SOW.pdf

DISTRIBUTION STATEMENT A. Approved for public release: Distribution is unlimited.

9 January 2019

Statement of Work (SOW) for

TRAILER, MUNITIONS HANDLING

Master NSN 1740-01-644-2083RN (Class 1, MHU-110V2) Master NSN 1740-01-644-2085RN (Class 2, MHU-141V2)

Prepared by

SUPPORT EQUIPMENT AND VEHICLES DIVISION

235 BYRON ST STE 19A

ROBINS AFB GA 31098-1813

THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS

1. APPLICABLE DOCUMENTS

2. Applicable Documents

2.1 Government documents

2.1.1 Specifications, standards, and handbooks

2.1.2 Other Government documents, drawings, and publications

2.2 Non-Government publications

2.3 Order of precedence

3. REQUIREMENTS

3.1 Program management

3.1.1 Program manager

3.1.2 Plant access

3.1.3 Monthly status report

3.1.4 Integrated master plan (IMP)

3.1.5 Integrated master schedule (IMS)

3.2 Conferences and program reviews

3.2.1 Post Award conference

3.2.2 Technical reviews

3.2.2.1 Design reviews

3.2.2.1.1 Design review location and schedule

3.2.2.1.2 Design review content

3.2.2.2 Test readiness review (TRR)

3.2.2.3 Technical review documentation

3.2.3 Program Management Review support

3.2.4 Conference room

3.2.5 Meeting agendas

3.2.6 Meeting minutes

3.3 Systems engineering

3.3.1 Environment, Safety, and Occupational Health (ESOH)

3.3.1.1 System safety

3.3.1.2 Hazardous materials

3.3.2 Corrosion control

3.3.3 Reliability-Centered Maintenance (RCM) analysis

3.3.4 Risk management

3.3.5 Design analysis

3.3.6 Finite element analysis (FEA)

3.3.7 Correlating finite element model to ground testing

3.3.8 Fatigue analysis

3.3.9 Damage tolerance and repair report (DTARR)

3.3.10 Aircraft transportability certification

3.3.11 MHU-141V2 nuclear surety certification

3.4 Logistics

3.4.1 Technical Order (TO) requirements

3.4.1.1 TO content

3.4.1.2 In-process review of Technical Data (T.O.) data

3.4.2 Provisioning

3.4.2.1 Provisioning Guidance Conference

3.5 Inspection (testing and evaluation)

3.5.1 First article

3.5.1.1 First article test plan

3.5.1.2 First article test procedure

3.5.1.3 First article testing

3.5.1.3.1 DT&E (contractor testing)

3.5.1.3.1.1 Test instrumentation

3.5.1.3.1.2 Test daily situation reports (SITREPs)

3.5.1.3.2 OT&E (Government testing)

3.5.1.3.2.1 OT&E locations

3.5.1.3.2.2 OT&E follow-on

3.5.1.3.2.3 OT&E report

3.5.1.3.3 First article test report

3.5.1.4 First article approval

3.5.1.5 First article restoration

3.5.1.6 First article disposition

3.5.2 Production acceptance test procedure and report

3.6 Configuration management

3.6.1 Configuration requirements

3.6.1.1 Baselines

3.6.1.1.1 Functional baseline

3.6.1.1.2 Allocated baseline

3.6.1.1.3 Product baseline

3.6.1.2 Production release

3.6.2 Engineering Change Proposals (ECPs)

3.6.3 Request for Deviation (RFD)

3.6.4 Engineering data

3.6.4.1 Model-based TDP (MTDP)

3.6.4.1.1 3D Models

3.6.4.1.1.1 Notes and Dimensions

3.6.4.1.1.2 Material

3.6.4.1.1.3 Standard Views

3.6.4.1.1.4 Assemblies

3.6.4.1.1.5 Parts List/Bill of Materials Integration

3.6.4.1.1.6 Applied Items and Non-Geometric Models

3.6.4.1.1.7 Multiple Configurations

3.6.4.1.1.8 Multi-Detail and Inseparable Assemblies

3.6.4.1.1.9 Reference Models

3.6.4.1.2 3D Intelligent PDFs (3Di PDFs)

