Amendment_SOW.pdf

STATEMENT OF WORK

BRU-56/A Modification

Aircraft Ejector Bomb Rack (A.K.A. 30-inch Ejector Rack)

NSN: 1095014120831MW

P/N: L6410301-081

11 Sep 2018

Prepared by

AFLCMC/WWD

Air Force Life Cycle Management Center

B-1 System Program Office (SPO)

Tinker Air Force Base (TAFB), Oklahoma 73145

CONTRACT #: ______________________________

SOW #: AFLCMC/WWNMA-1305

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense (DoD) and U.S. DoD Contractors only,Critical Technology 15OCT2013. Other requests shall be referred to B-1 System Program Office (SPO) Configuration Management Office, AFLCMC/WWDSC, Tinker AFB OK, 73145.

EXPORT CONTROL WARNING: Warning- This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et. seq.). or the

Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et. seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document

Approvals

David Bourbonnais II

B-1B BRU-56 Modification Program Manager

Revision History

Change Number Date of Change Name of Person Making

Change

1 12 Dec 2017 Elizabeth Blanche

2 02 Jul 2018 David Bourbonnais II

3 26 Jul 2018 David Bourbonnais II

4 11 Sep 2018 David Bourbonnais II

Table of Contents

1 PROGRAM OVERVIEW

1.1 Purpose

1.2 Scope

1.3 Background

1.4 Program Phases

2 APPLICABLE DOCUMENTS

2.1 Applicability

2.2 Military/Federal Specifications, Handbooks, and Standards

2.3 USAF Publications

2.4 B-1 OEM Drawings, Lists, and Specifications

2.5 Other Applicable Documents

3 PROGRAM MANAGEMENT

3.1 Program Tracking

3.2 Technical Support

3.3 Technical Interchange Meetings

3.4 Warranty

3.5 Program Protection

3.6 Information Assurance (IA)

3.7 Government Furnished Property

3.8 Over and Above

3.9 Travel Requirement

3.10 Small Business Participation Plan (SBPP)

4 CONFIGURATION AND DATA MANAGEMENT

4.1 Configuration Management

4.2 Technical Data Package Changes

4.3 Engineering Change Proposals

4.4 Requests for Variance (RFV)

4.5 Notices of Revision (NOR)

4.6 Diminishing Manufacture Source and Material Shortages (DMSMS) Issues

4.7 Configuration Control Board (CCB)

5 REQUIREMENTS

5.1 Critical Safety/Critical Application Items (CSIs/CAIs)

5.2 Environmental Stress Screening (ESS)

5.3 Quality Assurance

5.4 Safety Lock Solenoid

5.5 External Envelope

6 INTEGRATED LOGISTICS SUPPORT

6.1 Integrated Logistics Support (ILS) Program Management

6.2 Logistic Support Analysis (LSA)

6.3 Task Analysis

6.4 Logistics Support Analysis Record (LSAR)

6.5 Supply Support

6.6 Support Equipment Recommendation Data (SERD)

6.7 Packaging, Handling, Storage, and Transportability (PHS&T)

6.8 Transportation

7 Training

7.1 Aircrew Training

7.2 Load Crew Training

7.3 Maintenance Training

8 Data Rights

9 EMD PHASE

9.1 Design Requirements

9.2 Certification Requirements

9.3 Documentation Requirements

10 TESTING

10.1 Laboratory Testing

10.2 Fit Check and Demonstration

10.3 First Article Test (FAT)

10.4 Hook Testing

10.5 Individual Quality Conformance Inspection and Test

11 PRODUCTION PHASE

11.1 Production Requirements

12 ACRONYMS

13 APPENDICIES

13.1 Appendix A: Packaging Form 158

13.2 Appendix B: PEP Template

13.3 Appendix C: SEMP Template

13.4 Appendix D: Support Equipment Recommendation Data (SERD) Template

13.5 Appendix E: Cost Funds Status Report (CSFR), DD Form 1586

1 PROGRAM OVERVIEW

1.1 Purpose

The purpose of this Statement of Work (SOW) is to define the requirements for the acquisition, integration and installation, test, and documentation to accomplish the B-1B Bomb Rack Unit

(BRU)-56 Modification program. This SOW will serve as the standard for determining if the contractor meets the stated performance requirements.

1.2 Scope

The scope of this SOW includes Engineering and Manufacturing Development (EMD) objectives, hardware and documentation, Developmental Test and Evaluation (DT&E) support, Operational

Test and Evaluation (OT&E) support, and Production Phase to implement the BRU-56

Modification on the B-1B aircraft.

1.2.1 This SOW defines the tasking required to design, develop, and test modifications to correct safety deficiencies on the BRU-56/A Aircraft Ejector Bomb Rack, (A.K.A. 30-inch Ejector

Rack), NSN: 1095014120831MW, P/N: L6410301-081 (hereafter referred to as BRU-56) and be able to produce and deliver the required number of modified BRU-56 racks.

Specific efforts described in this SOW involve the design, testing, modification/production, quality assurance, packaging, delivery and program management of the BRU-56.

1.2.2 This SOW defines the effort to modify the BRU-56 ejector rack, while still depending on a pyrotechnic system to provide the forces to actuate weapons release. The general scope is defined below. Details of these top-level requirements are listed in the subsequent paragraphs.

1.2.2.1 Design a modification that addresses the major areas that the United States Air Force

(USAF) has identified as required features of a modified BRU-56 IAW the BRU-56

SRD. Only the items identified in the SRD are considered required for this modification program.

1.2.2.2 Produce and deliver a performance specification, Interface Control Document (ICD), and complete detailed technical data package for the modified BRU-56. The drawings, specifications, and other data shall be delivered in a format that conforms to a Level

3, Type 3Db (3D models with 2D drawings) per MIL-STD-31000.

1.2.2.3 Provide design analyses and/or other proven methodologies (i.e. Computerized

Physical Fit, Computer Aided Design, etc.) to prove the design concept.

