PWS.pdf

PR: FD2060-15-00019 PWS 1

PERFORMANCE-BASED WORK STATEMENT (PWS)

AN/ALQ-172 LRU-4 FORM, FIT, FUNCTION, AND INTERFACE REDESIGN

Purchase Request: FD2060-15-00019

Date: 28 October 2014

PREPARED BY: 408 SCMS/GULB

ROBINS AFB GA

APPROVED BY: 638 SUPPLY CHAIN MANAGEMENT GROUP ROBINS AFB GA

Distribution Statement C - Distribution authorized to the U.S Government Agencies and their contractors only. Other requests shall be referred to AFSC/PZABB, 235 Byron St., STE 19A, Robins AFB GA 31098. Questions concerning technical content should be directed to AFLCMC/WNYEBA. 235 Byron St. 19A, Robins AFB GA 31098-1607.

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.). Violators of these export laws are subject to severe criminal penalties.

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Performance-based Work Statement for

ALQ-172 LRU-4 Form, Fit, Function, and Interface Redesign

1.0 DESCRIPTION OF SERVICES.

The contractor shall provide engineering services to resolve ALQ-172 LRU-4 Obsolete Part and Vanishing Vendor issues with the NSN 5865-01-533-9874EW, Part Number (P/N) 2688804G001, and significantly improve the system Line Replaceable Unit (LRU) availability.

Reliability, maintainability, supportability, and produce-ability combine to determine the system availability a system can achieve. The ALQ-172 was developed by ITT Corporation, which is now Exelis. The AN/ALQ-172 described as being a "combat proven" equipment that is installed aboard US Air Force (USAF) B-52H strategic bombers (ALQ-172(V)2), special operations MC- 130E/H 'Combat Talon I' and 'II' transports (ALQ-172(V)1) and AC-130H (ALQ-172(V)3) and- 130U (ALQ-172(V)1) gunships. System design features include full automation, multiband coverage, simultaneous multiple threat recognition and jamming, digital computer control, "advanced" jamming techniques, a "high" effective radiated power value, threat re-programmability, a high-gain antenna array, a threat warning display, and "extensive" built-in test capabilities. An item that has a high level of Reliability and Maintainability (R&M), is producible, and is supportable, should achieve a high level of operational availability.

1.1 Objective(s). This Performance-based Work Statement (PWS) describes the services required to provide the engineering services to perform a form, fit, function, and interface (FFFI) replacement for the ALQ-172 LRU-4. These services include a LRU FFFI redesign, prototype fabrication, and test and delivery effort by reverse engineering the ALQ-172 LRU-4 and the least number of associated subassemblies within the LRU to meet legacy LRU specification performance requirements. The FFFI prototypes shall exhibit improved system availability and system performance equivalent or better than the existing ALQ-172 LRU-4. The contractor shall provide Test Requirement Documents (TRDs). Provide accurate technical monthly status addressing schedule and cost. The contractor shall build Form, fit, function and interface LRU prototypes with improved system availability by providing accurate red-line Technical Order (T.O.) changes. The ALQ-172 LRU-4 shall pass prototype testing requirements.

1.2 Benefit to United States Air Force (USAF). This acquisition will benefit the USAF by increasing the reliability and maintainability of the ALQ-172 LRU-4, as well as, sustain the electronic warfare suite for the B-52H and AFSOC C-130s until retirement.

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2.0 SERVICES SUMMARY.

Performance Objective PWS Reference Performance Threshold Provide Test Requirement Documents (TRDs)

5.10.5.1.1, 5.10.5.2, 5.10.6, 5.10.7, 5.10.8

Work products shall contain no more than one technical error and no more than five typographical errors per submittal.

Provide accurate technical monthly status addressing schedule and cost status

5.10.17.3 Monthly status reports that shall be

technically accurate and complete with no more than one technical error and no more than five typographical errors.

Errors shall be corrected and the report shall be resubmitted to the COR and engineer NLT 15 working days after receipt of Government comments.

Build Form, fit, function and interface LRU prototypes with improved system availability

5.10 The form, fit, function and interface

prototypes successfully pass the testing requirements with no more than two retest at the next higher assembly with a calculated (MIL-HDBK-217F) LRU MTBF of at least 6,000 hours.

Provide accurate red-line Technical Order (T.O.)

changes

5.10.13 100% of red-line T.O. changes shall be free of technical errors and require no major re-work, as determined by the Government, per submission.

Pass prototype testing requirements

5.10.7, 5.10.8, 5.10.9

Successfully pass prototype testing requirements with no more than two retests at the next higher assembly.

3.0 GOVERNMENT PROPERTY AND SERVICES.

3.1 Contractor Responsibility. The Contractor shall be responsible for Government property in their possession in accordance with the Federal Acquisition Regulation (FAR) and applicable supplements including, but not limited to, FAR Part 45, Government Property; FAR 52.245-1, Government Property; and Defense Federal Acquisition Regulation Supplement (DFARS) Part 245, Government Property. The FAR and applicable supplements can be accessed at the site below.

http://farsite.hill.af.mil

3.2 Government Property to be Provided. Government property to be provided includes the Enhanced Maintenance Test Set (EMTS), which is already at the contractor’s facility to support the repairs of ALQ-172 assets and accountable to FA8540-09-D-0002. These items will be transferred to the follow on repair contract as a result of RFP# FA8522-12-R-32134 at the time of award. It will be used on a non-interference basis in accordance with this contract.

