Motional_Xducer_SOW-v1.3.doc

9 September 2019

STATEMENT OF WORK

FOR

PROTOTYPE DESIGN and FABRICATION

TEST, REPAIR & OVERHAUL INSTRUCTIONS

FOR THE

TRANSDUCER, MOTIONAL PICKUP

Part Number: 344201 Prepared by:

Theodore Trimble (801-775-6403)

414 SCMS/GUEA

Hill AFB, UT 84056 Version 1.3 9 Sept 2019

CONTENTS

1.0. Scope & Background

2.0. Reference Documents

3.0. Contractor Tasks

4.0. Government Furnished Property (GFP)

5.0. Data Matrix

Changes from Version 1.1 to Version 1.2

1. Added Reference 4 to Table I, “MIL-STD-461”

2. Expanded and defined the test requirements in Section 3.7.3, adding Tables II, III, IV, and V outlining the specific types of testing, prototype quantities required for each test type and the governing documents.

3. Updated Section 3.3 limiting the total number of days for the SRR to “two” maximum, and the number of contractors attending to “three” maximum.

4. Updated Section 3.7.4 limiting the total number of days for the QTR to “two” maximum, and the number of contractors attending to “three” maximum.

Changes from Version 1.2 to Version 1.3

1. Changed page number style

2. Added Sections:

3.1.1 Records

3.1.2 Environmental Controls

3.1.3 Safety and Health Plan

3.1.4 Government Provided Training

3.1.5 eCRMA Report

3.2.1 Computer and Information Security

3.2.2 Physical Security

3. Changed section 3.7.1 Transducer Prototype Fabrication- replaced the word “deliver” with “test”

4. Added to section 3.7.3.3 Operational Testing- “for a maximum of 3 days and up to 3 contractor personnel.”

STATEMENT OF WORK

FOR

PROTOTYPE DESIGN & FABRICATION,

TEST, REPAIR & OVERHAUL INSTRUCTIONS

& TECHNICAL DRAWINGS

FOR THE

TRANSDUCER, MOTIONAL PICKUP

1.0. SCOPE AND BACKGROUND

1.1 Scope. This Statement of Work (SOW) describes tasking for the Prototype Design, Fabrication & Test, along with Test Procedures, Repair & Overhaul Procedures and a Technical Data Package including 2-dimensional Drawings for the Transducer, Motional Pickup, P/N 344201, NSN 6995-00-861-5233, and hereafter referred to as the “Transducer”.

1.2 Device Description. The Transducer is a mechanical vibration sensing device, originally manufactured by Mandrel Products Division – Geosource, Inc (See Figure 1). When disturbed by a vibration, a spring-mounted magnet moves and induces a voltage in a sensing coil that surrounds the magnet. This induced voltage varies in amplitude proportional to the intensity of the vibration. The Transducer must meet rigorous performance requirements for successful operation in the field. To ensure the Transducer meets government performance and quality requirements, the tasking described in this SOW covers extensive operational acceptance tests, which exceed typical commercial requirements.

Figure 1. Transducer, Motional Pickup

1.3 Objectives. The Air Force intends to accomplish the following regarding the Transducer:

A. Design, Build and Test twenty-two (22) prototype Transducers. Testing shall include Acceptance, Qualification, Electromagnetic Suppression, and Operational Testing (“in-circuit” test at 341st Missile Wing, Malmstrom Air Force Base, Montana).

B. Develop Complete Functional Test Instructions including identification of key specifications requiring measurement.

C. Develop Complete Repair Procedures to enable the repair, to the extent possible for a sealed unit, of any malfunctioning Transducer asset to restore the device to serviceable or like-new condition. Procedures shall be in Air Force Technical Order format.

D. Develop Complete Overhaul Procedures to enable full refurbishment of the Transducer, to the extent possible for a sealed unit, to like-new condition. Procedures shall be in Air Force Technical Order format.

E. Draft and Generate a Complete Set of Two Dimensional (2D) Technical Drawings to include Top-assembly Level, Sub-assembly Level and Component Level.

1.4 Definition of Terms:

Like New Condition: The asset has all damaged, worn and missing parts replaced. The asset has been tested to ensure it is serviceable.

Overhaul Procedures: A description of detailed processes and procedures to disassemble and reassemble a Transducer to restore the device to “like new” condition.