1.2.2.4 Perform the required hardware integration. Provide hardware prototypes of the redesign and subject the unit to various laboratory tests, aircraft installation and weapon fit checks, and flight tests.

1.2.2.5 The government shall provide 1 500 lb inert bomb, and 1 2000 lb inert bomb for fit check purposes. The contractor shall return the bombs back to the government upon fit check completion.

1.2.2.6 The contractor shall safeguard any/all Government Furnished Equipment (GFE) to prevent loss, theft, damage etc.

1.2.2.7 There is no limit on the number of technical reviews, but the maximum utilization and efficiency of Government and contractor resources shall be utilized. Design reviews shall be discrete and singular events that are the culmination of the various applicable technical reviews.

1.2.2.8 In accordance with the contract specifics, this SOW is broken into two primary phases, an EMD Phase to last approximately three years and a Production Phase to last approximately three years.

1.3 Background

1 . 3 . 1 The Air Force requires additional capabilities for the BRU-56 as part of the B-1 bomber mission requirements. The BRU-56 was originally designed to carry nuclear weapons with 30-inch lug spacing. Certain safety and functional issues have arisen over the years. Furthermore, additional munitions capability and flexibility, operational reliability and effectiveness, and reduced total ownership cost (RTOC) are needed.

1.3.2 A modification and upgrade to the BRU-56 ejector rack on the Multi-Purpose Rotary

Launcher (MPRL), to include 14-inch capability would contribute to increased safety, quicker sortie generation rates, lower maintenance times, increased reliability and lower maintenance personnel requirements.

1.4 Program Phases

The BRU-56 Modification program is divided into two phases: EMD, and Production.

2 APPLICABLE DOCUMENTS

2.1 Applicability

The following documents are applicable to this SOW to the extent specified herein. Unless otherwise stated, the following documents in effect for the request for proposal (RFP) shall form part of the SOW. The most current version of these documents, as of the date of this contract, shall be used.

2.2 Military/Federal Specifications, Handbooks, and Standards

Document Date Title

MIL-HDBK-516C 12 Dec 2014 Air Worthiness Certification Criteria

MIL-STD-882E 11 May 2012 Department of Defense Standard Practice for System Safety

MIL-STD-1760 1 Aug 2003 Aircraft/Store Electrical Interconnection System

MIL-STD-1553 30 Apr 1978 Aircraft Internal Time Division Command/Response

Multiplex Data Bus

MIL-STD-2088 29 May 2007 Bomb Rack Unit (BRU) Aircraft

MIL-STD-461G 2 Mar 2015 Electromagnetic Interference Characteristics Requirements for Equipment

MIL-STD-464 1 Dec 2010 Electromagnetic Environmental Effects Requirements for

Systems

MIL-STD-38784 25 Aug 2011 Standard Practice for Manuals, Technical: General Style and

Format Requirements

MIL-H-85042 11 Feb 1983 Hooks, Bomb Rack Specification

2.3 USAF Publications

Document Date Title

1B-1B-2-94GS-00 1 Feb 2017 Technical Manual, Weapons

1B-1B-33-2-1 1 Jun 2014 Technical Manual, Nonnuclear Munitions Loading

Procedures

11B29-3-75-2-

WA-1

15 Nov 2017 Technical Manual, Operation and Maintenance

Instructions with Illustrated Parts Breakdown, Aircraft

Ejector Bomb Rack (Ejector Rack) BRU-56/A, PN

L641031

00-5-1 14 Jun 2016 AF Technical Order System

AFI 63-101/20-

16 Sep 2016 Integrated Life Cycle Management

AFI 63-104 21 Jan 2005 The SEEK EAGLE Program

AFI 21-101 26 Jul 2010 Aircraft and Equipment Maintenance Management

DoDI 5000.02 2 Feb 2017 Operation of the Defense Acquisition System

AFPD 90-8 14 Mar 2017 Environment, Safety & Occupational Health

Management and Risk Management

2.4 B-1 OEM Drawings, Lists, and Specifications

L6410301-081 BRU-56/A Aircraft Ejector Bomb Rack, NSN:

1095014120831MW, Drawings and Associated Data

List

L6314022 14-inch Ejector Rack Hook Drawings/List

CP2569A06 Part I 2 Nov 1999 Specification for Rack, Ejector, 30-inch

CP2569A06 Part II 2 Nov 1999 Prime Item Product Fabrication Specification for Rack, Ejector, 30-inch

CP2569A04 Part I 18 Jan 1985 Specification for Rack, Ejector, 14-inch ejector rack specification

CP2569A04 Part II 14 Nov 1985 Prime Item Product Fabrication Specification for Rack, Ejector, 14-inch

GS2569A05B 24 Feb 1983 General Specification for Thermodynamic

Environment Design and Test Criteria

GS2569A03C 26 Jan 2016 General Specification for Vibration, Acoustic Noise, Shock and Acceleration Criteria

2.5 Other Applicable Documents

Systems Requirements

Document (SRD)

B-1B Bomb Rack Unit (BRU)-56

Modification Program

OC-ALCMAN 90-107 25 May 2017 Quality Manual

B-1 SEP Version 2.6 17 Feb 2017 B-1 Systems Engineering Plan

Program Protection Plan July 2017 B-1 Weapon System Protection Plan

B-1 Lancer Weapon System

Security Plan

12 Dec 2017 System Security Plan for the B-1

B-1 Program Protection Plan 11 Jan 2012 B-1 Weapon System Program Protection

Plan

BRU-56 SPI BRU-56 Special Packaging Instructions

3 PROGRAM MANAGEMENT

3.1 Program Tracking

3.1.1 Program Management Reviews

The contractor shall establish and maintain a program management system for total program management. The Contractor shall provide a Program Management Plan. The plan shall include the monitoring, implementation and performance based on cost, schedule and technical compliance with customer requirements. This includes providing a single point of contact Program

