Draft Statement of Work.pdf

High Frequency Sail Array (HFSA) Windows

1.0 Background

The Fleet Sensors and Cables Engineering Branch (Code 1535) of the Sensors and Arrays Division (Code 153) of the Naval Undersea Warfare Center, Division Newport (NUWCDIVNPT) serves as the Navy’s Technical Design Agent (TDA) and In-Service Engineering Agent (ISEA) and assists with all Acquisition Engineering Agent (AEA) activities for all surface ship and submarine transducers, hydrophones, and sensor assemblies (collectively referred to as transducers). Code 1535 maintains the Navy's transducer and associated acoustic window inventory in large part by establishing contract vehicles to procure transducers and acoustic windows that are delivered both to the stock system to support emergent fleet needs and to new construction shipyards for initial outfitting.

1.1 Places of Performance

All work will be performed at the contractor’s facility.

1.2 Authorized Users

NUWCDIVNPT Sensors and SONAR Systems Department, Code 15, is the only authorized user of this contract.

1.3 Sponsors

• PMS 401 Submarine Acoustic Systems Program Office

• PMS 450 Virginia Class Program Office

• PMS 397 Columbia Class Program Office

• Foreign Military Sales Office

• Type Commanders

• Naval Shipyards

1.4 Types of Funding

• Operation & Maintenance, Navy (O&MN)

• Other Procurement, Navy (OPN)

• Research, Development, Test & Evaluation, Navy (RDT&EN)

• Shipbuilding and Conversion, Navy (SCN)

• National Sea-Based Deterrence Fund (NSBDF)

• Foreign Military Sales (FMS)

2.0 Scope

The contractor shall design, document, manufacture, test, package, and deliver first article and prodution HFSA Windows that meet the performance requirements of the HFSA Window Critical Item Performance Specification (CIPS). The contractor shall also manufacture first article and production build-to-print items in accordance with their respective drawings: Acoustic Test Panel (Part Number: 8692176) and Sub-Element Test Panel (Part Number:

8692177).

There are four window variants, as follows:

Window Variants

Nomenclature Description NSN MX-12062/B SSN688I (Los Angeles) 5845014900963 MX-12063/B SSN774 (Virginia) 5845015121458

MX-12309/B SSGN/SSBN 5845015439703

MX-12351/U SSN21 (Seawolf)/SSBN826

(Columbia) 5845014900966

DRAFT

3.0 Applicable Documents

The contractor shall perform the tasking required in Section 4.0 in accordance with the below Applicable Documents.

3.1 COMMON SUBMARINE HIGH FREQUENCY SAIL ARRAY (HFSA) SONAR WINDOW

PERFORMANCE SPECIFICATION for VIRGINIA (SSN774), LOS ANGELES (SSN688I), SEAWOLF (SSN21), COLUMBIA (SSBN826), SSGN726 and SSBN730 CLASS SUBMARINES, 53711-7634166C dated 18 April 2022

3.2 HULL SENSOR SYSTEMS CONFIGURATION MANAGEMENT ENGINEERING

DRAWING REQUIREMENTS, 53711-00267RD, Rev C, dated 28 September 2020

3.3 HULL SENSOR SYSTEMS CONFIGURATION MANAGEMENT ENGINEERING

CHANGE DOCUMENT MANUAL, 53711-00266MN, Rev A, dated 28 September 2020

4.0 Technical Requirements

The contractor shall design, document, manufacture, test, package, and deliver the First Article and Production HFSA Windows that meet the requirements of Applicable Document (AD) 3.1. The Government will provide the following GFP to manufacture the HFSA Windows: MX-12062/B -SSN688I SONAR Window Mold, MX-12063/B -SSN774 Sonar Window Mold, MX-12309/B -SSGN/SSBN SONAR Window Mold, MX-12351/U SSN21/SSBN826 SONAR Window Mold. The contractor shall also manufacture first article and production build-to-print items in accordance with their respective drawings: Acoustic Test Panel (Part Number: 8692176) and Sub- Element Test Panel (Part Number: 8692177). Table 1 defines the requirements for this contract.