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3.3 Loss of Government Property.

3.3.1 Definition of Loss of Government Property. In accordance with DFARS 252.245-7002, Reporting Loss of Government Property, “loss of Government property” means unintended loss of or damage to Government property including property that cannot be found after a reasonable search, loss due to inadequate storage, theft, loss due to lack of security, damage requiring repair to restore the item to usable condition, or damage that renders the property useless for its intended purpose or Beyond Economical Repair (BER). Loss of Government property does not include manufacturing defects, obsolescence, normal wear and tear, or purposeful destructive testing. Unless otherwise stated in the contract/order, loss of Government property does not include normal and reasonable inventory adjustments, i.e., losses of low priority consumable material, such as common hardware, as agreed to by the Contractor and the Government Property Administrator.

3.3.2 Reporting Loss of Government Property. The Contractor shall use the Defense Contract Management Agency (DCMA) eTools software application to report loss of Government property at the site below. The reporting requirement does not change any liability provisions or other reporting requirements that may exist under the contract/order.

http://www.dcma.mil/aboutetools.cfm

3.3.3 Return of Government Property.

All property provided by the Government remains the property of the Government and shall be returned to the Government in accordance with current GFE loan/lease agreements upon completion of the contract. All Government property shall be returned to the Government in the condition provided unless approved in advance by the Procuring Contracting Officer (PCO). All materials generated under the contract becomes the property of the Government and shall be returned to the Government than upon completion of the contract. All Department of Defense (DD) Form 1423, Contract Data Requirements List (CDRL), deliverables become the property of the Government upon receipt.

3.4 Government System(s). Access to Government systems will not be required to perform tasks under the contract/order.

4.0 Technical Requirements

4.1 Period and Place of Performance: The place of performance for this contract will be exclusively not on a U.S. Government installation.

4.1.1 Contract/Order Period of Performance: The period of performance for the contract/order extends for 36 months from date of award.

4.1.2 Place of Performance: These services shall be performed at the contractor’s facility in Clifton, NJ.

4.2 Item Unique Identification (IUID)

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4.2.1 In accordance with DFARS 252-211.7003(a), Item Identification and Valuation / Definitions, “ ‘DoD unique item identification’ means a system of marking items delivered to DoD with unique item identifiers that have machine-readable data elements to distinguish an item from all other like and unlike items.” Unique item identification is required for all items that meet the criteria established by DFARS 211.274-2, Policy for unique item identification.

4.2.2 The Contractor shall mark items in accordance with DFARS 211.274-2, DFARS 252- 211.7003, and Military Standard (MIL-STD)-130N, Department of Defense Standard Practice / Identification Marking of U.S. Military Property.

4.2.3 In accordance with the Department of Defense Guide to Uniquely Identifying Items Assuring Valuation, Accountability and Control of Government Property, the Government user will add item(s) to the Department of Defense (DoD) IUID Registry. The Government user or Contractor representative responsible for causing “life cycle events” (i.e., abandoned, consumed, destroyed by accident, destroyed by combat, donated, exchanged – repair, exchanged – sold, exchanged – warranty, expended – experimental/target, expended – normal use, leased, loaned, lost, reintroduced, retired, scrapped, sold – foreign government, sold – historic, sold – nongovernment, sold – other federal, sold – state/local, and stolen) will update the item record(s) in the DoD IUID Registry.

4.2.4 IUID Marking Plan: The Contractor’s IUID Marking Plan shall fully detail and document the strategy and scope to be used to meet MIL-STD-130, DoD Standard Practice Identification Marking of US Military Property. The plan must be approved by Government Program Manager prior to implementation. (CDRL A016, DI-MGMT-81803, IUID Marking Plan).

4.2.5 IUID Marking Activity And Verification Report: The contractor shall provide an IUID Marking Activity and Verification Report. A key attribute for the report is the Verification column which indicates pass/fail for each item’s Data Matrix Symbol Quality. After the plan has been approved, all applicable items must be marked before they are returned to the Government.

(CDRL A017, DI-MGMT-81804A, Marking Activity and Verification Report).

4.3 Packaging. The Contractor shall package and mark material in accordance with the contract (basic or order, as applicable) Air Force Materiel Command (AFMC) Form 158, Packaging Requirements; MIL-STD-129P, Department of Defense Standard Practice / Military Marking for Shipment and Storage; MIL-STD-130N, Department of Defense Standard Practice / Identification Marking of U.S. Military Property; and MIL-STD-2073-1D, Standard Practice for Military Packaging. The Contractor shall ensure that classified material is packaged, marked and delivered in accordance with DoD 5220.22-M, National Industrial Security Program Operating Manual (NISPOM).

5.0 GENERAL INFORMATION.

5.1 Continuation of Mission-Essential Services During a Crisis.

5.1.1 Definition of Mission-Essential Services. In accordance with DFARS 252.237- 7023(a)(1), Continuation of Essential Contractor Services, “ ‘Essential contractor service’ means

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a service provided by a firm or individual under contract to DoD to support mission-essential functions, such as support of vital systems, … associated support activities, … and similar services provided to foreign military sales customers under the Security Assistance Program.

