contractor shall be compliant with International Standards for Phytosanitary Measures (ISPM) Number 15, Guidelines for Regulating Wood Packaging Material in International Trade, United Nations (UN), Food and Agriculture Organization (FAO). Within the United States, the contractor shall also adhere to the American Lumber Standard Committee (ALSC) and the National Wood Pallet and Container Association (NWPCA), guidelines on “Pest Free” WPM. In overseas areas, contractor shall procure all WPM in compliance with host nation implementation of UN IPPC Phytosanitary standards, if such standards have been implemented.

3.12.1.3.6 Existing WPM: The Contractors shall prevent non-compliant WPM from entering the DoD inventory. Non-compliant WPM shall be remediated into compliance by taking actions needed to allow the application of the DoD mark or IPPC international mark, by the most economic means, prior to entering the Defense Transportation System (DTS). The contractor shall inspect, treat, replace, or repack non- compliant WPM using the most economical solution that meets the required delivery date.

3.12.2 Design Change Notice (DCN)

3.12.2.1 The contractor shall develop changes to the Provisioning Parts List (PPL) as described by:

a. MIL-PRF-49506, Performance Specification for Logistics Management information and this entire paragraph (3.12.2).

b. CDRL A012, Design Change Notice.

c. Appendix A to this SOW entitled "Provisioning Requirements Statement".

d. Appendix B to this SOW entitled "Data Requirements Form".

e. Appendix C to this SOW entitled "Provisioning Data Element Definitions".

3.12.2.2 The contractor shall use Government supplied data (tape, drawings, RPSTL, etc.). The contractor shall use the data supplied on the Government-furnished CD readable by computers running the most currently utilized Microsoft Operating System, and furnish a CD readable by computers running the most currently utilized Microsoft Operating System to the Government containing only the changes to the PPL. The contractor shall submit Design Change Notices in accordance with the SOW and CDRL A012, Design Change Notice. DCNs shall document all differences between the Government furnished PPL and the configuration being produced under this contract and Engineering Change Proposals (ECPs), if applicable, which have been approved by the appropriate Government authority. DCNs shall document changes and impacts to any Technical Manuals. DCN data shall be provided to the Government on the required medium by completion of data blocks as shown by the Data Requirements Form (DRF), an appendix to this

SOW.

3.12.2.3 DCNs shall be supplied for changes to equipment or parts supplied by the contractor during this contract for any change that affects the part number of a part or assembly that is listed in the Provisioning Technical Documentation (PTD) or; any change that affects the listing of piece parts for a repairable assembly and any change that affects the Technical Manuals. PPL changes documented in the PTD should be developed in accordance with the following information.

3.12.2.4 The Data Requirements Form identifies the minimum data elements/card blocks to be delivered under this effort. Additional data elements/card blocks may be included in the PPL submitted by the contractor, provided that the minimum elements can be unambiguously retrieved from the submitted PPL.

3.12.2.5 If a new model is added to the PPL, the Usable on Code (UOC) of the new model must be added to all Provisioning Line Item Sequence Numbers (PLISNs) that are common to the new model. Only unique parts and new parts shall be given new provisioning lines.

3.12.2.6 The contractor shall be responsible for notifying the Government of any inaccurate Government data.

3.12.2.7 Special Tools required to fault isolate and repair the repairable items listed in the PPL, shall be included in the PPL. Special Tools are defined as tools, TMDE, or other support equipment designed and developed to perform a specific maintenance operation on specific assemblies or subassemblies of an end item. Common tools (those having multiple applications) shall not be listed in the PPL.

3.12.2.8 In the event that an item identified on a PPL has ceased to exist (i.e., not been replaced by a form, fit, and function equivalent item) for any reason, the…