Repair Procedures: A description of processes and procedures to disassemble an unserviceable Transducer to the level necessary to replace parts and reassemble the device to restore serviceability.

Maintenance Procedures: A description of processes and procedures to inspect, adjust, disassemble, lubricate, replace worn parts and reassemble the device to restore serviceability.

Validation: The process by which the contractor (or other activity as directed by the procuring entity) tests technical documents for accuracy, adequacy, comprehensibility, and usability. Validation is conducted at the contractor’s facility or at an operational site and involves the hands-on performance of operating and maintenance procedures including checkout, calibration, alignment, and scheduled removal and installation of time-change components.

Verification: The process by which technical data are tested and proved under procuring activity control to be technically accurate and complete, comprehensible, and usable for operation and maintenance of equipment or systems procured for operational units. Verification is conducted by using personnel with skill levels equivalent to those of the people who will be required to maintain the equipment or system in the operational environment. Verification consists of the actual performance of operating and maintenance procedures and associated checklists, including checkout, calibration, alignment, and scheduled removal and installation of time-change components.

2.0 REFERENCE DOCUMENTS

TABLE I

3.0 CONTRACTOR TASKS

3.1 Program Management. The contractor shall deliver an Integrated Master Schedule (IMS) describing the detailed tasks necessary to ensure successful completion of deliverables described in this SOW. The contractor shall deliver a Data Accession List (DAL) on a quarterly basis to ensure adherence to the IMS.

(A001, DI-MGMT-81861/T)

(A111, DI-MGMT-81453)

3.1.1 Records. The contractor shall be responsible for creating, maintaining, and disposing of only those Government required records that are specifically cited.

3.1.2. Environmental Controls. The contractor shall report environmental spills immediately to the appropriate authority. Written or e-mail notification shall be sent to the COR within 3 calendar days.

3.1.3. Safety and Health Plan. The contractor shall submit an annual safety report by the 15th of January for each performance year.

3.1.4. Government Provided Training. The contractor shall (as new personnel are hired) provide the COR a roster of personnel trained.

3.1.5. eCRMA Report. The contractor shall submit reporting inputs that will be for the labor executed during the period of performance for each Government fiscal year, which runs 1 October through 30 September. While inputs may be recorded anytime during the fiscal year, all data shall be reported no later than 31 October of each calendar year.

3.2 Operations Security Plan (OPSEC). The contractor shall implement an OPSEC Plan to reduce program vulnerability from successful adversary collection and exploitation of critical information. The Critical Information List will be provided by the government IAW AFI 10-701, Operations Security. The contractor shall familiarize and conduct refresher sessions in Operations Security AFI 10-701 Operations Security as supplemented, and AFI 31-401 information Security Program, standards for Storage and Handling Classified Material as supplemented for all employees.

(A112, DI-MGMT-80934)

3.2.1 Computer and Information Security. Contractors shall complete all required training via TSS.

3.2.2 Physical Security. The contractor shall provide a copy of their Key Control methods. Shall immediately report the occurrence of a lost or duplicated key to the appropriate security managers.

3.3 Systems Requirement Review (SRR). The contractor shall participate in a two-day (maximum) Transducer SRR at the 341st Missile Wing at Malmstrom Air Force Base, Montana. The purpose of the SRR is to complete an engineering review of the Transducer requirements to ensure full understanding of all technical requirements by the contractor and government. The SRR will also provide the contractor an opportunity to test and characterize the Motion Transducer interfaces. The maximum number of contractor personnel attending the SRR shall be three (3). The contractor shall deliver a Transducer specification describing all performance and interface requirements for the Transducer. Exit criteria for SRR shall be (1) government acceptance of Transducer specification; (2) acceptance of published SRR minutes; and (3) completion of all action items assigned to the contractor.

(A002, DI-ADMN-81249B)

(A003, DI-ADMN-81605)

(A004, DI-ADMN-81505)

(A033, DI-IPSC-81431A)

3.4 Preliminary Design Review (PDR). The contractor shall conduct a PDR at their facility. The purpose of the Transducer PDR is to (1) evaluate the progress, technical adequacy, and risk resolution (on a technical, cost, and schedule basis) of the selected Transducer design approach, (2) determine the Transducer design compatibility with performance and engineering specialty requirements of the Minuteman III weapon system, and (3) establish compatibility of the physical and functional interfaces of the Transducer design with the Minuteman III weapon system. Exit criteria for PDR shall be (1) acceptance of published PDR minutes; and (2) completion of all action items assigned to the contractor.