The following terms apply throughout this requirements section:

Table 1. Requirements

Task Task Description Contract

Timeframe CDRL Deliverable

4.1 GENERAL

Configuration Item The Configuration Item (CI) for this contract is the HFSA Window.

Functional Baseline The Functional Baseline is established at contract award and is defined by

AD 3.1.

First Article Baseline The First Article Baseline is established prior to First Article testing and consists of the engineering drawings and applicable revisions that define the CI.

Product Baseline The Product Baseline is established upon completion of the Functional and Physical Configuration Audits (FCA and PCA) and consists of the engineering drawings and applicable revisions that define the CI.

4.1.1 Contract Kick-Off

Meeting

The contractor shall conduct a contract kick-off meeting at its facility. The contractor shall prepare the kick-off meeting agenda. The contractor shall present its planned configuration and present a Program Objectives and Milestone Schedule (POAMS) for the First Article and Production phases to include:

- tasks and milestones

- requirements review

- data submittals

- schedule The contractor shall prepare conference minutes and shall submit the POAMS with the conference minutes.

Within 45 days after contract award

CDRL A001

DI-ADMN-81249C (Meeting Agenda)

CDRL A002

DI-ADMN-81250C

(Meeting Minutes)

4.1.2 Progress Reports The contractor shall prepare and submit Progress Reports using Government Furnished Information (GFI) item 5.1. The progress report shall contain contractual requirements, projected delivery schedules and amplifying information with delivery concerns, or progress.

Quarterly over the life of the contract

CDRL A003

DI-MGMT-81867 (Production Report)

4.1.3 Failure Reports The contractor shall handle all material it determines to be non-conforming. The contractor shall also handle all windows that fail a First Article or Production Acceptance test. The contractor shall submit Failure Summary and Analysis reports that identify the nature of the failure, and identify remedial and corrective action for preventing future occurrences.

Draft due 10 days after failure is identified.

CDRL A004

DI-SESS-80255B (Failure Summary and Analysis Report)

4.2 HFSA WINDOW FIRST ARTICLE PHASE

4.2.1 HFSA Window First

Article Hardware

The contractor shall design, document, inspect, fabricate, test, package and deliver the First Article HFSA Window including First Article Test Panels.

The contractor shall sequentially serialize the First Article window starting with FA001. The contractor shall fabricate the First Article HFSA Window including First Article Test Panels to meet the performance requirements of applicable document 3.1.

Prior to fabrication, the contractor shall perform 100% inspection of all incoming parts for the First Article window. The contractor shall record variables data for all dimensions specified on the drawings for all first article parts. The contractor shall have this information available at the First Article Physical Configuration Audit (see section 4.2.4).

Defined in Delivery Orders (DO)

Applicable Deliverables identified in subsequent sections.

4.2.2 HFSA Window

Preliminary Configuration Review (PCR)

The contractor shall conduct a PCR via Video Teleconference (VTC), conference call, or other remotely enabled delivery system. The purpose of the PCR is for the Government to evaluate the technical adequacy of the contractor's preliminary build configuration in meeting the Functional Baseline requirements. Prior to the PCR, the contractor shall submit Engineering Change Notices (ECNs) which document changes to the Reference Baseline (GFI 5.2) and which reflect its build configuration at the PCR. The contractor shall develop the drawing changes via ECNs and any drawing changes shall conform to NAVSEA requirements in accordance with applicable document 3.2.

Within 90 days after First Article window delivery order award.

CDRL A005

NUWC DRAWING 50225-

00266MN (Engineering Change Notice

4.2.3 HFSA Window

Final Configuration Review (FCR)

The contractor shall conduct an FCR at its facility.

The purpose of the FCR is for the Government to evaluate the technical adequacy of the contractor's final build configuration in meeting the Functional Baseline requirements. At the FCR, the contractor shall be prepared to review:

‐ the drawing package (GFI 5.2 and all ECNs previously submitted for PCR and

FCR)

‐ manufacturing flow chart which identifies the manufacturing build steps, in-process steps and inspection points and final production acceptance tests

‐ POAMS

‐ Any risks and mitigation plans if applicable

Prior to the FCR, the contractor shall submit ECNs which document any additional changes to the Reference Baseline (GFI 5.2) since the PCR and which reflect the final build configuration. The contractor shall develop the drawing changes via ECNs so that any drawing changes conform to NAVSEA requirements in accordance with applicable document 3.2.