Services are essential if the effectiveness of defense systems or operations has the potential to be seriously impaired by the interruption of these services, as determined by the appropriate functional commander or civilian equivalent.”

5.1.2 Designation of Services as Mission-Essential. In accordance with DFARS 237.7602(a), The Continuation of Essential Contractor Services / Policy, DFARS 252.237-7023(a)(2), and Air Force Instruction (AFI) 10-403, Deployment Planning and Execution, paragraph 1.9.1.33.2, the Functional Commander (FC) or civilian equivalent has determined these services are not mission-essential and will not continue in the event of a crisis.

5.2 Security Requirements.

5.2.1 General. Knowledge and/or generation of classified information and/or Controlled Unclassified Information (CUI) are required for performance of the contract/order. The Contractor shall ensure applicable Contractor personnel have security clearances at the SECRET level.

5.2.2 Government Security Regulations. The Contractor shall ensure personnel, information, system, property and facility security requirements are met. The Contractor shall comply with Government security regulations including, but not limited to, DoD 5220.22-M, National Industrial Security Program Operating Manual (NISPOM); DoD Directive (DoDD) 5205.02E, DoD Operations Security (OPSEC) Program; and DoD Manual 5205.02-M, DoD Operations Security (OPSEC) Program Manual.

5.2.3 Operations Security (OPSEC). The purpose of OPSEC is to reduce the vulnerability of USAF missions to adversary collection and exploitation of critical information. The Contractor shall ensure compliance with DoDD 5205.02E and DoD Manual 5205.02-M to protect U.S.

Government interests.

5.2.4 Security Clearance. The Contractor shall ensure applicable Contractor personnel have security clearances at the SECRET level for proper accomplishment of contract/order requirements. The security clearance shall be obtained in accordance with the DD Form 254, Department of Defense Contract Security Classification Specification. Contractor personnel whose clearances have been suspended or revoked shall immediately be denied access to classified information and/or CUI and classified items.

5.2.5 Security Incident or Violation. The Contractor shall immediately notify the Government Security Office of any potential or actual security incident or violation including potential or actual unauthorized disclosure or compromise of classified information and/or CUI.

5.2.6 Security of Contractor System(s). The Contractor shall ensure the security of Automated Information System(s) (AIS) at the Contractor’s facility to preclude potential security

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incidents or violations including potential unauthorized disclosure or compromise of classified information and/or CUI.

5.2.7 Access to Government Facility. The Contractor shall ensure Contractor personnel who require access to a Government facility comply with the security requirements of the facility.

5.3 Environmental Management System (EMS).

5.3.1 Authority. Executive Order (E.O.) 13423, Strengthening Federal Environmental, Energy, and Transportation Management, and E.O. 13514, Federal Leadership in Environment, Energy, and Economic Performance, establish the requirement for an EMS.

5.3.2 Applicability. In accordance with the Assistant Secretary of the Air Force (SAF) Policy Letter, Conformance with Air Force Environmental Management System (EMS) Requirements for Contracts Performed on Air Force Installations, dated 11 Dec 06, and the Air Force Materiel Command/Vice Commander (AFMC/CV) Policy Letter, Conformance with Air Force Environmental Management System (EMS) Requirements for Contracts Performed on Air Force Installations, dated 1 Aug 07, Contractor personnel who perform work on any USAF installation shall comply with the EMS requirements established by the installation.

5.3.3 EMS Training. These services shall be performed only at the Contractor’s facility in Clifton, NJ; therefore, the EMS requirement does not apply.

5.4 Green Procurement Program (GPP).

5.4.1 Authority and Applicability. Under Secretary of Defense (USD) Memorandum, Establishment of the DoD Green Procurement Program, dated August 27 2004, establishes the requirement for a GPP. The GPP is a mandatory federal acquisition program that focuses on the purchase and use of environmentally-preferable products and services. In accordance with FAR 23.404, Agency Affirmative Procurement Programs, the GPP requires 100% of purchases of Environmental Protection Agency (EPA)-designated products, included in the Comprehensive Procurement Guidelines (CPG) list, contain recovered materials unless the item cannot be acquired competitively within a reasonable timeframe, meet appropriate performance standards, and/or be acquired at a reasonable price. In accordance with FAR 23.101, Sustainable Acquisition Policy / Definition, the GPP requirement applies to all acquisitions, including services, using U.S. Government appropriated funds.

5.4.2 GPP Requirement Flow to Subcontractors. The prime Contractor shall ensure subcontractors comply with the GPP requirement.

5.5 Safety Requirements.

5.5.1 Mishap Reporting.

While performing work under this contract the Contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. In accordance with AFI 91-204, Safety Investigations and Reports, paragraph 2.4.6.1.1, the Contractor shall report

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mishaps involving damage or injury to USAF. The Contractor shall notify the Government Representative (GR), within eight hours of any damage to Government property where the dollar value exceeds $500,000.00 and within two business days, for any damage to Government property less than $500,000.00 during the execution of the contract.