(A002, DI-ADMN-81249B)

(A003, DI-ADMN-81605)

(A004, DI-ADMN-81505)

3.5 Counterfeit Prevention Plan (CPP). The contractor shall deliver a Counterfeit Prevention Plan (CPP) describing the contractor’s plan to eliminate counterfeit parts from the Transducer design and delivered prototypes.

(A014, DI-MISC-81832)

3.6 Qualification Test Plan. The contractor shall deliver a Qualification Test Plan for the fabricated prototype components. The plan scope shall include Acceptance testing (factory) qualification testing, Electromagnetic Suppression testing (EMI) and operational testing (field) requirements and measurement limits. The contractor shall use Table I, Reference 1, Boeing document 10-20975 when creating the Test Plan.

(A005, DI-NDTI-80566A)

(A060, DI-NDTI-80566)

(A061, DI-NDTI-80603)

3.7 Transducer Prototype 3.7.1 Transducer Prototype Fabrication. The contractor shall fabricate and test twenty-two (22) prototype Transducers representing the design approved at CDR. The prototype Transducers shall be used as test articles only.

3.7.2 Transducer Part Marking. The contractor shall ensure the Transducer marking complies with DoD-recognized item unique identification (IUID) requirements in accordance with the current version of MIL-STD-130, “Identification Marking of U.S. Military Property” and DFARS 252.211-7003, “Item Identification and Valuation”.

(A103, DI-MGMT-81803)

(A104, DI-MGMT-81804)

3.7.3 Acceptance/

Qualification/Operational/EMI Testing. The contractor shall conduct Acceptance, Qualification, Operational and Electromagnetic Interference (suppression) testing of the prototype units pursuant to the specifications listed in Boeing document 10-20975, Table 1, Reference 1. (See exception for EMI testing in Table V below). Prototype quantities and locations for each test type are listed in the paragraphs and Tables below:

3.7.3.1 Acceptance Testing (See Table II): The contractor shall conduct Acceptance testing per the approved Acceptance Test Plan, to include tests specified in Boeing document 10-20975, Section 4.3. (See Table 1, Reference 1 in this SOW). Acceptance testing shall be conducted at the contractor’s facility on all 22 prototype units:

TABLE II

3.7.3.2 Qualification Testing (See Table III): The contractor shall conduct Qualification testing per the approved Qualification Test Plan, to include tests specified in Boeing document 10-20975, Section 4.2. (See Table 1, Reference 1 in this SOW). Qualification testing shall be conducted at the contractor’s facility on a total of six (6) prototype units, identified as Item A1, Item A2, Item B1, Item B2, Item C1, and Item C2. Breakdown of the unit testing shall be as follows:

TABLE III

Note: Four of the six test units, Items A1, A2, B1 & B2, will complete Performance Tests prior to being separated to go through Environmental Testing (A1 & A2) and Dynamic Testing (B1 & B2). Test Items C1 & C2 do not require Performance Testing prior to Life Testing.

3.7.3.3 Operational Testing (See Table IV): The contractor shall conduct prototype Operational testing on-site, at the 341st Missile Wing at Malmstrom Air Force Base, Montana, as described in the approved Operational Test Plan. Operational testing shall be conducted with no less than 6 prototype Motional Transducers, for a maximum of 3 days and up to 3 contractor personnel.

TABLE IV

3.7.3.4 Electromagnetic Interference Suppression Testing (See Table V): The contractor shall conduct prototype Electromagnetic Suppression testing per the approved EMI Test Plan, to include testing specified in AFBSD Exhibit 62-87, or the acceptable alternate Mil-STD-461 (see Table V below). EMI testing shall be conducted at the contractor’s facility on no less than 2 prototype Motional Transducers.

TABLE V

Total Units Tested

MIL-STD-461, July 1967 (Alternate)

Exception Note: In the event that “AFBSD Exhibit 62-87” is unobtainable, use of MIL-STD-461, dated 31 July 1961 is acceptable as a similar Era requirement document. (See Table 1, Reference 4 in this SOW).

The contractor shall deliver a Qualification Test Report to describe the results of the acceptance, qualification, operational, and EMI tests performed by the contractor demonstrating the prototype designs conform to all requirements defined by the Specifications approved at SRR. The contractor shall include a Verification Cross Reference Matrix (VCRM) in the Qualification Test Report to validate that all specification requirements have been successfully tested.

