SOW - ALE-47 Prod 3.4 Ctr FINAL.pdf

SOW Production 3.4 -

18 Jan 2024

File No. FD2060-24-31387 Page 1 of 57

Statement Of Work

For

AN/ALE-47 Countermeasures Dispenser System

Production-3.4

Prepared By: EO/IR Integrated Product Team AFLCMC/WNY

Approved By:

Air Force Life Cycle Management Center

EW/Avionics Engineering Branch

Robins AFB, GA 31098–1813

DISTRIBUTION STATEMENT A: Approved for Public Release.

File No. FD2060-24-31387 Page 2 of 57

Revision Page

The following revisions have been made to this document:

# Revision Affected Pages

- Initial Release

File No. FD2060-24-31387 Page 3 of 57

Table Of Contents

1. Background

1.1 Objectives

1.2 Scope

2. Requirements

2.1 Pre-Production Requirements

2.1.1 Pre-Production Environmental Stress Screening (ESS)

2.1.2 Pre-Production Acceptance Test

2.1.2.1 Pre-Production LRU ATPs

2.1.2.2 Pre-Production SRU ATPs

2.1.3 Pre-Production Interchangeability Test

2.1.4 Pre-Production Government Inspection And Test

2.2 Production Requirements

2.2.1 Environmental Stress Screening (ESS)

2.2.2 Production Acceptance Test

2.2.2.1 Production LRU ATPs

2.2.2.2 Production SRU ATPs

2.2.3 Production Interchangeability Test

2.3 System Software Loading

2.3.1 Control Display Unit (CDU)

2.3.2 Programmer

2.3.3 Sequencer

2.4 Lead-Free Control Plan

2.5 Program Management

2.5.1 Post Award Conference

2.5.2 Program Management Reviews (PMRs)

2.5.3 Technical Interchange Meetings (TIMs)

2.5.4 Production Surveillance and Reporting System

2.6 Communications

2.7 Data Management

2.7.1 Data Accession List (DAL)/Internal Data

2.7.2 GFE Detail Transaction Status Data Report

2.7.3 Rights In Data

2.8 Configuration Management

2.8.1 ECPs, NORs, And Variances

2.8.2 Programmable Devices

2.8.3 Parts Management

2.8.4 Counterfeit Prevention Plan

2.8.4.1 Risk Assessment

2.8.4.2 Counterfeit Notification and Reporting

2.8.4.3 Detection and Avoidance Responsibilities

2.8.4.4 Counterfeit Prevention Training

2.8.5 Engineering Data

2.8.5.1 Engineering Data Guidance Conference

2.8.5.2 In-Process Review (IPR) of the TDP

2.8.5.3 Relationship of Contractor with Subcontractors/Vendors

2.8.5.4 Engineering Data Updates and Revisions

2.8.6 Technical Manuals

File No. FD2060-24-31387 Page 4 of 57

2.9 System Safety

2.10 Green Procurement Program

2.11 Security Requirements

2.11.1 Security Regulations

2.11.2 Operations Security (OPSEC)

2.11.3 Communications Security (COMSEC)

2.11.4 Security Clearance

2.11.5 Security Incident or Violation

2.11.6 Security of Contractor Systems(s)

2.11.7 Access to Government System(s)

2.11.8 Access to Government Facility

2.11.9 Access to Robins AFB

2.11.9.1 Identification (ID) Card/Badge

2.11.10 Labeling Of Classified Hardware

2.12 Safety & Health Plan

2.13 Warranty

2.14 Warranty Returns of Classified Hardware

3. Government Furnished Property and Services

3.1 Government Furnished Equipment (GFE)

3.2 Reporting Loss Of Government Property

3.3 Government Furnished Software (GFS)

4. General Information

4.1 Cautions

4.1.1 Obsolete Parts

4.1.2 Code For Programmable Parts

4.1.3 PCB Apertures

4.1.4 Gerber File Format

4.1.5 TRDs In The TDP

4.1.6 Integrated System Performance Test

4.1.7 Programmer Discrete I/O CCA ATP

4.1.8 Sequencer Poll Source Circuit

4.1.9 Missing Drawings

4.1.10 New Programmer Configuration

4.2 Applicable Documents and Order of Precedence

4.2.1 Military Standards

4.2.2 Other Documents

4.3 Definitions

Table 1 Software For Shipment In Hardware

Attachment 1. LRU Listing

Attachment 2. SRU Listing

Attachment 3. Capability Table

Attachment 4. MIL–STD–882E Extracted Requirements

Attachment 5. Safety Appendix

File No. FD2060-24-31163 Page 5 of 57

1. Background

The AN/ALE-47(V) Countermeasures Dispenser System (CMDS) is an integrated, threat-adaptive, reprogrammable, computer-controlled airborne defensive system. The AN/ALE-47 dispenses countermeasure decoys (Chaff, Flare and others) against radar and infrared homing threats to enhance aircraft survivability.

The AN/ALE-47 CMDS procurable under this Statement Of Work (SOW) consists of the Line

Replaceable Units (LRUs) listed in Attachment 1. Each LRU consist of one or more lower assemblies called Shop Replaceable Units (SRUs). See Attachment 2 for a list of SRUs. The individual aircraft determines the system configuration and the number of LRUs.

The Air Force and Army support the AN/ALE-47 with two-level maintenance concept. The

Navy supports the AN/ALE-47 with a three-level maintenance concept. Warner Robins Air

Logistics Complex is the organic depot for Air Force, Army, and Navy AN/ALE-47 hardware and Operational Flight Program (OFP) software.