Manager to ensure proper planning, scheduling, visibility, control and performance of the BRU-

56 mod contract. The Contractor shall conduct a Post Award Conference Meeting, host an annual

Program Management Review (PMR) with the first PMR to begin approximately six months after contract award. The Contractor shall provide an agenda, presentation material, and minutes for all meetings. (CDRL A006, DI-ADMN-81250A/T) (CDRL A007, DI-ADMN-81373/T) (CDRL

A009, DI-ADMN-81249A/T) (CDRL D00E, DI-MGMT-81468/T) (CDRL D00F, DI-MGMT-

81797/T)

3.1.2 Financial Management

The contractor shall provide a Contract Funds Status Report (CSFR) in lieu of Earned Value

Management (EVM) - Appendix E. At a minimum, the CSFR shall include: (CDRL D00E, DI-

MGMT-81468/T)

3.1.2.1 Updating and forecasting contract funds requirements

3.1.2.2 Planning and decision making on funding changes in contracts

3.1.2.3 Developing funds requirements and budget estimates in support of approved programs

3.1.2.4 Determining funds in excess of contract needs available for deobligation

3.1.2.5 Obtaining rough estimates of termination costs

3.1.2.6 Determining if sufficients funds are available by fiscal year to execute the contract

3.1.3 Subcontract/Material Management

The contractor shall ensure proper flow down of the requirements to all subcontractors. The contractor shall implement and document procedures to monitor and control subcontractor(s), vendor(s), and material efforts. The contractor shall ensure the Government can participate in subcontractor reviews and other significant meetings. The contractor shall comply with all applicable Federal Acquisition Regulation (FAR) requirements (e.g., FAR Part 44) and its supplements and any other applicable law or regulation that pertain to subcontracting. The

Contractor shall promptly report subcontractor problems affecting schedule, cost, quality and performance to the PCO via e-mail.

3.1.4 Contractor Change Proposals

The contractor shall develop Contractor Change Proposals (CCPs), if required. CCPs shall be used to propose changes to contractual and non-technical documentation. Contractor shall provide a monthly status report. (CDRL A00A, DI-MGMT-80368A/T) (CDRL H006, DI-ADMN-

81401B/T)

3.1.5 Integrated Master Schedule

The contractor shall create, maintain, manage and deliver a B-1 BRU-56 Modification Inegrated

Master Schedule (IMS). Updates and/or schedule changes shall be accepted by the

Government prior to implementation. The BRU-56 Modification Program IMS shall include the necessary links to other programs it is dependent upon, or shares concurrent efforts with, to ensure awareness of potential impacts across individually managed programs. Details shall be such that the schedule(s) can be utilized by the government and contractor activity required to fabricate, procure, deliver modified BRU-56 ejector racks, and delivery of associated material/support equipment (as applicable). The IMS shall support program planning, tracking, decision/problem analysis(es), and schedule reporting. The IMS shall include all contractor and government decision and delivery activities. To ensure compatibility with both contractor and government resources, the contractor shall coordinate and gain approval for scheduling software used, and any proposed changes to the scheduling software with the program office prior to transitioning to the new schedule system. (CDRL A00Z, DI-MGMT-81861A/T)

3.1.6 Program Execution Plan

The contractor shall create and deliver a B-1 BRU-56 Program Execution Plan (PEP). A PEP template is located in Appendix B. (DI-MGMT-80909)

3.2 Technical Support

3.2.1 The contractor shall provide engineering technical support and assistance throughout the life of the contract. This includes telecons, emails, and onsite support. Onsite support locations may include Dyess AFB, Ellsworth AFB, Edwards AFB, and Eglin

AFB. Support functions will include, but are not limited to, backshop training, aircrew training, and SME support during ground and flight testing. The contractor shall participate in kickoff meeting, multiple Technical Interchange Meetings (TIMs) and readiness reviews as required by the Government Program Manager or Government

Engineer.

3.2.2 Systems Engineering Management Plan

The contractor shall develop and deliver a Systems Engineering Management Plan

(SEMP). A SEMP template is located in Appendix C. (CDRL D00K, DI-SESS-

81785A/T)

3.3 Technical Interchange Meetings

3.3.1 TIMs are a combined Government and contractor meeting and could be combined

Technical and Program Reviews. These shall be held quarterly and shall cover any of the following reviews as determined by the schedule:

1) Kick-Off Meeting

2) Requirements Reviews: Requirements Analysis and Specification Development

3) Design Reviews: As designated by acquisition schedule such as Program Design Review

(PDR), Critical Design Review (CDR)

4) Test Reviews: As designated by acquisition schedule, such as Test Readiness Review

(TRR)

5) Production Reviews: As designated by acquisition schedule, such as Production Readiness

Review (PRR)

6) Engineering Data Reviews: Guidance Conference, In-Process Reviews, Final Review

7) Plans & Reports Reviews: Qualification Plan, Quality Assurance Program, Foreign Object

Damage/Foreign Object Elimination (FOD/FOE) Control Process and Plan, Certification

Plan, Production Plan, Configuration Management Plan, Program Protection

Implementation, Test Plans (Ground, Flight, First Article, Environmental Stress Screening

(ESS), Individual Quality Conformance Inspection and Test, Acceptance)

8) Program Reviews: To discuss status of Cost, Schedule, and Performance

3.3.2 The TIMs shall be held at contractor facility or via Teleconference/Videoconference approximately 4 times per year or as directed by the Government. Where applicable, Program Reviews and Technical Reviews shall be consolidated and combined to be held at the same TIM. The TIM meeting minutes shall be provided by the contractor. The contractor will specify agenda and attendance requirements. The contractor shall submit Meeting Minutes to the Government for review IAW (CDRL A006, DI-

ADMN-81250A/T) (CDRL A007, DI-ADMN-81373/T) (CDRL A009, DI-ADMN-

81249A/T)

3.4 Warranty

The contractor shall provide the terms and conditions of any warranty including but not limited to covering workmanship, parts, and labor. This information shall be submitted with the contractor’s proposal.