5.5.2 Mishap Notifications Elements.

Mishap notifications shall contain, at a minimum, the following information:

a. Contract, Contract Number, Name and Title of Person(s) Reporting

b. Date, time and exact location of accident/incident

c. Brief narrative of accident/incident (Events leading to accident/incident)

d. Cause of accident/incident, if known

e. Estimated cost of accident/incident (material and labor to repair/replace)

f. Nomenclature of equipment and personnel involved in accident/incident

g. Corrective actions (taken or proposed)

h. Other pertinent information

5.5.3 Mishap Scene.

If requested by the designated GR, the Contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office.

5.6 Inspection of Services.

5.6.1 Government Inspection Rights. In accordance with FAR 52.246-5, Inspection of Services Cost Reimbursement, the Government reserves the right to inspect Contractor performance.

5.6.2 Inspection and Process Records. In accordance with FAR 52.246-5, the Contractor shall maintain an inspection process acceptable to the Government. The Contractor and shall maintain records of inspections which shall be made available to the Government as long as the contract requires.

5.7 Trafficking in Persons.

5.7.1 The Contractor shall comply with FAR 52.222-50, Combating Trafficking in Persons.

Additional information about Trafficking in Persons is available at the site for the Department of State’s Office to Monitor and Combat Trafficking in Persons below.

http://www.state.gov/j/tip

5.7.2 In accordance with the Defense Contingency COR Handbook section on Combating Trafficking in Persons, the COR must inform the PCO if the Contractor fails to comply with the requirements of FAR 52.222-50. The PCO must convey the information to DoD Combat Trafficking in Persons (CTIP) Law Enforcement and Support / Office of Under Secretary of Defense (OUSD) Personnel and Readiness (P&R) Defense Human Resources Activity (DHRA).

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5.8 Contract Manpower Reporting.

5.8.1 Authority. In accordance with the Secretary of the Air Force for Acquisition (SAF/AQ) Memorandum, Implementation of FY11 NDAA [National Defense Authorization Act] Section 8108 [of Public Law 112-10 of the Department of Defense and Full-Year Continuing Appropriations Act, 2011], Contractor Inventory, dated Nov 13 2012, the Contractor shall provide an annual count of Contractor personnel performing work if the DoD is the requiring activity, if the acquisition is using U.S. Government appropriated funds, and if the acquisition is equal to or greater than the Simplified Acquisition Threshold (SAT) [currently $150,000.00].

5.8.2 Reporting Requirements. In accordance with the Office of the Secretary of Defense (OSD) Memorandum, Enterprise-wide Contractor Manpower Reporting Application, dated Nov 28 2012, the Contractor shall report all Contractor labor hours, including subcontractor labor hours, required for performance of the services provided under the contract at the Enterprise-wide Contract Manpower Reporting Application (eCMRA) site below. Reporting shall be conducted for each fiscal year (FY), which extends October 1 through September 30. While inputs may be made any time during the FY, all data shall be reported no later than October 31 of the following FY. The Contractor may direct questions to the help desk at the eCMRA site below.

http://www.ecmra.mil

5.9 Invoicing/Payment and Receipt/Acceptance.

5.9.1 Wide Area Workflow Mandate. In accordance with DFARS 252.232-7003, Electronic Submission of Payment Requests and Receiving Reports, the Contractor shall submit/process payment requests (invoices, Receiving Reports or combos) and receipt/acceptance documents via Wide Area Workflow (WAWF). Additional information regarding WAWF is available at the site below.

https://wawf.eb.mil

5.9.2 CDRL Deliverables. CDRL deliverables may be submitted using WAWF or be submitted directly to the applicable MFT member in accordance with the CDRL. The CDRL will determine submittal requirements; however, separately priced data must be accepted in WAWF in order for the Contractor to receive payment, and both separately priced and non-separately priced data must be accepted in WAWF in order for the contract line item to be closed out.

5.9.3 Submission Acceptance. Services will be accepted by the COR.

5.10 Technical Requirements.

The contractor shall develop a FFFI replacement LRU configuration that eliminates part obsolescence and replaces the ALQ-172 LRU-4 with a single design. The form, fit, function and interface prototypes shall successfully pass the testing requirements with no more than two retest at the next higher assembly with a calculated (MIL-HDBK-217F) LRU MTBF of at least 6,000 hours. The contractor shall not degrade ALQ-172 system performance. The contractor shall design the ALQ-172 LRU-4 equipment only such that no Group A modifications shall be required to incorporate the design. The contractor shall maximize use of Non-Developmental

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Technology, with consideration given to multiple supply channels, produce-ability and long-term availability. The contractor shall consider and include current state-of-the-art technology wherever possible. The contractor shall conduct a survey of vendors down to the component level to determine if there is an acceptable industry base for the components being recommended in the redesign options. The contractor shall ensure that all redesign options maintain existing performance allowing for no system level degradation due to proposed hardware or software changes. The contractor shall identify, minimize, and document impacts to contractor and government existing fielded support equipment due to the new ALQ-172 LRU-4. The contractor shall identify and document any required modifications to Test Program Sets (TPSs), with respect to both hardware and software. The contractor shall identify update requirements for the documents listed in the Affordable System Operational Effectiveness Diagram and generate development documentation sufficient to allow Air Force installation and test of the LRU with the new LRU-4 on B-52H aircraft. The contractor shall produce an as built and tested technical data package for the LRU configuration. The contractor shall not recommend proprietary or sole source components unless there is no alternative available. Any proprietary or sole source components recommended shall be explicitly identified at status and design reviews. The Development Phase Relationship Illustration provides a top level overview of the development process to be accomplished by the contractor. All PWS activity shall be planned and scheduled using a detailed integrated master schedule (IMS) as part of a comprehensive program management plan described later in this document.