1.1 Objectives

This SOW identifies the objectives to fabricate, integrate components, test, and deliver production LRUs and SRUs in accordance with the Technical Data Package (TDP) and contract schedule. Other objectives include corrective action and maintenance of the TDP. AN/ALE-47 production will support Air Force, Navy, Army, US State Department, National Aeronautical

Space Administration (NASA), Foreign Military Sales (FMS) and other US Government aircraft.

1.2 Scope

This SOW is applicable to Contractors that the Government has considered qualified on all

LRUs listed in Attachment 1.

2. Requirements

Requirements that are not specific to Pre-Production (section 2.1) or Production (section 2.2) apply to both Pre-Production and Production. Pre-Production is synonymous with qualification by First Articles.

File No. FD2060-24-31163 Page 6 of 57

2.1 Pre-Production Requirements

Pre-production is synonymous with qualification by First Articles. Pre-Production encompasses all efforts required to demonstrate that the Contractor is prepared for production. Contractors that have one or more unqualified LRUs may qualify the LRU(s) by meeting the Pre-Production

Requirements. Briefly, this includes developing Government approved Environmental Stress

Screening (ESS) procedures, developing Government approved ATPs for LRUs and SRUs, performing ESS test on First Article LRUs, performing Acceptance Test on SRUs and First

Article LRUs, submitting successful ESS reports and Acceptance Test reports for Government approval, conducting Interchangeability Test, submitting First Article LRUs for Government

Inspection And Test, and obtaining Government approval of First Article LRUs. Government

Inspection And Test will include dimensional verification, Interchangeability Test, LRU testing, and some software testing for LRUs containing software. The Government reserves the right not to award production orders until all LRUs are qualified.

The Contractor must obtain a delivery order from the Government Procuring Contracting Officer

(PCO) before commencement of pre-production. The Contractor shall fabricate, integrate, test and deliver LRUs listed in 0 in accordance with the quantities listed in the contract delivery order. The Contractor’s First Articles shall conform to the contract, this Statement Of Work, and the TDP. First Articles shall be 100% representative of production items. The Contractor shall maintain current test equipment calibration in accordance with the requirements of ANSI/NCSL-

Z540.3.

2.1.1 Pre-Production Environmental Stress Screening (ESS)

The Contractor shall prepare a Reliability Test Plan (subtitle Environmental Stress Screening

(ESS) Procedures) for each LRU listed in 0, excluding the Safety Switch and the Dispenser. ESS

Procedures prepared under a prior contract are not acceptable. ESS procedures shall be consistent with requirements specified by each LRU’s Critical Item Product Fabrication

Specification (CIPFS). The ESS procedures shall use the number of thermal cycles specified by the Sequencer CIPFS when an LRU's CIPFS does not specify the number of cycles. The

Contractor may cover multiple LRUs in an ESS Procedures document. ESS Procedures shall include:

• LRU(s) covered and the LRU(s) part number(s),

• Types of failures classified as nonrelevant,

• Step by step procedures,

• Pass criteria,

• Data to be recorded,

• Sample data sheets,

• Identification of computer software to be used, if applicable,

• Computer software to be used, if applicable (source and object code), File No. FD2060-24-31163 Page 7 of 57

• Action to be taken if a reject decision is reached,

• List of test equipment,

• Test equipment calibration requirements,

• Test set-up including interconnecting cable diagrams and cable labels, and

• Requirements for root cause analysis and failure determination for failed items.

The Contractor shall obtain Government approval of ESS procedures before using the procedures for ESS. The Contractor shall conduct ESS on each First Article LRU. LRUs must pass ESS test before proceeding to the Contractor's final Acceptance Test. The Contractor shall report

ESS test results in Reliability Test Reports (subtitle Environmental Stress Screening (ESS)

Report). The report shall include the part number and serial number of the part tested on each page, the elapsed time from the start of test (vibration or thermal) to each failure (if any), the part number and name of the failed part, and corrective action(s) taken or planned.

(B/F/K/P/T001, DI-SESS-81629B) (B/F/K/P/T00G, DI-SESS-81628B/T)

If an uncosted Engineering Change Proposal proposes to use a part that has a temperature range not meeting the temperature requirements of the target LRU, the Contractor shall first have conducted ESS using a prototype item with the proposed Engineering Change Proposal incorporated. If a costed Engineering Change Proposal proposes to use a part that has a temperature range not meeting the temperature requirements of the target LRU, the Contractor shall include ESS in the proposed Engineering Change Proposal. See paragraph 2.8.1 for other

Engineering Change Proposal requirements.

2.1.2 Pre-Production Acceptance Test

The Contractor shall conduct Acceptance Test after passing ESS. The Contractor shall conduct

Acceptance Test on each SRU listed in Attachment 2 before installing the SRU in the First

Article LRU. The Contractor shall then conduct Acceptance Test on each First Article LRU (and quantities) listed in 0. The Contractor shall conduct Acceptance Test using Government approved Acceptance Test Procedures (ATPs). The Contractor shall document the results of each Acceptance Test via Test/Inspection Reports. The Contractor shall obtain Government approval of each First Article LRU Acceptance Test Report and its associated SRU Acceptance

Test Reports before submitting the First Article LRU for Government Inspection And Test. The

Contractor is cautioned that successful completion of its Acceptance Test does not constitute

Government approval or acceptance of a First Article, and that Government Inspection And Test of a First Article may evaluate contract, Statement Of Work, or Technical Data Package requirements that are not included in the Contractor's ATP.

(Exhibit A, DI-NDTI-80809B)

File No. FD2060-24-31163 Page 8 of 57

2.1.2.1 Pre-Production LRU ATPs

The Contractor shall prepare and submit for Government approval an ATP for each LRU listed in 0. The Contractor shall obtain Government approval of each ATP before using the ATP for

Acceptance Test. The Contractor shall have performed dry-run Acceptance Test using its unapproved ATP before submitting it to the Government for approval. The Contractor shall design, develop, and fabricate test hardware and software for ATP use, making use of commercial equivalent test hardware/software where practical. The Contractor's ATP procedures may differ from the TDP's ATP procedures to accommodate different test hardware.