The contractor shall provide to the Government ECNs which document any additional changes subsequent to the FCR.

The contractor shall resolve all technical discrepancies noted at the PCR and FCR and subsequent to the FCR, prior to delivering the First Article window.

After PCR and prior to delivering First Article window

CDRL A005

NUWC DRAWING 50225-

00266MN (Engineering Change Notice)

4.2.4 HFSA Window First

Article Physical Configuration Audit (FA-

PCA)

The contractor shall conduct an FA-PCA for the Government to validate that the components that comprise the First Article window match the technical documentation and that all key processes are properly documented. The contractor shall have copies of the reference drawing package and all ECNs from the PCR, and the FCR available for audit team members at the FA-PCA. The contractor shall have all First Article piece parts available and shall provide the incoming inspection variables data for all the parts. The contractor shall deliver any drawings that have changed since the FCR (which includes changes resulting from discrepancies identified at the PCR and FCR).

Prior to First Article window fabrication

CDRL A005

NUWC DRAWING 50225-

00266MN (Engineering Change Notice)

4.2.5 HFSA Window First

Article Test Procedures

The contractor shall develop First Article test procedures for contractor-performed tests and inspections in accordance with applicable document 3.1. The contractor shall include applicable acceptance and rejection criteria for First Article tests and inspections to ensure that the CI meets the requirements.

Prior to First Article testing

CDRL A006

DI-NDTI-80603A (Test Procedure-First Article Acceptance Test Procedures)

4.2.6 HFSA Window First

Article Baseline Configuration

The contractor shall document changes to the CI that occur between FA-PCA and First Article (FA) testing and include that information in the First Article Baseline Report.

The contractor shall submit ECNs which document any changes to the First Article Baseline since the FA-PCA and which reflect the final build configuration. The contractor shall develop the drawing changes via ECNs so that any drawing changes conform to NAVSEA requirements in accordance with applicable document 3.2.

Upon successful FA- PCA and prior to commencing First Article testing

CDRL A007

DI-MISC-80508B (Technical Report – Study/Services - First Article Baseline Report)

CDRL A005

NUWC DRAWING 50225-

00266MN Engineering Change Notice)

4.2.7 HFSA Window First

Article Test and Inspection

The contractor shall verify that the First Article window meet the CIPS requirements by performing First Article tests and inspections using the test procedures developed in SOW section

4.2.5. In the event that any First Article unit fails

to meet CIPS requirements, the contractor shall be responsible for redesign, rework, retest, and First Article unit replacement. The contractor shall submit a First Article Test Report detailing the contractor-performed First Article tests and corresponding test results for each First Article window identified by serial number.

After First Article fabrication

CDRL A008

DI-NDTI-80809B

(Test/Inspection Report- Contractor First Article Testing)

CDRL A004

DI-SESS-80255B (Failure Summary and Analysis Report)

4.2.8 HFSA Window

Functional Configuration Audit (FCA) and Physical Configuration Audit

(PCA)

The contractor shall conduct a concurrent FCA and PCA at its facility. The FCA is to verify that the CI is compliant with the CIPS; the PCA is to verify that the First Article CI conforms fully to the First Article Baseline. The contractor shall have the following documentation available for auditing at the FCA/PCA:

‐ The complete drawing package ‐ Inspection/Test Flow Chart with inspection/test criteria and procedures ‐ Manufacturing methods and process sheets ‐ Incoming inspection control procedures ‐ Production acceptance test procedures ‐ Test method sheets and standards selection procedures describing operation and calibration of test equipment

‐ Non-standard parts and parts requiring source control

‐ Material Review Board (MRB) and Failure Review Board (FRB) process and procedures

The complete drawing package includes the reference baseline drawings and all changes resulting from ECNs and discrepancies identified at the PCR, FCR, FA-PCA, and during FA testing phase.