5.10.1 Requirements Definition. The contractor shall follow a structured IPPD systems engineering process to accomplish ALQ-172 LRU-4 redesign. The contractor shall accomplish system analyses to define and develop system technical requirements that address all identified requirements. The contractor shall calculate legacy ALQ-172 LRU-4 system availability utilizing reliability, maintainability, supportability, and produce-ability data. The exit criteria for this phase shall be: program objectives and execution plan (including processes and metrics);

program constraints; system concept architecture; program risk assessment; technology readiness assessment; system performance specification; allocation of system requirements to hardware and software subsystems; identification of all software components; cost and critical path drivers; product support plan; draft system/subsystem specification tree; program R&M plan;

draft R&M methodology; and successful System Requirements Review (SRR) that establishes the requirements baseline. The contractor shall document the analysis in a requirements definition engineering report in accordance with (IAW) the IMS. Work products shall contain no more than one technical error and no more than five typographical errors per submittal. (CDRL A001, DI-MISC-80711A, Scientific and Technical Reports; CDRL A002, DI-IPSC-81431A, System/Subsystem Specification).

5.10.1.1 Systems Requirement Review (SRR). The contractor shall conduct a multi-functional technical SRR to ensure that all system and performance requirements: are defined in sufficient detail to enable system functional definition and functional decomposition; and are consistent with program cost, schedule, risk, and other system constraints. The SRR shall demonstrate consistency between the system requirements, system specification, system/subsystem specification tree, the recommended system solution, and available technologies. SRR approval is required prior to proceeding to the system design phase. The contractor shall prepare an SRR agenda and submit final briefing charts one week prior to the review. The contractor shall

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develop and deliver SRR minutes IAW the IMS. (CDRL A003, DI-ADMN-81249A, Conference Agenda; CDRL A004, DI-ADMN-81250A, Conference Minutes).

5.10.2 System Design Engineering. The contractor shall follow a structured IPPD systems engineering process to accomplish ALQ-172 LRU-4 redesign. The contractor shall progressively identify and analyze the system function and sub-function alternatives for meeting system performance and design requirements. The contractor shall identify the required system functions based on the requirements performance parameters and all other requirements and constraints, and allocate subsystems to each function. The contractor shall define subsystem interfaces and integration requirements based on this partitioning. The contractor shall evaluate alternative solutions to optimize system availability using the functional architecture, allocated performance, and design specification requirements. The systems analysis goal is achievement of the proper balance among operational, economic, and logistic factors by use of a trade-off matrix to compare the alternative solutions. The analysis shall address cost of ownership and Reliability and Maintainability (R&M) parameters in addition to technical, cost and schedule performance. The analysis shall result in system functional definition and functional decomposition to the configuration item level to provide a system description in performance requirements terms. The contractor shall develop plans for the subsystem integration, verification, and validation processes, as well as verification and validation plans for the system as a whole. The exit criteria for this phase shall be: trade-off analysis results; program objectives and execution plan (including processes and metrics); program constraints; cost and critical path drivers; program risk assessment; technology readiness assessment; requirements functional allocation to a hardware and software top-level design (functional architecture); system specification updates; system architecture updates; subsystem specifications; draft development specifications; draft interface specification; R&M analysis results; R&M methodology; approved product support plan; and successful System Functional Review (SFR) that establishes the system functional baseline. The contractor shall document the work effort in a system design engineering report IAW the IMS. Work products shall contain no more than one technical error and no more than five typographical errors per submittal. (CDRL A001, DI-MISC-80711A, Scientific and Technical Reports).

5.10.2.1 SFR. The contractor shall conduct a multi-disciplined technical SFR to ensure that: the system functional requirements are captured in system specifications; all required system performance is fully decomposed and traced to lower-level subsystem functionality that define hardware and software requirements; and the system functional design is consistent with program cost, schedule, risk, and other system constraints. The SFR shall demonstrate consistency between the system requirements, system specification, system/subsystem specifications, the recommended system solution, and available technologies. SFR approval is required prior to proceeding to preliminary design. The contractor shall prepare an SFR agenda and submit final briefing charts one week prior to the review. The contractor shall develop and deliver SFR minutes IAW the IMS. Minutes shall include all briefing materials as an attachment. (CDRL A003, DI-ADMN-81249A, Conference Agenda; CDRL A004, DI- ADMN-81250A, Conference Minutes).

5.10.2.2 Safety Assessment Report. A Safety Assessment Report shall be submitted 15 calendar days prior to the preliminary design review. The Government approval/comments will be provided within 30 business days after submittal. Contractor format is acceptable. Additional

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Safety Assessment Reports shall be submitted if there are any additional changes after first approval. (CDRL A005, DI-SAFT-80102B/T, Safety Assessment Report).