The Contractor's ATP shall identify commercial equivalents of Contractor-peculiar test hardware/software. Software needed to run or automate the ATP is part of the ATP by definition. The Contractor shall deliver ATP software with the ATP. ATPs included in the TDP are for reference only and may lack ATP software. ATPs included in the TDP are intended to provide a starting baseline for the Contractor's preparation of its ATP test cases and pass criteria.

ATPs included in the TDP may contain imperfect test cases and pass criteria, or may depend on software that is no longer available. The Contractor's ATP test cases and pass criteria may therefore deviate from the ATPs contained in the TDP. When deviations from the TDP's ATP test cases or pass criteria are needed, the Contractor shall submit a technical justification for the deviations concurrent with the ATP submission. Acceptability of the deviations is at the sole discretion of Government.

(Exhibit D, DI-NDTI-80603A)

When a change to any Government approved ATP is needed due to a defect discovery or engineering change, the Contractor may submit an unsolicited ATP update for Government approval, or submit the ATP update as part of an Engineering Change Proposal, as applicable.

The Contractor shall submit a technical justification with the changed ATP. The Contractor shall obtain Government approval of each proposed ATP change before using the ATP for Acceptance

Test.

File No. FD2060-24-31163 Page 9 of 57

2.1.2.2 Pre-Production SRU ATPs

The Contractor shall prepare and submit for Government approval an ATP for each SRU listed in Attachment 2. The Contractor shall obtain Government approval of each ATP before using the ATP for Acceptance Test. The Contractor shall have performed dry-run Acceptance Test using its unapproved ATP before submitting it to the Government for approval. The Contractor shall design, develop, and fabricate test hardware and software for ATP use, making use of commercial equivalent test hardware/software where practical. The Contractor's ATP procedures may differ from the TDP's ATP procedures to accommodate different test hardware.

The Contractor's ATP shall identify commercial equivalents of Contractor-peculiar test hardware/software. Software needed to run or automate the ATP is part of the ATP by definition. The Contractor shall deliver ATP software with the ATP. ATPs included in the TDP are for reference only and may lack ATP software. See also paragraph 4.1.7 concerning an ATP that is missing from the TDP. ATPs included in the TDP are intended to provide a starting baseline for the Contractor's preparation of its ATP test cases and pass criteria. ATPs included in the TDP may contain imperfect test cases and pass criteria, or may depend on software that is no longer available. The Contractor's ATP test cases and pass criteria may therefore deviate from the ATPs contained in the TDP. When deviations from the TDP's ATP test cases or pass criteria are needed, the Contractor shall submit a technical justification for the deviations concurrent with the ATP submission. Acceptability of the deviations is at the sole discretion of

Government.

(Exhibit D, DI-NDTI-80603A)

When a change to any Government approved ATP is needed due to a defect discovery or engineering change, the Contractor may submit an unsolicited ATP update for Government approval, or submit the ATP update as part of an Engineering Change Proposal, as applicable.

The Contractor shall submit a technical justification with the changed ATP. The Contractor shall obtain Government approval of each proposed ATP change before using the ATP for Acceptance

Test.

File No. FD2060-24-31163 Page 10 of 57

2.1.3 Pre-Production Interchangeability Test

The purpose of Pre-production Interchangeability Test is to ensure standardization of the

Contractor's items with prior manufacturer's items. In other words, to ensure precise replication of LRU and SRU form, fit, and function. Pre-production Interchangeability Test has two parts.

The first part is placing each of the Contractor's SRUs (see Attachment 2), one at a time, into the corresponding GFE LRU, performing Acceptance Test on the GFE LRU, and then returning each LRU to its original configuration before the next SRU swap. The second part is a reversal of the first part: Placing GFE SRUs taken from the GFE LRUs, one at a time, into the

Contractor produced LRU, performing Acceptance Test on the Contractor produced LRU, and then returning each LRU to its original configuration before the next SRU swap. The Contractor shall perform Interchangeability Test on one each of its First Article LRUs (see 0) excluding

Programmer PN 179730-0005, Programmer PN 8448453-1, Sequencer PN 179250-0012, and

Safety Switch PN 179720-0001. The Contractor shall perform the Interchangeability Test using

GFE LRUs from each prior manufacturer (i.e. Tracor, BAE, and Symetrics). The Contractor shall conduct a failure analysis of any item that fails interchangeability test, determine the failure mechanism, implement corrective action, and rerun the test. The Contractor shall certify by letter to the Procuring Contracting Officer that the applicable First Article LRUs passed

Interchangeability Test before submitting them to the Government.

2.1.4 Pre-Production Government Inspection And Test

The Contractor is responsible for all First Article transportation cost. The Contractor shall submit each First Article for Government Inspection And Test. The Contractor’s LRU is not qualified for production until it has passed Government Inspection And Test and all Contract

Data Requirements List (CDRL) items associated with the First Article are approved by the

Government. Before the Contractor submits a LRU for Government Inspection And Test:

• The First Article and its SRUs must have no pending Request For Variances;

• The First Article and its SRUs must have no approved but unincorporated Class I

Engineering Change Proposals and associated Notice Of Revisions;

• The First Article must have a Government approved ATP;

• Each SRU within the LRU must have a Government approved ATP (see Attachment 2 for applicable SRUs);

• The First Article must have passed Environmental Stress Screening and Acceptance Test and have Government approved test reports;

• Each SRU within the LRU must have passed Acceptance Test and have a Government approved Acceptance Test Report. (See Attachment 2 for applicable SRUs); and

• The First Article must have passed Interchangeability Test, if applicable.