Upon Government First Article testing completion

CDRL A001

DI-ADMN-81249C (Meeting Agenda)

CDRL A002

DI-ADMN-81250C (Meeting Minutes)

CDRL A005

NUWC DRAWING 50225-

00266MN (Engineering Change Notice)

4.3 HFSA WINDOW PRODUCTION PHASE

4.3.1 HFSA Window

Production Hardware

Upon receipt of delivery order, the contractor shall manufacture, test, package and deliver Production windows to meet the performance requirements of applicable document 3.1 and the Product Baseline provided as GFI 5.3. The contractor shall serialize the production windows in accordance with GFI item 5.4. The contractor shall package and deliver spare parts in accordance with applicable drawings of the Product Baseline provided in GFI 5.3.

Defined in Delivery Order

Applicable Deliverables identified in subsequent sections.

4.3.2 HFSA Window

Production Test and Inspection

The contractor shall develop Production Acceptance Test Procedures in accordance with applicable document 3.1. The contractor shall perform final acceptance testing of all production hardware items prior to delivery to the Government. Through acceptance testing, the contractor shall ensure that all HFSA Windows meet the requirements of applicable document 3.1 and the Product Baseline provided as GFI 5.3.

During active production

CDRL A009

DI-NDTI-80603A (Test Procedure-Production Acceptance Test Procedures)

4.3.3 HFSA Window

Production Acceptance Test and Inspection Reports

For each production unit, the contractor shall record actual test results by serial number, including date of acceptance by the Government.

In the Production Acceptance and Inspection Reports, the contractor shall identify units that failed Production Acceptance Tests or were otherwise accepted only after rework and retest and shall explain the circumstances and corrective actions taken where rework occurred.

During active production

CDRL A00A

DI-NDTI-80809B

(Test/Inspection Report- Production Acceptance Test and Inspection Data)

CDRL A004

DI-SESS-80255B (Failure Summary and Analysis Report)

4.3.4 Production Program

Reviews (PPRs)

The contractor shall conduct Production Program Reviews annually. The purpose of the PPRs is to review programmatic and technical issues.

During active production

CDRL A001

DI-ADMN-81249C

(Meeting Agenda)

CDRL A002

DI-ADMN-81250C (Meeting Minutes)

4.3.5 Engineering

Changes

The contractor shall prepare Engineering Change Documents in accordance with applicable document 3.3.

As required during production

CDRL A00B, A00C

DI-SESS-80639E,

DI-SESS-80640E (Engineering Change Proposal (ECP), Request for Variance (RFV))

4.4 HFSA Window BUILD-TO-PRINT ITEMS

4.4.1 HFSA Window Test

Panels

The contractor shall manufacture the Sub-Element Test Panels and Acoustic Test Panels using their respective drawings

Defined in Delivery Order

No CDRLs

NOTE: In the case of First Article waiver, task (and sub-tasks) 4.2 HFSA WINDOW FIRST ARTICLE PHASE will not be applicable and will be marked ‘RESERVED’ in the resulting contract award.

5.0 Government Furnished Information (GFI)

5.1 DD Form 375 Production Progress Report Form

5.2 NAVSEA HFSA Window Drawing Package (Reference Baseline)

Government will provide the contractor the HFSA Window engineering drawing package in pdf form for each of the four window variations. This forms the Reference Baseline.

5.3 NAVSEA HFSA Window Drawing Package (Product Baseline)

Contractor will redline the drawings for any updates. The Government will review all ECNs from the PCR, FCR and through FA testing. Upon successful completion of FCA/PCA the updated baseline drawing package will be released via ECP and the Government will assume configuration management control, any drawing will be advanced by a letter revision. The updated drawing package forms the Product Baseline.

5.4 Production window serial numbers

Block of serial numbers that the contractor shall use to serialize HFSA Windows.

5.5 Acoustic Test Panel Drawing #: 8692176

5.6 Sub-Element Test Panel Drawing #: 8692177