5.10.3 Preliminary Design. The contractor shall follow a structured IPPD systems engineering process to accomplish ALQ-172 LRU-4 preliminary design. The contractor shall allocate the functional architecture to system functions and sub-functions, across all configuration items, each with an associated set of performance and design requirements addressing all identified requirements. The derived requirements shall be stated in sufficient detail for allocation to ALQ- 172 LRU-4 hardware, software, and interface. The derived requirements shall be traceable, through the analysis by which they were derived, to the system requirement they are designed to fulfill. The output of this analysis will be allocated performance and other limiting requirements to all functional levels documented in the first set of subsystem and component product performance descriptions. The contractor shall establish an allocated baseline that includes all functional and interface characteristics allocated from the system, interface requirements with other critical items (CI), and design constraints. The allocated baseline shall describe the verification required to demonstrate the achievement of specified functional and interface characteristics, with emphasis on critical concept components. The contractor shall accomplish a Failure Mode Effects and Criticality Analysis, a Failure Tree Analysis, and a Reliability- Centered Maintenance (RCM) Analysis on the allocated baseline. The exit criteria for this phase shall be: trade-off analysis results; program objectives and execution plan (including processes and metrics); program constraints; cost and critical path drivers; program risk assessment;

updates to the top-level functional architecture design; system specification updates; subsystem specifications; requirements allocation to hardware and software development specifications for all configuration items; interface specifications (physical and functional); R&M analysis updates;

R&M predictions; test method for verification of requirements; CI configuration management plan; production support plan update; and successful Preliminary Design Review (PDR) that establishes the allocated baseline. The contractor shall document all the work effort in a preliminary design engineering report IAW the IMS. (CDRL A001 DI-MISC-80711A, Scientific and Technical Reports).

5.10.3.1 PDR. The contractor shall conduct a multi-disciplined technical PDR to ensure that:

each function in the functional baseline has been allocated to one or more system configuration items; the allocated hardware and software requirements are completely captured in performance specifications for each configuration item of the preliminary design (allocated baseline);

subsystem and configuration item requirements trace to system design; and the system preliminary design is consistent with program cost, schedule, risk, and other system constraints.

PDR approval is required prior to proceeding to detailed design. The contractor shall prepare a PDR agenda and submit final briefing charts one week prior to the review. The contractor shall develop and deliver PDR minutes IAW the IMS. Minutes shall include all briefing materials as an attachment. (CDRL A003, DI-ADMN-81249A, Conference Agenda; CDRL A004, DI- ADMN-81250A, Conference Minutes).

5.10.4 Critical Design. The contractor shall follow a structured IPPD systems engineering process to accomplish ALQ-172 LRU-4 detailed design. The contractor shall accomplish detailed design of all hardware and software components, each with an associated set of performance and design requirements addressing identified requirements. The contractor shall accomplish detailed design of the entire system, to the subsystem/component level, to

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demonstrate that the allocated baseline hardware, software, and system requirements are satisfied by the design. The contractor shall develop drawings and other documentation required for building components, subsystems, and the ALQ-172 LRU-4. The contractor shall accomplish testing and validation of critical system components and plan for the integration and testing of all components. The contractor shall develop a Level of Repair Analysis and a Maintenance Task Analysis. The contractor shall update the projected system reliability based on demonstrated reliability rates. The contractor shall project improved system availability based on the detailed design reliability, maintainability, supportability, and produce-ability. The contractor shall identify critical manufacturing processes that impact key performance characteristics and determine their capability to meet design tolerances. The exit criteria for this phase shall be:

trade-off analysis results; program objectives and execution plan (including processes and metrics); program constraints; cost and critical path drivers; program risk assessment; updates to the top-level functional architecture design; system specification updates; subsystem specifications update; function and sub-function development specifications update; interface specifications (physical and functional) update; hardware and software development specifications update for all configuration items; R&M analysis updates; R&M predictions updates; critical CI test results; updated test methodology (performance, qualification, environmental, etc.); updated Interface Control Documents (ICDs); CI configuration management plan update; production support plan update; ALQ-172 LRU-4 minimum MTBF of 6,000 hours; ALQ-172 LRU-4 maximum MTTR of two hours, excluding TPS run time; and successful Critical Design Review (CDR) that establishes the product baseline (built-to). The contractor shall document all the work effort in a detailed design engineering report IAW the IMS. (CDRL A001, DI-MISC-80711A, Scientific and Technical Reports).

5.10.4.1 CDR. The contractor shall conduct a multi-disciplined technical CDR to ensure that:

subsystem detailed design correctly and completely implement all system requirements allocated to the subsystem; each hardware and software product in the product baseline has been captured in the detailed design documentation to enable hardware fabrication and software coding of configuration items; upward and downward traceability of final subsystem requirements to final system detailed design; the system under review can proceed into system fabrication and test;

and the detailed design is consistent with program cost, schedule, risk, and other system constraints. CDR approval is required prior to proceeding to fabrication and test. The contractor shall prepare a CDR agenda and submit final briefing charts one week prior to the review. The contractor shall develop and deliver CDR minutes IAW the IMS. Minutes shall include all briefing materials as an attachment. (CDRL A003, DI-ADMN-81249A, Conference Agenda;

CDRL A004, DI-ADMN-81250A, Conference Minutes).