Government Inspection And Test will include the below aspects.

• Inspection for markings and workmanship at Warner Robins, GA;

• Dimensional verification of the LRU's envelope at Warner Robins, GA;

File No. FD2060-24-31163 Page 11 of 57

• Limited Computer Software Configuration Item (CSCI) testing for LRUs that contain

CSCIs at Warner Robins, GA;

• LRU testing at Warner Robins, GA, on an AN/ALM-205B, Depot LRU Automatic Test

Station ALE-47 (DLATS47), or equivalent test station. LRU testing will include SRU interchangeability testing with SRUs from past manufactures; and

• LRU testing at the Navy’s In-Service Support Center (ISSC), Jacksonville, FL, using a

Consolidated Automated Support Station (CASS) AN/USM-636.

Inspection And Test may verify Technical Data Package requirements that are not included in the Contractor’s ATP. The Government's LRU testing may differ from the Contractor's ATP.

The Government may reject a First Article that does not conform to contract or Statement Of

Work requirements. The Government may fail a First Article that does not conform to a requirement listed in the Technical Data Package, even though the First Article may have passed the Contractor's Acceptance Test. The Government will allow the Contractor to rework, retest, and resubmit rejected or failed First Article(s) once. The Contractor shall re-accomplish ESS and Interchangeability Test on reworked First Articles. The Contractor shall re-accomplish

Acceptance Test on reworked First Articles and reworked SRUs. The Contractor shall document

Acceptance Test results in a Test/Inspection Report. The Contractor shall submit Acceptance

Test Reports for reworked SRU(s) and its associated LRU, and obtain Government approval of the test reports before First Article resubmission for Government Inspection And Test.

(Exhibit A, DI-NDTI-80809B)

2.2 Production Requirements

The Contractor must obtain a delivery order from the Government Procuring Contracting Officer

(PCO) before commencement of production. The Government reserves the right not to award production orders until all LRUs are qualified. The Contractor shall fabricate, integrate, test, and deliver LRUs listed in 0 and SRUs listed in Attachment 2 in accordance with the quantities listed in each contract delivery order. The Contractor’s production articles shall conform to the contract, this Statement Of Work, and the TDP. The Contractor shall maintain current test equipment calibration in accordance with the requirements of ANSI/NCSL-Z540.3. The

Contractor shall maintain a minimum capability requirement which will include maintained equipment and qualified personnel as listed in, but not limited to, Attachment 3.

Funding for a delivery order is provided at the time the order is awarded. The contractor will be responsible for procurement of all piece parts, including long-lead items, in order to meet required delivery timelines. The USG will not provide investment capital to pre-position supply for production.

File No. FD2060-24-31163 Page 12 of 57

2.2.1 Environmental Stress Screening (ESS)

The Contractor shall prepare a Reliability Test Plan (subtitle Environmental Stress Screening

(ESS) Procedures) for each LRU listed in 0, excluding the Safety Switch and the Dispenser. ESS

Procedures prepared under a prior contract are not acceptable. ESS procedures shall be consistent with requirements specified by each LRU’s Critical Item Product Fabrication

Specification (CIPFS). The ESS procedures shall use the number of thermal cycles specified by the Sequencer CIPFS when an LRU's CIPFS does not specify the number of cycles. The

Contractor may cover multiple LRUs in an ESS Procedures document. ESS Procedures shall include:

• LRU(s) covered and the LRU(s) part number(s)

• Types of failures classified as non-relevant,

• Step by step procedures,

• Pass criteria,

• Data to be recorded,

• Sample data sheets,

• Identification of computer software to be used, if applicable,

• Computer software to be used, if applicable (source and object code),

• Action to be taken if a reject decision is reached,

• List of test equipment,

• Test equipment calibration requirements,

• Test set-up including interconnecting cable diagrams and cable labels, and

• Requirements for root cause analysis and failure determination for failed items.

The Contractor shall obtain Government approval of ESS procedures before using the procedures for ESS. The Contractor shall conduct ESS on each production LRU. The Contractor shall conduct ESS on each SRU that the Contractor will sell to the Government as an individual SRU

(not part of an LRU). The Contractor shall conduct SRU ESS with the SRU installed in a

Contractor-furnished LRU. The Contractor-furnished LRU shall be externally marked for ESS and shall not be sold to the Government under a production delivery order. Each LRU and separately procured SRU must pass ESS before proceeding to the Contractor's final Acceptance

Test. The Contractor shall summarize and report ESS results, including failure determination data, in the Status Report.

(B/F/K/P/T001, DI-SESS-81629B) (B/F/K/P/T002, DI-MGMT-80368A)

File No. FD2060-24-31163 Page 13 of 57

If an uncosted Engineering Change Proposal proposes to use a part that has a temperature range not meeting the temperature requirements of the target LRU, the Contractor shall first have conducted ESS using a prototype item with the proposed Engineering Change Proposal incorporated. If a costed Engineering Change Proposal proposes to use a part that has a temperature range not meeting the temperature requirements of the target LRU, the Contractor shall include ESS in the proposed Engineering Change Proposal. See paragraph 2.8.1 for other

Engineering Change Proposal requirements.

2.2.2 Production Acceptance Test

The Contractor shall conduct Acceptance Test on each production SRU sold separately and on each production SRU sold as part of an LRU. See Attachment 2 for a list of SRUs. For production SRUs sold separately, the contractor shall conduct SRU Acceptance Test after the

SRU passes its ESS. The Contractor shall conduct Acceptance Test on each production LRU after the LRU passes its ESS. See 0 for a list of LRUs. The Contractor shall conduct

Acceptance Test using Government approved Acceptance Test Procedures (ATPs). The

Contractor shall document Acceptance Test results in Test/Inspection Reports, using

DI-NDTI-80809B as a guide. The Contractor shall store Test/Inspection Reports and make them available to the Government upon request for up to five years after contract end.