3.5 Program Protection

3.5.1 The contractor shall follow current B-1 Program Protection Plan. The contractor shall comply with, and ensure its subcontractors comply with DoDI 5200.1R as it pertains to this contract. The contractor shall classify appropriately marked documents developed for this effort in accordance with Security Classification Guide (SCG) for the B-1 Aircraft, DoDD 5230.24, and DoDI 5200.01. The contractor shall assess their program for Critical

Program Information (CPI) and Critical Technologies as indicated by DoDI 5200.39, DoD

5200.1-M, DoD S-5230.28.

3.5.2 The contractor shall develop and deliver a Program Protection Implementation Plan (PPIP).

The Plan shall be reviewed annually at a minimum, and update it as required; based on revised information provided by the government, or as a result of changes in the contractor’s procedures. The contractor shall conduct PPIP unique training to personnel with access to sensitive, technical and CPI information annually at a minimum in accordance with DoDI 5200.39, to include all contractor developed PPIP requirements and emphasizing the changes in the latest version of the contractor’s PPIP. The contractor shall address Operational Security (OPSEC) per DoDD 5205.02, DoDD 5230.20 and DoD

5205.02-M in the PPIP. The contractor shall flow down this requirement to all subcontractors that have access to CPI information, as defined in the Program Protection

Plan (PPP). The contractor shall determine the need for subcontractors without access to

CPI information, as defined in the PPP, to develop OPSEC plans DoDD 5205.02.(CDRL

D00A, DI-ADMN-81306/T)

3.6 Information Assurance (IA)

3.6.1 Architecture

3.6.1.1 The network architecture shall maximize use of the contractor’s existing infrastructure and that of its subcontractors, suppliers, the Internet and the Government Wide Area

Networks (WANs), such as Non-classified Internet Protocol Router Network

(NIPRNET), Defense Research and Engineering Network (DREN). The contractor shall continue to utilize a network architecture which shall support the mission needs of the B-

1 Program for the purposes of interoperability while maintaining the quality and timeliness of the technical information data access and delivery. The contractor shall share all observed network trends; to be utilized in quarterly IA reviews for the purposes of ascertaining the success of the accomplishment of the preceding. The contractor shall implement electronic data sharing for the purposes of data reduction and to avoid transmitting large data files over the network.

3.6.1.2 The contractor shall address these requirements within the PPIP. (CDRL D00A, DI-

ADMN-81306/T)

3.6.2 Practices

The contractor shall adhere to the USAF’s IA Program prescribed methodologies for the protection of information to support USAF missions. The contractor shall utilize existing methods and processes in order to deliver secure, interoperable and integrated information management (IM) and information technology (IT) to the USAF and its contract support. The contractor shall ensure that all IT systems, software and interfaces meet Government security certification standards and requirements appropriate to the particular classification level of operation as specified by the

USAF, DoD, or other cognizant Government authority for the purposes of the above mentioned

USAF goals.

3.6.3 Electronic Mail (E-Mail)

The contractor shall utilize encryption via DoD PKI digital certificates on all e-mail messages containing Controlled Unclassified Information (CUI), and sensitive information, including but not limited to: For Official Use Only (FOUO) content, Privacy data, Contract Information, Unclassified Technical Data, Accountability information, Department of Defense Sensitive But

Unclassified (SBU) and e-mail that discusses any matter that may serve as an OPSEC indicator, per DoDI 8520.2. The contractor shall utilize PKI when interacting with DoD PKI Enabled information systems; and accessing DoD sensitive information.

3.7 Government Furnished Property

The Government will provide the following Government Furnished Property (GFP):

1) 1054 ea. L6410301-081 racks total

a. 44 units for EMD phase

i. 40 units for drop testing (included as part of 1044 production units to be delivered)

ii. 3 units for contractor use (will need these units returned back to

Government in F condition)

iii. 1 unit for contractor use for destructive testing

b. 1004 units for Production phase

c. 6 units for contractor facility spares (will be returned back to Government in F condition)

2) MK107s for testing – as required

3) Support equipment required for testing

3.7.1 Contractor Responsibilities

The contractor shall be responsible for safeguarding all Government Property, information and property provided for the contractor use in accordance with FAR Part 45 and 52.245-1 and will be responsible for all damages. If the contractor acquires any additional hardware not provided by the Government to accomplish this work, this property will belong to the Government and will be maintained on a property list and submitted to the Government for tracking. (CDRL A004, DI-

MGMT-80269/T)

3.7.2 Disposition of Materials

After CDR, a comprehensive listing of configuration items to be removed from the BRU-56 during the production phase shall be made available. At that time, the Government will provide disposition (de-militarization) instructions to the vendor for these removed items. The contractor shall provide a certificate of destruction for these items to the Procuring Contracting Officer

(PCO).

3.8 Over and Above

The Contractor May be authorized by the Procuring Contracting Officer (PCO) to perform over and above work requests to support unforeseen circumstances not specifically addressed in the

SOW.

3.9 Travel Requirement

The Contractor shall travel using commercial air and other conventional modes as required to support DT/OT test activities. The Contractor shall be responsible for obtaining all passenger transportation, lodging, and subsistence, both domestic and overseas, required in the performance of DOs.

Allowable travel costs are described in the Federal Acquisition Regulation (FAR) 31.205-46.

Travel costs not specifically covered at FAR 31.205-46 may be addressed on an as-needed basis.