5.10.5 Prototype Fabrication. The contractor shall fabricate, assemble, code (using the product baseline build-to documentation), and deliver fully functional, operational, compatible prototypes as the contract defined quantity of FFFI ALQ-172 LRU-4 prototypes. The contractor shall maintain configuration control of the product baseline build-to documentation to accurately reflect final prototype configuration. The contractor shall screen all the electrical/electronic components selected in the redesign of the ALQ-172 LRU-4 to eliminate any premature Diminishing Manufacturing Sources and Material Shortages (DMSMS). The ALQ-172 LRU-4 and all repairable sub-assemblies shall be marked with permanently attached machine-readable “unique identifier” or “UID”. Military Standard 130M (MIL-STD 130M) provides further clarification and increased insight and guidance for the implementation of machine-readable

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information (MRI) processes for item identification marking and facilitating automatic data capture. Official AF guidance is provided in: DFARS Clause 252.211-7003.

5.10.5.1 Prototype Delivery. The contractor shall deliver five fully functional, operational, and compatible FFFI prototypes to the Government.

5.10.5.1.1 Test Readiness Review (TRR). The contractor shall conduct a multi-disciplined technical TRR to ensure that: planned tests are traceable to program requirements; all planned preliminary, informal, functional, unit level, subsystem, system, and qualification tests have been conducted; the test objectives, test methods and procedures, scope of tests, and safety issues have been properly identified and documented; required test resources have been properly identified and coordinated to support planned tests; the ALQ-172 LRU-4 and applicable components subsystems and system are ready to proceed into formal test; and the fabricated prototypes are consistent with program cost, schedule, risk, and other system constraints. TRR approval is required prior to proceeding to formal test. The contractor shall prepare a TRR agenda and submit final briefing charts one week prior to the review. The contractor shall develop and deliver TRR minutes IAW the IMS. Minutes shall include all briefing materials as an attachment. Work products shall contain no more than one technical error and no more than five typographical errors per submittal. (CDRL A003, DI-ADMN-81249A, Conference Agenda;

CDRL A004, DI-ADMN-81250A, Conference Minutes).

5.10.5.2 Prototype Test. The contractor shall develop and use new, special test equipment to test the FFFI ALQ-172 LRU-4 prototypes in accordance with the approved test methodology to verify and validate that operational performance and system availability requirements are met.

The contractor shall accomplish individual configuration item, integrated subsystem, and assembled ALQ-172 LRU-4 prototype testing. The contractor shall demonstrate, according to the verification and validation plans, the physical, electrical, software, and other characteristics of the individual configuration items to be integrated. The contractor shall demonstrate, according to the verification and validation plans, integrated subsystem hardware and software performance compliance to their respective subsystem design requirements specifications. The contractor shall demonstrate, according to the verification and validation plans, integrated ALQ- 172 LRU-4 hardware and software system performance compliance to the system design requirements specification IAW the IMS. The FFFI LRU prototypes shall successfully pass subsystem testing requirements with no more than two retests at the next higher assembly.

(CDRL A006, DI-NDTI-80603A, Test Procedure; CDRL A007, DI-NDTI-80809B Test Report).

5.10.6 System Level Test. The contractor shall develop an ALQ-172 system level test procedure to demonstrate form, fit, function and interface compliance of the ALQ-172 LRU-4 prototypes in the ALQ-172 system and submit the system level test procedure for government approval. The contractors shall conduct system level tests on the redesigned ALQ-172 LRU-4 prototypes in accordance with the government approved test procedure and document the results in a system level test report. The government reserves the right to witness all testing performed by the contractor. The contractor shall perform baseline system level tests in the Electronic Warfare Avionics Integration Support Facility (EWAISF) with the existing ALQ-172 LRU-4 prior to inserting the redesigned ALQ-172 LRU-4 into the AN/ALQ-172 system IAW the IMS.

The results of both tests shall be compared to demonstrate that there are no impacts to the

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AN/ALQ-172 system. Work products shall contain no more than one technical error and no more than five typographical errors per submittal. (CDRL A006, DI-NDTI-80603A, Test Procedure; CDRL A007, DI-NDTI-80809B Test Report).

5.10.7 Acceptance Test Procedure (ATP). The contractor shall develop a detailed acceptance test procedure for the ALQ-172 LRU-4 and submit the acceptance test procedure for government approval. The contractor shall conduct acceptance test on each prototype ALQ-172 LRU-4 in accordance with the approved ATP testing and submit a test report for each prototype ALQ-172 LRU-4 for government approval following testing. The contractor shall deliver the prototype ALQ-172 LRU-4, following successful acceptance test, for formal Air Force test IAW the IMS.

Work products shall contain no more than one technical error and no more than five typographical errors per submittal. Successfully pass prototype testing requirements with no more than two retests at the next higher assembly. (CDRL A006, DI-NDTI-80603A, Test Procedure, CDRL A007, DI-NDTI-80809B Test Report).