2.2.2.1 Production LRU ATPs

Government approved pre-production LRU ATPs are acceptable for production (i.e.

resubmission not required). Government approved LRU ATPs from a prior contract are acceptable (i.e. resubmission not required). The Contractor remains responsible for the design, development, fabrication, and maintenance of test hardware and software to support its ATPs.

Software needed to run or automate the ATP is part of the ATP by definition.

When a change to any Government approved ATP is needed due to a defect discovery or engineering change, the Contractor may submit an unsolicited ATP update for Government approval, or submit the ATP update as part of an Engineering Change Proposal, as applicable.

The Contractor shall submit a technical justification with the changed ATP. The Contractor shall obtain Government approval of each proposed ATP change before using the ATP for Acceptance

Test.

2.2.2.2 Production SRU ATPs

The Contractor may use Government approved SRU ATPs from a prior contract (i.e.

resubmission not required). A Contractor with qualified LRUs may or may not have Government approved ATPs for Attachment 2 SRUs. The requirements of this paragraph apply to a

Contractor that does not have Government approved ATPs for Attachment 2 SRUs. The

Contractor shall prepare and submit for Government approval an ATP for each SRU listed in

Attachment 2. The Contractor shall obtain Government approval of each ATP before using the

ATP for Acceptance Test. The Contractor shall have performed dry-run Acceptance Test using https://usaf-my.dps.mil/personal/richard_hennig_2_ctr_us_af_mil/Documents/Microsoft%20Teams%20Chat%20Files/%20/l https://usaf-my.dps.mil/personal/richard_hennig_2_ctr_us_af_mil/Documents/Microsoft%20Teams%20Chat%20Files/%20/l https://usaf-my.dps.mil/personal/richard_hennig_2_ctr_us_af_mil/Documents/Microsoft%20Teams%20Chat%20Files/%20/l

File No. FD2060-24-31163 Page 14 of 57 its unapproved ATP before submitting it to the Government for approval. The Contractor shall design, develop, and fabricate test hardware and software for ATP use, making use of commercial equivalent test hardware/software where practical. The Contractor's ATP procedures may differ from the TDP's ATP procedures to accommodate different test hardware.

The Contractor's ATP shall identify commercial equivalents of Contractor-peculiar test SOW 3.4 hardware/software. Software needed to run or automate the ATP is part of the ATP by definition.

The Contractor shall deliver ATP software with the ATP. ATPs included in the TDP are for reference only and may lack ATP software. ATPs included in the TDP are intended to provide a starting baseline for the Contractor's preparation of its ATP test cases and pass criteria. ATPs included in the TDP may contain imperfect test cases and pass criteria, or may depend on software that is no longer available. See also paragraph 4.1.7 concerning an ATP that is missing from the TDP. The Contractor's ATP test cases and pass criteria may therefore deviate from the

ATPs contained in the TDP. When deviations from the TDP's ATP test cases or pass criteria are needed, the Contractor shall submit a technical justification for the deviations concurrent with the ATP submission. Acceptability of the deviations is at the sole discretion of Government engineering.

(Exhibit D,H,M,R,V DI-NDTI-80603A)

2.2.3 Production Interchangeability Test

Production Interchangeability Test differs from Pre-production Interchangeability Test in its scope and purpose. The purpose of Production Interchangeability Test is to ensure standardization of the Contractor's production items. In other words, to ensure that an

Engineering Change Proposal implementation will not impact individual LRU's or SRU's form, fit, and function. The Contractor shall conduct Production Interchangeability Test before submitting uncosted Engineering Change Proposals and report the test results in the Engineering

Change Proposal. The Contractor shall include a requirement for Interchangeability Test as part of a costed Engineering Change Proposal submission. Production Interchangeability Test consists of:

• Conducting an SRU Acceptance Test with the proposed Engineering Change Proposal installed. (This requirement does not apply when the Contractor does not have a

Government approved ATP for the affected SRU.);

• Placing the SRU, with the proposed Engineering Change Proposal installed, into a

Contractor produced LRU and performing LRU Acceptance Test;

• Placing the SRU, with the proposed Engineering Change Proposal installed, into a

Government Furnished Tracor LRU and performing LRU Acceptance Test; and

• Placing the SRU, with the proposed Engineering Change Proposal installed, into a

Government Furnished Symetrics LRU and performing LRU Acceptance Test; and https://usaf-my.dps.mil/personal/richard_hennig_2_ctr_us_af_mil/Documents/Microsoft%20Teams%20Chat%20Files/%20/l

File No. FD2060-24-31163 Page 15 of 57

See paragraph 3.1 for Government Furnished Equipment. See paragraph 2.8.1 for other

Engineering Change Proposal requirements. The Production Interchangeability Test requirement does not apply when an Engineering Change Proposal:

• affects the Safety Switch because it has no SRUs, or

• does not affect an item's technical requirements. For example, altering a drawing to change the suggested source of supply.

2.3 System Software Loading

The Contractor is responsible for fabricating or procuring all hardware, software (excluding

Government Furnished Software (GFS) as identified in paragraph 3.3), and technical skills required to meet the requirements of System Software Loading subparagraphs. The Government may render little or no System Software Loading technical assistance to the Contractor.

2.3.1 Control Display Unit (CDU)

Before CDU sell-off, or, when sold separately, before Central Processing Unit (CPU) Circuit

Card Assembly (CCA) (reference designator 1A3A1) sell-off, the Contractor shall load

Firmware as indicated in paragraph 3.3, or as directed by the Procuring Contracting Officer

(PCO).