Prior to traveling, the contractor shall obtain approval and provide a trip report to the government. The Joint Travel Regulation (JTR) does not apply to Contractors; however, may be used to aid the PCO in making individual decisions regarding travel rules. (CDRL A005, DI-

MISC-81943/T)

3.10 Small Business Participation Plan (SBPP)

The Contractor shall have a Small Business Participation Plan (SBPP) to manage subcontractor performance to meet and maintain the 10% annual Small Business Subcontracting Requirement

(by % of total contract value). The Contractor may utilize Second-Tier subcontractors in meeting this requirement but no lower tiers will be considered. This is in addition to the required

Small Business Subcontracting Plan (FAR 52.219-9 and DFARS 2523219-7003). The

Contractor shall deliver a Small Business Participation Report to demonstrate the effort in fulfilling the Small Business participation goals. (CDRL C001, DI-MGMT-81453A/T)

4 CONFIGURATION AND DATA MANAGEMENT

4.1 Configuration Management

The contractor shall establish a configuration control system – as described in ANSI/EIA-649, ISO

10007, and MIL-HDBK-61 – ensuring control of: (1) product identification, (2) document and change control, (3) traceability and verification of functional and physical requirements, and (4) design interface management. The Contractor shall submit for review and approval a

Configuration Management (CM) Plan describing their process. This will also include the CM performance of any subcontractor. The Government may periodically examine the contractor’s configuration control system to ensure the intended product design is maintained. The contract shall submit a Final Service Engineering Report at the end of EMD and Production phase. (CDRL

J012, DI-SESS-80858C/T) (CDRL B009, DI-MISC-81384/T)

4.2 Technical Data Package Changes

The Contract shall submit all changes to the Technical Data Package (TDP) for government acceptance and shall be submitted by the contractor through an Engineering Change Proposal

(ECP) for review and approval prior to implementation of the ECP and update to the TDP. (CDRL

C004, DI-SESS-80639D/T)

4.3 Engineering Change Proposals

The contractor shall submit ECPs for changes to Configuration Items that impact Government-approved configuration documentation in the TDP. ECPs are classified as either Class I or Class

II; MIL-HDBK-61 provides classification guidance. ECPs, if approved by the Government, will be implemented with a contract modification. Normally, the contractor shall submit a Class I ECP for the BRU-56 as a solicited ECP. Unsolicited Class I ECPs are discouraged; however, at the discretion of the PCO, a preliminary unsolicited ECP may be submitted. Circumstances that may justify an unsolicited ECP include: safety; compatibility; correction of defects; security;

technology improvements; or product improvement to reduce life cycle costs. (CDRL C004, DI-

SESS-80639D/T)

4.4 Requests for Variance (RFV)

The contractor shall prepare RFVs according to the definitions found in MIL-HDBK-61. The contractor shall ensure that all units impacted by an RFV are identified by serial number, lot number, or similar identifier that allows identification of affected units. The Defense Contract

Management Agency (DCMA) Quality Assurance Representative (QAR) shall review all RFVs for proper classification prior to submission to the PCO. Minor RFVs applicable to items other than Critical Safety Items (CSIs) or Critical Application Items (CAIs) may be approved (or disapproved) by the QAR, but the PCO shall be notified when a deviation is granted. (CDRL J008, DI-SESS-80640D/T)

4.5 Notices of Revision (NOR)

The contractor shall prepare a NOR that describes the proposed changes to a technical document being requested by an ECP. After ECP approval, the NOR is forwarded to the custodian of each specification, drawing, associated list, or other applicable document so they can make the required documentation changes. (CDRL J011, DI-CMAN-80642D/T)

4.6 Diminishing Manufacture Source and Material Shortages (DMSMS) Issues

The contractor shall identify any DMSMS and obsolescence items and issues. The contractor shall provide advance notification of anticipated obsolescence to items related to hardware and related software. This involves surveying all supplying vendors. The results shall identify parts that are, or are scheduled to become obsolete. Components surveyed shall include hardware and software, which may affect the form, fit, and/or function of the system. If configuration changes are required to correct the DMSMS issue, the contractor shall update the TDP and support additional

Government Configuration Control Boards (CCB). If additional testing is required, the contractor will follow the original program management processes, and perform technical reviews, and submit test plans and reports. (CDRL D010, DI-MGMT-81948/T), (CDRL C004, DI-SESS-

80639D/T), (CDRL A00E, DI-QCIC-80553A/T), (CDRL D007, DI-QCIC-81891/T)

4.7 Configuration Control Board (CCB)

The contractor shall participate in the Government CCB activities, providing technical information as requested. Establish the responsibilities and procedures for implementing requirements for configuration management of hardware procured or changed.

5 REQUIREMENTS

5.1 Critical Safety/Critical Application Items (CSIs/CAIs)

5.1.1 With the concurrence of the Government, the contractor shall identify which items are CSI and which are not. Components and assemblies are designated CAIs and CSIs based on the implications of their failure, as defined by Air Force Instruction 20-106 (Interservice

Publication) Management of Aviation Critical Safety Items. The term CAI is used to describe items and equipment that have serious safety implications, can impact system performance or mission capability, can significantly reduce fleet readiness or increase maintenance actions, or can cause severe environmental damage. The term CSI is used to describe a subset of CAIs that, if they failed, have the potential for catastrophic or Critical consequences to personnel or equipment.

5.1.2 In addition to the hook testing, paragraph 10.4, the contractor shall conduct component-level Lot Acceptance Testing (LAT) on CSI/CAI components. The contractor shall use

Government-approved facilities to conduct these tests and shall provide a test report with the results to government. The Contractor shall develop component test procedures and provide to the government. (CDRL B004, DI-NDTI-80603A/T), (CDRL D007, DI-

QCIC-81891/T)

5.2 Environmental Stress Screening (ESS)

The Contractor shall develop and deliver an ESS Test Plan. ESS testing provides for a uniform screening to be utilized for effectively disclosing manufacturing defects in electronic equipment.