5.10.8 Qualification Testing. The contractor shall develop a qualification test procedure (QTP) based on MIL-HDBK-781A to qualify the ALQ-172 LRU-4 and submit the QTP for government approval. The contractor shall conduct qualification tests on the ALQ-172 LRU-4 in accordance with the government approved QTP and document the results in a qualification test report.

Qualification-by-similarity shall be considered where applicable. The government reserves the right to witness all testing performed by the contractor. The contractor shall submit a test report for government approval following testing IAW the IMS. Successfully pass prototype testing requirements with no more than two retests at the next higher assembly. (CDRL A006, DI- NDTI-80603A, Test Procedure, CDRL A007, DI-NDTI-80809B Test Report).

5.10.9 Government Testing. The prototype of the redesigned ALQ-172 LRU-4 configuration will be tested at the EWAISF at Robins AFB GA, the Robins AFB depot, and flight tested on a B-52H aircraft at a main operating base to ensure full system level interoperability and operational performance compliance IAW the IMS. The contractor shall provide technical support for government testing efforts, as required. Government testing of the prototypes will be performed using existing and/or new/modified procedures and new technical orders.

Successfully pass prototype testing requirements with no more than two retests at the next higher assembly.

5.10.10 Functional Configuration Audit (FCA)/Physical Configuration Audit (PCA). The contractor shall conduct a multi-disciplined FCA/PCA of the final government tested, redesigned prototype ALQ-172 LRU-4 within two months after delivery of prototypes to ensure that: the actual performance meets the functional specification requirements (derived from the requirements specifications) documented in the Functional, Allocated, and Product Baselines; the configuration controlled product baseline (build-to) documentation reflects the physical item tested; and the system functional design is consistent with program cost, schedule, risk, and other system constraints. The contractor shall update, as required, the technical data package to reflect any changes that occur during test. The contractor shall prepare a FCA/PCA agenda and submit final presentation material one week prior to the review. The contractor shall develop and deliver a FCA/PCA report that documents audit findings IAW the IMS. (CDRL A003, DI- ADMN-81249A, Conference Agenda; CDRL A004, DI-ADMN-81250A, Conference Minutes; and CDRL A008, DI-CMAN-81022C, Configuration Audit Summary Report).

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5.10.11 Hardware Deliverables. The contractor shall deliver all prototype units, test fixtures and special test equipment that was developed, fabricated and tested under this work effort to

AFLCMC/WNYEBA.

5.10.12 Software Deliverables. The contractor shall deliver all software, source code and executable code, with applicable documentation, that is designed and/or developed under this effort to AFLCMC/WNYEBA.

5.10.13 Technical Order Impact. The contractor shall refer to TMCR for technical orders impacted by any redesign effort associated with the ALQ-172 LRU-4. 100% of red-line T.O.

changes shall be free of technical errors and require no major re-work per submission. T.O.

changes will be negotiated on a case by case basis. All submissions will be IAW the IMS.

(CDRL A009, TM-86-01N (TMCR); CDRL A010, DI-CMAN-80642C, Notice of Revision).

5.10.14 Data.

5.10.14.1 Hardware Requirements Specifications. The contractor shall update the hardware requirements specifications for all items developed under this effort, as necessary. This is to include developmental specifications and product specifications. All submissions will be IAW the IMS. (CDRL A002, DI-IPSC-81431A, System/Subsystem Specification).

5.10.14.2 Engineering Data. The contractor shall develop/produce/ maintain a Technical Data Package (TDP) that accurately depicts the final product. The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement or manufacture of an interchangeable item that duplicates the physical and performance characteristics of the original product, without additional design engineering effort or recourse to the original design activity.

TDP data includes, but is not limited to, Computer Aided Design (CAD) data, CAD models, model based definition data sets, Gerber data and Master Bill of Materials (BOM). The contractor shall provide sufficient test and performance data to allow re-qualification and procurement of suitable future replacement ALQ-172 LRU-4. The contractor shall not develop or allow the development or use of any proprietary data except as approved by the USAF Procurement Contracting Officer (PCO). All engineering product definition data created as a result of this contract shall be considered a part of the TDP and shall be delivered to the Government with unlimited rights. The TDP shall be delivered in accordance with Air Force Product Data Specification drawing 9579776 Revision L (CAGE 98752), reference attached DD Form 1423 Block 16. For all technical rights and submission of proprietary rights please refer to CDRL A011. Any proprietary data requests must be sent to the Government contracting officer in writing and for written Government approval authorizing use of proprietary data. (CDRL A011, DI-SESS-81000E/T, Product Drawings/Models and Associated List)

5.10.14.3 Engineering Data Guidance Conference. The contractor shall support and co-chair a Guidance Conference for engineering data within 60 calendar days after contract award. The Conference shall be convened at a site and on a date agreed upon by the government contracting officer and the contractor. The contractor shall prepare an agenda and record the minutes of the

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Guidance Conference IAW the IMS. The contractor shall address, discuss, and provide status on the following:

5.10.14.3.1 Understanding of all CDRL requirements, applicable DIDs, specifications and standards.

5.10.14.3.2 TDP review…