2.3.2 Programmer

Before Programmer sell-off, the Contractor shall load firmware and software into the

Programmer, or, when sold separately, the CPU CCA (reference designator 2A3) or PGMR

CPU-Discrete Interface CCA (reference designator 2A4) as indicated in paragraph 3.3, or as directed by the Procuring Contracting Officer (PCO).

2.3.3 Sequencer

Before Sequencer sell-off, the Contractor shall load firmware and software into the Sequencer, or when sold separately, the Control Logic CCA (reference designator 8A2A2) as indicated in paragraph 3.3, or as directed by the Procuring Contracting Officer (PCO).

2.4 Lead-Free Control Plan

The Contractor shall develop a Lead-Free control plan to ensure that all equipment supplied by the Contractor shall meet the reliability and product life requirements of project specification(s) including the absence of, and prevention of Tin Whiskers and other deficiencies caused by the use of Lead-Free solder and components. The authorized soldering processes (SnPb, 1, 2, 3, or

4) identified in paragraph 6.2.3 and associated Table 1 of WR-ALC Lead-Free Control Plan assure meeting these reliability requirements. The use of non-Sn (e.g. gold, nickel palladium, nickel palladium gold) as a termination finish is permitted (process 1) and presents no Tin whisker risk. The use of hot solder dipping (process 2); pure Sn as a termination finish (process

3); and pure Sn as a termination and board finish (process 4) present reliability risks due to Tin

File No. FD2060-24-31163 Page 16 of 57 whiskering, but are permitted provided Tin whisker mitigation per GEIA-STD-0005-2 has been utilized.

The Lead Free Control Plan shall implement all applicable provisions of WR-ALC Lead-Free

Control Plan and shall demonstrate how the Contractor shall be compliant with same. The

Contractor's Lead-Free Control Plan shall include provisions for testing, evaluation, and analysis to ensure that any hardware produced under this contract shall meet the expected reliability requirements of the TDP associated with this effort. The Contractor shall include the testing requirements into any Qualification Test Plan/Procedures required under this contract.

(B/F/K/P/T003, DI-MISC-80508B)

2.5 Program Management

The Contractor shall perform program management tasks. Tasks include planning, budgeting, financial management, Pre-production schedules, Production schedules, and directing and monitoring contract tasks. The Contractor shall submit regular Status Reports and Integrated

Master Schedules. The Status Report shall contain information on warranty returns, repair information, and number of items delivered. Repair information is cumulative identification of the failed SRUs and associated components.

(B/F/K/P/T002, DI-MGMT-80368A) (B/F/K/P/T005, DI-MGMT-81650)

2.5.1 Post Award Conference

The Contractor shall attend a Post Award Conference at Robins Air Force Base within 60 days of contract award. The Contractor shall submit a conference agenda and conference minutes. The

Post Award Conference is intended to ensure that all parties understand the contract requirements and to identify and clarify the roles of Government personnel who will be involved in performance assessment and the contract administration. At the Government's option, it may elect to replace travel with teleconference for the Post Award Conference. As a minimum, the below topics shall be addressed at the Post Award Conference.

• Points of Contact and roles

• Contract Performance Assessment Report (CPAR)

• Statement Of Work review

• Deliverables and Acceptance Procedures

• Payment and Invoice Procedures

• Government Furnished Property

• Safety Requirements

• Security Procedures and Requirements

• Technical Manual Update Requirements

• Engineering Data Guidance Conference (See paragraph 2.8.5.1)

(B/F/K/P/T006, DI-ADMN-81249C) (B/F/K/P/T007, DI-ADMN-81250C)

File No. FD2060-24-31163 Page 17 of 57

2.5.2 Program Management Reviews (PMRs)

The Contractor shall schedule and conduct four annual PMRs during each of the first two years

(if in pre-production) and up to two annual PMRs during the years thereafter. The Contractor shall host half of the PMRs at its facility, and travel to Robins Air Force Base for the other half.

At the Government's option, it may elect to replace travel with teleconference for any PMR. The

Contractor shall combine all conferences/meetings to fullest extent possible. The Contractor shall submit a conference agenda and conference minutes for each meeting. Key topics for review should include, but are not limited to: Recent accomplishments, progress against

Integrated Master Schedule, progress towards manufacturing readiness, Diminishing

Manufacturing Sources and Material Shortages (DMSMS) activities, change proposals, risk and risk mitigation, status of contract deliverables, supplier progress/issues.

(B/F/K/P/T006, DI-ADMN-81249C) (B/F/K/P/T007, DI-ADMN-81250C)

2.5.3 Technical Interchange Meetings (TIMs)

The Contractor shall host, conduct, and document up to five (5) TIMs for the life of the contract.

At the Government's option, it may elect to replace travel with teleconference for any TIM. The

Contractor shall submit a conference agenda and conference minutes for each meeting. At the

Government's option, it may elect to replace travel with teleconference for any TIM.

(B/F/K/P/T006, DI-ADMN-81249C) (B/F/K/P/T007, DI-ADMN-81250C)

2.5.4 Production Surveillance and Reporting System

The Contractor shall submit Production Status Reports documenting a surveillance system. The surveillance system shall document the progress toward meeting milestones and contractual delivery schedules. The system shall identify factors that may prevent hardware delivery in accordance with the schedule. The system shall reflect the time phasing of critical components from order release through final stocking. Critical components include in-house and major purchased/subcontract items.

(B/F/K/P/T004, DI-MGMT-81255)

2.6 Communications

The Contractor shall not divulge information related to this effort to any parties other than those called out in this Statement Of Work without written permission from the Government Procuring

Contracting Officer (PCO). The Contractor and the Government need to communicate effectively and in a timely manner with each other when issues/questions arise from the

Contractor’s investigation, analysis, or other efforts supported within this Statement Of Work.