ESS shall be conducted on 3 modified BRU-56s during production. ESS testing shall include vibration and temperature cycling. The ESS test procedures shall be developed using MIL-

HDBK-2164A as a guide. The ESS test plan shall describe and define the requirements for ESS of electronic equipment including environmental test conditions, durations of exposure, procedures, equipment operation, actions taken upon detection of defects and test documentation required. (CDRL B00M, DI-ENVR-81014A/T)

5.3 Quality Assurance

5.3.1 The contractor shall establish, implement, maintain, and provide a quality assurance program to the Government. The contractor’s program shall provide for the investigation, corrective action and timely response to Quality Deficiency Reports (QDR) issued by the

Government in accordance with DLAR 4155.24, Product Quality Deficiency Report

(PQDR) Program. The Quality Management System (QMS) shall conform to SAE

Aerospace Standard AS9100B or AS9100C or a functional equivalent. The contractor shall implement standards, establish controls, and integrate quality plans into the system engineering process. The contractor shall incorporate policies, procedures, and processes to ensure that all subcontractors and vendors conform to and meet program requirements.

The contractor shall develop and submit a Quality Assurance Program Plan (QAPP) for production of the modified BRU-56. The contractor shall maintain and use quality cost data as a management element of the QAPP. The contractor shall determine the specific cost data to be used and maintained. The contractor shall maintain a process for ensuring that all special processes and services are provided by suppliers who are National

Aerospace and Defense Contractors Accreditation Program (NADCAP) certified. The

QAPP shall identify the FOD/FOE control process and plan. Additionally, the QAPP shall establish processes and procedures for identifying, controlling, and verifying key characteristics associated with the modified BRU-56. The Government reserves the option to periodically assess the acceptability of the quality program through plant visits to audit the quality program. (CDRL J041, DI-QCIC-81794/T)

5.3.2 The modified BRU-56 manufacturing, testing and quality assurance efforts performed as described in this SOW shall meet the requirements of the specification for the modified

BRU-56/A Aircraft Ejector Bomb Rack, MIL-STD-2088B and MIL-STD-8591.

5.3.3 Production modifications developed in order to improve the modified BRU-56 product quality, reliability, or manufacturability shall not alter the product baseline form, fit, or function. All proposed modified BRU-56 design enhancements shall be presented to the

Government for approval prior to the fabrication of the First Article test units.

5.3.4 The contractor shall include new identification plate per modified production unit IAW

MIL-STD-130. (CDRL B00X, DI-MGMT-81804A/T)

5.3.5 Sampling

ANSI/ASQ Z1.4 shall be used in determining whether supplies delivered hereunder meet the applicable specifications. Unless otherwise provided in this contract or applicable specification, the particular Acceptable Quality Level shall be 1.0 percent of all categories of defects. The contractor still bears the cost of correcting the deficiencies.

5.3.6 Magnetic Particle Inspection Requirements

Whenever magnetic inspection is required on a drawing, the contractor shall follow the requirements of MIL-STD-1907 for soundness requirements, using Grade A unless otherwise specified by drawing.

5.3.7 Soldering

Procedures and requirements for preparation and soldering of electrical connections shall be in accordance with IPC/J-STD-001, and workmanship per IPC-6100 Class III.

5.3.8 Workmanship

Workmanship shall be in accordance with 14/30-inch ejector rack specifications.

5.3.9 Packaging

The contractor shall package each modified BRU-56 in accordance with the packaging instructions in BRU-56 SPI. All containers shall be tagged or labeled to identify (with part numbers and serial numbers) and quantify the items and indicate dates of acquisition or time limits for use or service. See Appendix A for Packaging Form 158. (CDRL B00Q, DI-

PACK-80120C/T)

5.4 Safety Lock Solenoid

The contractor shall provide a new safety lock solenoid to replace the existing BRU-56 solenoid

(P/N LE458-0001-4003) that has an equivalent function IAW BRU-56 SRD 3.2.8.5.

5.5 External Envelope

The BRU-56 Modification shall not result in a change to weapon spacing and fit, and shall remain inside the existing BRU-56 envelope IAW BRU-56 SRD 3.2.4.

6 INTEGRATED LOGISTICS SUPPORT

6.1 Integrated Logistics Support (ILS) Program Management

The contractor shall designate an ILS Manager and provide ILS Management. ILS Management, including Team Integration, shall be tasked with the overall responsibility to direct and provide status and visibility into all ILS efforts associated with the BRU-56 modification program to ensure contractual and schedule requirements are met within current budget. ILS Project Management will direct all ILS activities associated with the BRU-56 modification program to include production deliveries, Logistics Support Analysis (LSA), and Maintainability functions. ILS Management shall provide data inputs as required to the Integrated Support Plan

(ISP) to include any new support equipment, pre- and post-operational support, and maintenance updates.

6.2 Logistic Support Analysis (LSA)

The contractor shall conduct a LSA. Iterations of LSA tasks and subsequent data development shall be in detail sufficient to support the BRU-56 modification program. The contractor shall also update the LSA from the EMD phase, as required during production. The contractor shall accomplish tasks IAW MIL-HDBK-502, including, but not limited to, the following:

(CDRL B00C, Dl-ILSS-80114/T)

1) LSA Reviews

2) Supportability and supportability related design factors

3) Functional Requirements Identification

4) Task Inventory

5) Design Alternatives

6) Operations and Maintenance Task Requirements Update

7) Identify Risk

8) Task Analysis

9) Training

10) Identify Support Equipment requirements (if applicable) IAW AFI 63-101/20-101 –

Appendix D

11) Identify manpower and skill requirements

6.3 Task Analysis

The contractor shall identify and update the LSA tasks, as required, during the production effort to ensure total, timely supportability to the modified BRU-56 when fielded. The contractor shall update the task analysis for each affected task. Analysis documentation shall cover: (a) support resource requirements; (b) task times and intervals; (c) skill requirements; and (d) hazardous materials, etc.

6.4 Logistics Support Analysis Record (LSAR)

The contractor shall update and maintain the LSAR database used during EMD. Updates and maintenance shall be scheduled to ensure availability of information for tasks. The LSAR database shall be updated and maintained in the event of: (a) changes in system/equipment design; (b) changes in operational or support requirements; (c) logistics support improvements; (d) implementation of a correction of a deficiency; (e) corrections of errors in the LSAR; (f) deficiencies discovered during test results; (g) Air Force provisioning actions; and, (h) mutually agreed-to changes as a result of program and LSAR reviews.