(A006, DI-QCIC-81890)

(A060, DI-NDTI-80566)

(A061, DI-NDTI-80603)

(A062, DI-NDTI-80809)

(A114, DI-MISC-81283)

3.7.4 Qualification Test Review (QTR). The contractor shall participate in a two-day (maximum) QTR at Hill AFB, Utah. The purpose of the QTR is to conduct an engineering review of all testing results (Acceptance/Qualification/Operational/EMI) and resolve any outstanding issues associated with testing of the Transducer. The maximum number of contractor personnel attending the SRR shall be three (3). Exit criteria for the QTR shall be (1) acceptance of published Transducer QTR minutes; and (2) completion of all action items assigned to the contractor.

(A002, DI-ADMN-81249)

(A003, DI-MGMT-81605)

(A004, DI-ADMN-81505)

3.8 Test, Repair & Overhaul Procedures 3.8.1 Test Procedures. The contractor shall develop and provide detailed Functional Test Procedures to include the critical parameters/specifications requiring measurement, the determined thresholds/limits, and the associated equipment and technique(s) required to make those measurements. The scope shall be sufficient that upon completion of the specified Functional Test Procedures the Transducer shall be deemed qualified for full service. The procedures shall be provided in Air Force Technical Order format as described in the Data Item Description (DID).

(A110, TM 86-01)

3.8.2 Repair Procedures. The contractor shall develop and provide detailed Repair Procedures (to the extent possible for a sealed unit) to include all steps for disassembly repair and re-assembly of the Transducer. The Transducer repair procedures shall be provided in Air Force Technical Order format as described in the Data Item Description.

(A110, TM 86-01)

3.8.3 Overhaul Procedures. The contractor shall develop and provide detailed overhaul procedures (to the extent possible for a sealed unit) to include all steps for disassembly, refurbish and re-assembly of the Transducer. The overhaul procedures shall include replacement/installation instructions for any consumable or high wear components identified in the device, and shall be provided in Air Force Technical Order format as described in the Data Item Description (DID).

(A110, TM 86-01)

3.8.4 Test, Repair & Overhaul Procedures Technical Interchange Meeting (TIM). The contractor shall conduct a two-day Transducer Overhaul Procedures TIM at their facility. The purpose of the TIM is to complete an engineering review of the Transducer Test, Repair & Overhaul procedures with the government. The TIM shall address the compatibility and technical compliance of the procedures with the Minuteman III weapon system requirements. Exit criteria for the TIM shall be (1) acceptance of published TIM minutes; and (2) completion of all TIM action items assigned to the contractor.

(A002, DI-ADMN-81249)

(A003, DI-MGMT-81605)

(A004, DI-ADMN-81505)

3.8.5 Test, Repair & Overhaul Procedures Validation and Verification (Val/Ver). The contractor shall conduct a three-day validation and verification of Transducer Test, Repair & Overhaul procedures at the contractor’s facility with a government representative(s) present. The contractor shall deliver a Transducer Test, Repair & Overhaul procedure Val/Ver report summarizing the results of the validation/verification and any recommended actions regarding correction or improvement of Transducer procedures.

(A002, DI-ADMN-81249)

(A003, DI-MGMT-81605)

(A004, DI-ADMN-81505)

(A062, DI-NDTI-80809)

(A113, DI-TMSS-81670)

3.9 Technical Data

3.9.1 Scientific Technical Information (STINFO). Department of Defense (DoD) Instruction 5230.24, Distribution Statements on Technical Documents, Enclosure 4, Table 5, identifies six (6) authorized distribution statements for Scientific and Technical Information (STINFO). The Contractor shall mark all technical data, regardless of media or form, with the appropriate STINFO markings (i.e., distribution statement, export control warning [if applicable], and destruction notice) as specified on the DD Form 1423-1, Contract Data Requirements List (CDRL). For written or printed material, the STINFO markings shall appear in full text on the front cover/title page and the abbreviated markings shall appear on subsequent pages as specified in the CDRL. Distribution statements shall include all applicable “reasons” based on the contents of the document. The “date of determination” within each distribution statement shall reflect the date the CDRL was signed. The Controlling DoD Office (CDO) will review all technical data (e.g., technical reports, test reports, final summaries, and briefings) prior to finalization to ensure the correct STINFO markings (i.e., distribution statement, export control warning [if applicable], and destruction notice) are applied to all documents. A distribution statement designation is distinct from, and in addition to, a security classification marking applied in accordance with (IAW) DoD Manual 5200.01, Volume 2, DoD Information Security Program: Marking of Classified Information.