Communications may be conducted in the form of telephone conversations, email, official letters, meetings or any other form that is needed.

File No. FD2060-24-31163 Page 18 of 57

2.7 Data Management

The Contractor shall implement and use a web site and email for communication and delivery of

CDRL items. Web site usage shall not require the Government to install Trust Certificate(s) on its computers as a condition of data access and data download. Performance of this Statement Of

Work requires the Contractor to have Microsoft Office Professional 2010 and Adobe Acrobat X

Professional or later versions thereof.

The Contractor shall establish, implement, and maintain a data management program process.

Data Management shall collect, control, and distribute documents in accordance with this

Statement Of Work and the CDRLs. The Contractor shall assure that subcontractor(s) data management procedures, programs, and data meet the requirements of this Statement Of Work.

The Contractor shall not make partial data deliveries.

The Contractor shall place the following on each and every page of data submitted under CDRL

Exhibits A, B, and D: CAGE code (Contractor's CAGE for Exhibits A and D; CAGE 98752 for

Exhibit B), document number, revision letter, and document date. Pages should be marked with the page number and the total number of pages. Some exceptions may apply, such as

Engineering Change Proposals and Notice Of Revisions, which have a predefined format and content.

2.7.1 Data Accession List (DAL)/Internal Data

The Contractor shall maintain and provide to the Government a complete listing of all internally generated data resulting from the contract. The Contractor shall deliver data listed on the DAL upon request from the Government.

(B/F/K/P/T008, DI-MGMT-81453B)

2.7.2 GFE Detail Transaction Status Data Report

The Contractor shall not alter or repair Government Furnished Equipment (GFE). The

Contractor shall be responsible for repair cost incurred by the Government, when repair results from improper storage or abuse. See also paragraph 3.1. The Contractor shall report status of the Government Furnished Equipment (GFE) on the GFE Detail Transaction Status Data Report.

(B/F/K/P/T009, DI-MGMT-80377)

2.7.3 Rights In Data

The Government shall have unlimited non-exclusive rights in data, documentation, computer software, and computer software documentation deliverable under this Statement Of Work or associated Contract Data Requirements Lists. The Government shall have unlimited non-exclusive rights in data, documentation, computer software, and computer software documentation developed exclusively with government funds or developed with mixed funding.

The Contractor shall not mark briefings, reports, drawings, or other types of data with trade

File No. FD2060-24-31163 Page 19 of 57 secrets markings, proprietary markings, or copyright markings. When the Contractor’s drawings reference design activity specifications / standards, the Contractor shall furnish the complete design requirements, including processes and materials for the item covered and shall deliver the documents without proprietary or copyright limits of any kind. Data produced directly or indirectly, using funds from this contract, becomes Government property.

2.8 Configuration Management

The product starting baseline is the TDP that the Government delivers to the Contractor. The

Contractor shall document and follow a systems engineering process for generating and incorporating new or modified drawings, Engineering Change Proposals, Notice Of Revisions, Engineering Change Orders, and Engineering Orders into the TDP. The Contractor shall incorporate new or modified drawings, Notice Of Revisions and Engineering Orders from the

Government or other manufacturers into the TDP when directed by the Government PCO. The

Contractor is responsible for having engineering capabilities (including systems engineering, reverse engineering, and software engineering) sufficient to resolve TDP defects, resolve diminishing manufacturing resources issues, resolve obsolete parts issues, use and interpret the

TDP, maintain the TDP, and produce modifications to the TDP. The Contractor shall be an accredited organization demonstrating a quality program meeting AS9100C (Quality

Management Systems - Requirements for Aviation, Space and Defense Organizations) requirements.

File No. FD2060-24-31163 Page 20 of 57

2.8.1 ECPs, NORs, And Variances

The Contractor shall prepare and submit an Engineering Change Proposal (ECP) using

DD Form 1692 and Notice Of Revision (NOR) using DD Form 1695 for any proposed TDP change. MIL-HDBK-61A shall be used as a guide in classifying Class I and Class II

Engineering Change Proposals. The Contractor shall submit price basis information for costed

Engineering Change Proposals. The Contractor shall submit costed ECPs when the

Government's cost will be $20,000 or more. Otherwise ECPs shall be uncosted (i.e. no cost). In the production phase, an uncosted Engineering Change Proposal shall report passage or failure of

ESS (if applicable) and Interchangeability Test (if applicable). When the Engineering Change

Proposal does not affect the Life Cycle Cost (LCC), the AN/ALE-47 system or support equipment, engineering, test, software, logistics, Technical Manuals, maintenance, or safety, the

Engineering Change Proposal shall so state. Otherwise, the Contractor's Engineering Change

Proposal shall include the impacts to AN/ALE-47 system and support equipment, engineering, test, software, logistics, Technical Manuals, maintenance impacts, safety, and include a Life

Cycle Cost (LCC) analysis. Software includes test software, software used to program programmable devices, Computer Software Configuration Items (e.g., OFPs), and Mission Data.

Applicable Technical Manuals are 12P3-2ALE47-3 and 12P3-2ALE47-4. See paragraph 2.8.6 for other Technical Manual Requirements. The Contractor shall initially categorize any hardware change that impacts software as a Class I change. With the exception of changes associated with costed Engineering Change Proposals and Class I changes, the Contractor shall incorporate all Government approved Notice Of Revisions and Engineering Orders into the TDP.

The Contractor shall incorporate changes associated with costed Engineering Change Proposals and Class I changes into the TDP only when the change is incorporated into the contract by contract modification, or when directed by the Government PCO. The Contractor shall incorporate Notice Of Revisions and Engineering Orders into the drawings when the Contractor is the current design activity. In the production phase, see paragraph 2.2.1 for ESS requirements and paragraph 0 for Interchangeability Test requirements related to Engineering Change

Proposal submission.