6.5 Supply Support

6.5.1 Provisioning Data

The contractor shall provide data for and participate in the provisioning process for those items identified in the BRU-56 modification in accordance with Contract Data Requirements List (DD

Forms 1423) and the Initial Provisioning Performance Specification (IPPS) in the contract. The

Contractor shall recommend logical spare/repair parts sufficient to meet operability and supportability objectives.

6.5.2 Provisioning Technical Documentation (PTD)

PTD will be submitted in a format compatible with the Air Force Materiel Command (AFMC)

Automated Provisioning System (D220) as required by the IPPS, including attachments. Schedule for submitting the PTD shall be in accordance with the CDRLs and the Provisioning Performance

Schedule (PPS) (AFMC Form 718) which will be completed at the Provisioning Guidance

Conference (PGC) (CDRL B006, DI-SESS-81758A/T)

6.5.3 Engineering Data for Provisioning (EDFP)

Schedule and requirements for submitting EDFP shall be in accordance with the CDRL for EDFP.

Order of precedence for EDFP will be in accordance with the IPPS. (CDRL B007, DI-SESS-

81874/T)

6.5.4 Provisioning Conferences

The Contractor shall support a PGC hosted by the Prive Provisioning Activity (PPA) at Tinker

AFB within 45 days of receipt of the contract by the PPA. The Contractor shall support Spares

Provisioning Conference(s) as determined by the PGC.

6.6 Support Equipment Recommendation Data (SERD)

6.6.1 Support Equipment Provisioning

The Contractor shall define the Provisioning Parts List (PPL) on required new and modified items of Support Equipment as indicated on the SERD Approval Document. (CDRL B006, DI-

SESS-81758A/T)

6.6.1.1 Identify the end item, component or assembly, and all support items which can be disassembled, reassembled, or replaced, and when combined, constitute the end item component, or assembly

6.6.1.2 PPL includes: Items such as parts, materials, connecting cabling, piping and fittings required for operation and maintenance of the end item, component, or assembly.

6.6.1.3 Range and quantity of support items required to maintain the end item for an initial period of service.

6.6.1.4 All repairable Contractor Off-The-Shelf (COTS) items unless excluded by the PPA.

6.6.1.5 All Government Furnished Equipment (GFE) will be listed as one line entries with no breakout unless specified otherwise by the PPA.

6.6.1.6 Items of common and special design hardware such as nuts, bolts, screws, keys, washers and fittings.

6.7 Packaging, Handling, Storage, and Transportability (PHS&T)

6.7.1 Production Hardware

The contractor shall be responsible for the preservation, packaging and packing of all items delivered to meet the requirements of ASTM D 3951-98. The contractor shall make use of multi-application consumable containers (PPP-B-1672) in lieu of specialized container designs. The contractor shall insure all items are transportable by all modes of transportation IAW MIL-STD-

1366.

6.7.2 Markings

The contractor shall mark all items packaged for shipment IAW MIL-STD-129. (CDRL B00Q, DI-PACK-80120C/T)

6.8 Transportation

The Contractor shall have all appropriate shipping and export licenses as required to meet the requirements within the contract to ship BRU-56 end items.

7 Training The contractor shall provide training to USAF personnel for the BRU-56/A modification. Training shall allow for one week at Dyess AFB and one week at Ellsworth AFB.

7.1 Aircrew Training

The contractor shall provide aircrew training to include the Multi-Function Display (MFD) format changes associated with this modification. (CDRL F001, DI-ILSS-80872/T)

7.2 Load Crew Training

The contractor shall provide load crew training consisting of classroom instruction followed by hands-on load training IAW 1B-1B-33-2-1 and AFI 21-101. (CDRL F001, DI-ILSS-80872/T)

7.3 Maintenance Training

The Contractor shall provide maintenance procedures to include classroom instruction and disassembly/reassembly of the rack with hands-on training. (CDRL F001, DI-ILSS-80872/T)

8 Data Rights The contractor shall furnish services, hardware, materials, facilities and equipment required as described in this SOW. The contractor shall provide all technical, planning, management and modification/production functions required to complete this effort. All data (to include associated drawings, modification procedures, new & altered parts lists), shall be submitted to the government prior to implementation. The government will own unlimited data rights to all data generated by this requirement. All data shall be delivered with “Unlimited Rights” as defined by FAR Part 27 and Title 10 U.S.C. §2320. The contractor shall retain no intellectual property rights to the documentation delivered to the Government. The contractor shall waive any/all rights of intellectual property with regard to concepts, principles, and/or theory used in the design(s) submitted to the Government. Data elements delivered to the Government may include, but are not limited to:

1) Developmental design drawings/models and associated lists (CDRL B00J, DI-SESS-

81002F/T)

2) Production drawings/models and associated lists (CDRL B001, DI-SESS-81000E/T)

3) Special Tooling (ST) Drawings/Models and Assoc. (CDRL B00L, DI-SESS-81008E/T)

9 EMD PHASE

9.1 Design Requirements

9.1.1 The contractor shall conduct design and fabrication requirements analysis for the modification of the BRU-56 ejector rack and develop a single, consolidated specification from the 30-inch Specification CP2569A06A Part I and Part II, and 14-inch Specification

CP2569A04A, Part I and Part II for one combined 30/14-inch Ejector Rack with no consideration given to external carriage and nuclear carriage requirements.

9.1.1.1 Design requirements shall be presented to the Government via engineering report for review and approval following analysis completion. (CDRL B00E, DI-MISC-

80508B/T)

9.1.2 The contractor shall redesign the BRU-56 Ejector Rack as stated in the BRU-56

Modification SRD. The modified rack shall meet requirements IAW MIL-STD-2088.