3.9.2 TDP Technical Interchange Meeting (TIM). The contractor shall conduct a two-day Transducer Technical Data Package TIM at their facility. The contractor shall use MIL-STD-1521B as a guide for the TIM. The purpose of the meeting, is to (1) evaluate the progress, technical adequacy, and risk resolution (on a technical, cost, and schedule basis) of the technical data package, (2) determine the Transducer technical data package compatibility with performance and engineering specialty requirements of the Minuteman III weapon system. Exit criteria for TIM shall be (1) acceptance of published Transducer TDP TIM minutes; and (2) completion of all action items assigned to the contractor, and (3) government approval of all CDRLs due at this system engineering milestone.

(A002, DI-ADMN-81249)

(A003, DI-MGMT-81605)

(A004, DI-ADMN-81505)

(A010, DI-MGMT-81808)

3.9.3 TDP Validation & Verification (Val/Ver) Procedure. The contractor shall provide a validation and verification procedure for the Transducer TDP.

(A113, DI-TMSS-81670)

3.9.4 Technical Data Package (TDP). The contractor shall deliver a complete technical data package to include drawings and specification(s) describing the Transducer. Specifically, the technical data package shall include:

(1) Two dimensional (2D) drawings at the transducer top-assembly level, sub-assembly level and discrete component level. The contractor shall provide exploded view drawings of component groups as appropriate.

(2) The Test Procedures data package shall be provided in Air Force Technical Order format.

(3) The Overhaul Procedures data package shall be provided in Air Force Technical Order format.

(4) The Repair Procedures data package shall be provided in Air Force Technical Order format.

The contractor shall use reference documentation S-133-111-3-4, 1801400-01 and 31X3-27-6-7, including any updated information from the SRR as guidance for delivery of the technical data package. The Transducer Technical Data Package will be incrementally reviewed and approved by the Air Force at design reviews described in this SOW. The contractor shall deliver technical data with unlimited rights in accordance with FAR subpart 27.404-1(b).

(A027, DI-SESS-81000/T)

(A033, DI-IPSC-81431)

(A034, DI-MISC-82127)

(A038, DI-SESS-80776)

3.9.5 Critical Design Review (CDR). The contractor shall conduct a two-day Transducer TDP CDR at their facility. The contractor shall use MIL-STD-1521B as a guide for the CDR. The purpose of the CDR is to (1) determine that the technical data packages satisfies cost, schedule, and performance requirements, (2) establish the technical data packages compatibility with the Minuteman III weapon system, (3) assess all technical data package risk areas and provide risk mitigation/rationale. Exit criteria for CDR shall be (1) acceptance of published CDR minutes; and (2) completion of all action items assigned to the contractor, and (3) government approval of all CDRLs due at this system engineering milestone.

(A002, DI-ADMN-81249)

(A003, DI-MGMT-81605)

(A004, DI-ADMN-81505)

(A010, DI-MGMT-81808)

(A031, DI-SESS-80639)

4.0 GOVERNMENT FURNISHED PROPERTY

4.1 GFP Transducer Hardware. The contractor will be provided two (2) serviceable Transducers and eight (8) unserviceable Transducers (Part Number 344201) representing the legacy design. The GFP is provided by the government to assist in evaluation and detailed design of the replacement part. The GFP Transducers will be provided to the contractor under the Air Force loan/lease program. The contractor shall conduct a yearly inventory of GFP or at completion of the contract whichever comes first.

5.0 DATA MATRIX

5.1 Contract Data Requirements List (CDRL) Matrix. The CDRLs listed in Table VI describe the data deliverables described in this SOW. The CDRL form, Department of Defense (DD) Form 1423 included with this contract, specifies the data required to be delivered to the Government, as well as the frequency and approval requirements. Any correspondence related to requests for data delivery deviations and/or amendments or deletions to the CDRL form shall be addressed to the Procurement Contracting Officer (PCO).

TABLE VI

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only for administrative and operational use determined 02 March 2015. Other requests for this document shall be referred to ICBM System Directorate or AFNWC/NI, Hill AFB, UT 84056-5816.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export‐control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

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

Attachment 4

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