The Contractor shall not consider any Request For Variance to be effective until it is incorporated into the contract by contract modification, or until directed by the Government

PCO. The Contractor shall use DD Form 1694 to submit Request For Variances. The scope of

Request For Variances is the Contractor's ATPs and all TDP content excluding the TDP's ATPs.

The Contractor shall address safety in every Request For Variance.

The ALE-47 Air Force engineering office has the discretionary right to require any Engineering

Change Proposal to include Government Inspection And Test. Government Inspection And Test may include dimensional verification, Interchangeability Test, LRU testing, and some software testing for LRUs containing software.

File No. FD2060-24-31163 Page 21 of 57

The ALE-47 AF engineering office will approve Class I Engineering Change Proposals, Notice of Revisions and all deviations. The contractor is required to notify the cognizant government engineering office of any proposed Class II ECPs prior to approval and implementation. The contractor shall provide a copy of the proposed Class II ECP along with supporting rationale.

The cognizant government engineering office will have 45 days to review such Class II ECPs. If a determination is made that such Class II ECP is more appropriately categorized as a Class I

ECP, the contractor will submit it as such. If the cognizant government engineering office deems such ECP to be appropriate as a Class II, the contractor may then proceed to submit such Class II

ECP along with the governments' affirmation of such to DCMA for approval. DCMA will approve Class II Engineering Change Proposals, Notice of Revisions in such cases as deemed appropriate by the cognizant government engineering office.

(B/F/K/P/T00A, DI-SESS-80639E) (B/F/K/P/T00B, DI-SESS-80642E) (B/F/K/P/T00C,

DI-SESS-80640E)

2.8.2 Programmable Devices

The Contractor shall have a capability to load firmware and software into components such as

Field Programmable Gate Arrays (FPGA), Programmable Array Logic (PAL), and Erasable

Programmable Read Only Memory (EPROM). The Government provided TDP may lack source code for programmable devices. The Government cannot and will not provide missing source code for programmable devices. The Contractor may need to reverse engineer programmable device object code to the extent needed to satisfy the requirements of this Statement Of Work.

As part of Engineering Change Proposal submission, Notice Of Revision submission, or TDP updates, the Contractor shall develop and deliver drawings (i.e. a software product specification), using DI-IPSC-81441A as a guide, for programmable devices that it replaces due to hardware changes. The drawings shall include source and object code. This software requirement does not apply to Operational Flight Programs (OFPs) and Mission Data Files

(MDFs).

(C/G/L/Q/U001, DI-SESS-81000F/T)

2.8.3 Parts Management

The Contractor shall prepare and submit for Government approval a Parts Management Plan

(PMP). The Contractor may use MIL-STD-3018 as a guide in PMP preparation. The plan shall include a Parts List cross referenced to the TDP's Parts List Item Numbers. Parts identified in the TDP are the starting baseline for the Parts List. The PMP shall address the following:

• Government participation in parts selection,

• procedures for authorizing changes to the Parts List,

• obsolete parts management procedures,

• subcontractor management,

• parts quality, and

• parts documentation.

File No. FD2060-24-31163 Page 22 of 57

The Contractor shall disclose point of contact information for the source of parts supply to the

Government when so requested. The Contractor shall accomplish 100% parts traceability from the purchase orders to the LRU part number and serial number (if applicable), SRU part number and serial number, contract delivery order, and shipped-to address.

The Contractor is responsible for having the engineering and reverse engineering capability necessary to accomplish parts replacement and redesign associated with diminishing manufacturing resources and parts obsolescence, including reverse engineering associated with

FPGAs and PAL components and associated software. The Contractor shall maintain a parts control program and use qualified parts per MIL-STD-965 when available. The Contractor shall use only new, not other-than-new parts in AN/ALE-47 LRU and SRU manufacture. The

Contractor shall notify the Government that a part is obsolete or will become obsolete within two months of the manufacturer's publication of a Last Time Buy Date. If the manufacturer did not publish a Last Time Buy Date, the Contractor shall notify the Government within two months of learning that a part is obsolete or will become obsolete. To resolve obsolete parts issues, the

Contractor shall follow and accomplish the below steps, in order, within six (6) months of a part becoming obsolete. A lifetime buy of an obsolete part does not meet the requirements of this

Statement Of Work.

a) Locate a second source. If unsuccessful then:

b) Locate a different MIL-qualified part that performs the same function without redesign.

Submit an Engineering Change Proposal and Notice Of Revision for the MIL-qualified part in accordance with paragraph 2.8.1. If unsuccessful then:

c) Locate a non-standard part that performs the same function without redesign. Submit an

Engineering Change Proposal and Notice Of Revision for the non-standard part in accordance with paragraph 2.8.1.. (A separate non-standard parts request is not required.) If unsuccessful then:

d) Submit an Engineering Change Proposal and Notice Of Revision for redesign in accordance with paragraph 2.8.1..

The Contractor shall use Engineering Change Proposals and Notice Of Revisions to overcome parts obsolescence or correct latent design deficiencies (i.e., correct errors found in the TDP).

No changes shall be permitted that affect the form, fit, or function of the individual LRU, SRU, the system’s functional allocation, or interface definition.

(B/F/K/P/T00D, DI-SDMP-81748/T)

2.8.4 Counterfeit Prevention Plan

The Contractor shall prepare and submit for Government approval a Counterfeit Prevention Plan

(CPP) for counterfeit parts avoidance, detection and reporting. The Contractor shall base the plan on ASE AS 5553, Aerospace Standard for Counterfeit Electronic Parts; Avoidance, Detection, Mitigation, and Disposition. The Contractor shall identify all Business locations and programs to which the plan applies.