9.1.3 KPPs, KSAs, and supporting requirements shall be IAW the BRU-56 Modification SRD.

9.2 Certification Requirements

9.2.1 Airworthiness

An airworthiness evaluation and certification process shall be both followed and executed prior to flight testing and shall be administered by the B-1 System Program Office. The contractor shall support these efforts as required. The contractor shall provide the Program Management and

Systems Engineering support required to develop the Modified Airworthiness Certification

Criteria (MACC) matrix as defined in MIL-HDBK-516C. The contractor shall verify the certification criteria using the standards, method of compliance, and evidence of compliance as outlined in the MACC. The contractor shall provide system engineering data and analyses needed to satisfy the Air Force MACC. The data provided shall be updated and completed to include any aircraft system impacts. (B00E, DI-MIS-80508B/T) (CDRL D004, DI-MGMT-81808/T)

(CDRL B00W, DI-MISC-81356A/T) (D005, DI-MGMT-81809/T)

9.2.2 Risk Assessment

The contractor shall implement a risk management process and work jointly with the Government program office to develop a risk management program utilizing the Air Force standard Automated

Risk Management System. Conduct risk identification and analysis IAW MIL-STD-882E and Air

Force Instruction (AFI) 90-802 throughout the B-1B BRU-56 Modification contract period of performance, when awarded, to include program risks. Develop appropriate risk mitigation strategies and plans. Incorporate identified risk handling strategies into program plans. Once risks have been realized and turn into an issue, incorporate the issue into work planning documents, IMS, and ensure integration with ongoing work to minimize impacts. (CDRL D004, DI-MGMT-

81808/T

9.2.3 Systems Safety

The contractor shall use MIL-STD-882E for the minimum hazard probability and severity reporting thresholds for all new hazards. The contractor shall document the analysis using the

Preliminary Hazard List (MIL-STD-882E Task 201) and Preliminary Hazard Analysis (MIL-STD-

882E Task 202). The contractor shall prepare and provide the Safety Assessment Report (SAR).

(CDRL A008, DI-SAFT-80102C/T)

The contractor shall prepare an Operating and Support Hazard Analysis Report (MIL-STD-882E

Task 206) to examine hardware and software system test and operation. (CDRL D00B, DI-SAFT-

81841/T)

The contractor shall prepare a Programmatic Environment, Safety, and Occupational Health

(ESOH) Evaluation (PESHE) for the modified BRU-56/A program using the B-1 Platform PESHE as a guide. The modified BRU-56/A shall exhibit an acceptable level of risk for all identified

ESOH hazards, as specified in Risk Acceptability section of the BRU-56/A ESOH Program Plan.

A Hazard Tracking System (HITS) will be used to document and track essential information from contractors for accomplishing the required closed-loop ESOH hazard tracking processes. (CDRL

D00C, DI-ENVR-81840/T), (CDRL D00D, DI-SAFT-82085/T)

9.2.4 Non-Nuclear Munitions Safety Board

The BRU-56 shall be processed through the Non-Nuclear Munitions Safety Board (NNMSB) IAW

AFI91-205 prior to flight testing. The contractor shall support these efforts as required.

9.2.5 Qualification

9.2.5.1 The contractor shall develop a Qualification Plan (QP) for Government review and approval. TRR shall be included in the QP. A Flight Readiness Review (FRR) shall be included as a sub-set of the TRR to ensure an acceptable Risk Management Plan (RMP) is defined by the contractor and approved by the Government. Contractor shall qualify the modified BRU-56 per approved Qualification Plan and provide Qualification Report.

(CDRL J038, DI-QCIC-81890/T)

9.2.5.2 A Critical Design Review (CDR) shall be accomplished prior to the contractor proceeding with manufacturing of parts in the production phase.

9.2.5.3 The contractor shall manufacture the parts required to modify 40 government provided

L6410301-081 BRU-56 racks for usage in qualification testing, including fit check and demonstration. The 40 BRU-56 racks allow for 1 to be destructively tested, 24 for a full fit check, and 12 will be used as spares. 8 racks per Multi-Purpose Rotary Launcher

(MPRL) will be used for flight test. The Government will provide 3 additional racks for contractor engineering development. The Government will provide an additional 6 racks to be used as spares during EMD. The 3 racks used for EMD, and the 6 racks used for spares will need to be returned to the Government in F condition at the completion of the contract.

9.2.5.4 The contractor shall perform the necessary strength, functionality, and other analysis on the modified rack prior to laboratory testing, fit check, demonstration and system integration testing to ensure safe operation. Contractor shall provide an engineering report of analysis and testing. (CDRL B00E, DI-MISC-80508B/T)

9.2.5.5 40 BRU-56 racks shall be modified and utilized for qualification testing to include laboratory testing, fit check, demonstration and system integration testing. At conclusion of qualification testing, the qualification article BRU-56 racks shall be overhauled to latest design configuration and placed in serviceable condition to be included in the production lot. At the Government’s discretion, Qualification Testing shall be conducted at either contractor or to be determined (TBD) government-designated facility. The contractor shall be responsible for delivery of all test articles to the testing facility.

9.3 Documentation Requirements

9.3.1 The contractor shall develop, support and deliver a certified and verified Technical Order

(TO) Change Package and source data to T.O. 11B29-3-75-2-WA-1, for maintenance and repair of the modified Ejector Rack in compliance with government T.O. format and requirements. Contractor shall support T.O. verification at a government-designated

Continental United States (CONUS) facility. (CDRL B002, TM-86-01Q/T) (CDRL

A006, DI-ADMN-81250A/T) (CDRL A007, DI-ADMN-81373/T) (CDRL A009, DI-

ADMN-81249A/T) (CDRL B005, DI-TMSS-81812/T)

9.3.2 The contractor shall develop and deliver government reviewed and approved Production

Level 3, Type 3Db, Element “d” - Commercial drawings and associated lists - per MIL-

STD-31000 with non-proprietary/unlimited rights (Technical Data Package) in government approved format after Ejector Rack…