3.6.4.1.2.1 File Names

3.6.4.1.2.2 USAF Native Files

3.6.4.1.2.3 Reference Model Files

3.6.4.1.2.4 Derived Neutral Files

3.6.4.1.2.5 Other Files

3.6.4.1.3 Metadata

3.6.4.1.4 Verification and validation

3.6.4.2 TDP requirements

3.6.4.3 Engineering Data Guidance Conference

3.6.4.4 In-Process review (IPR) of the TDP

3.6.4.5 Relationship of contractor with subcontractors/vendors

3.6.4.6 Engineering data updates and revisions

3.7 Government furnished equipment (GFE)

3.8 Warranty

1. SCOPE

This document defines the tasks associated with the procurement of two (2) munitions trailer classifications, the MHU-110V2, NSN 1740-01-644-2083RN and MHU-141V2, NSN 1740-01- 644-2085RN, Munitions Trailer, as described by PD15WRWNZEA05 and is to be used in conjunction with PD15WRWNZEA05.

2. APPLICABLE DOCUMENTS

The following documents are applicable to the SOW to the extent specified herein.

2.1 Government documents.

2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this SOW to the extent specified herein.

FEDERAL STANDARDS

FED-STD-313E Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-882E System Safety MIL-STD-1568D Materials and Processes for Corrosion Prevention and

Control in Aerospace Weapons Systems

2.1.2 Other Government documents, drawings, and publications.

AIR FORCE INSTRUCTION (AFI)

AFI 32-7086 Hazardous Materials Management, dated 4 Feb 2015

(Copies of this document are available online at http://www.e-publishing.af.mil/.)

DATA ITEM DESCRIPTIONS (DIDs)

DI-MGMT-80004A Management Plan DI-SAFT-80101C System Safety Hazard Analysis Report DI-MGMT-80227 Contractor's Progress, Status and Management Report DI-MISC-80508B Technical Report/Study Services DI-NDTI-80603A Test Procedure DI-SESS-80639D Engineering Change Proposal (ECP) DI-SESS-80640D Request for Variance (RFV) DI-SESS-80642D Notice of Revision (NOR)

DI-NDTI-80809B Test/Inspection Report DI-SESS-81000E Product Drawings/Models and Associated Lists DI-CMAN-81218 Product Base Line Index (PBLI) DI-ADMN-81249A Conference Agenda DI-ADMN-81250B Conference Minutes DI-SAFT-81626 System Safety Program Plan DI-SESS-81758 Logistics Product Data DI-MGMT-81861A Integrated Program Management Report (IPMR) DI-SESS-81874 Engineering Data for Provisioning (EDFP)

DI-NDTI-80566A Test Plan DI-MFFP-81403 Corrosion Prevention and Control Plan DI-GDRQ-81256B Mathematical Model Finite Element Structure Report DI-GDRQ-81257A Mathematical Model Finite Element Analysis Report DI-SESS-81485A Durability and Damage Tolerance (DADT) Test Report

(Copies of these documents are available online at http://quicksearch.dla.mil.)

DEPARTMENT OF DEFENSE GUIDES

(no identifier) Risk Management Guide for DoD Acquisition, Sixth Edition, Version 1.0

GEIA-HB-0007A Logistics Product Data Handbook

(Copies of this document are available online at http://www.GEIA.org.)

DEPARTMENT OF DEFENSE MANUALS

TM-86-01Q Air Force Technical Manual Contract Requirements

PURCHASE DESCRIPTIONS

PD15WRWNZEA05 TRAILER, MUNITIONS HANDLING

2.2 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

N/A

2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Program management.

3.1.1 Program manager. The contractor shall identify to the Government and maintain a single point of contact (Program Manager) for all matters under this contract. The contractor shall also ensure that all program management personnel assigned to the program shall be available, as required, to meet program objectives.

3.1.2 Plant access. The contractor shall arrange for full access to applicable contractor facilities and offices by Government representatives conducting any business, making observations, or performing inspections required by public law or by this contract.

3.1.3 Monthly status report. The contractor shall track program progress and document such via monthly status reports. The contractor shall submit a monthly status report that shall cover the engineering and technical development of the system and subsystems as well as a projection of planned work for the remaining effort. Reports shall document tasks, issues, actions, and deliverables. Problem areas shall be identified with proposed solutions and outcomes. The current program integrated master schedule (IMS) (see 3.1.5) and risk management analysis, mitigation plan, and tracking (see 3.3.4) shall be provided as an attachment to the monthly status report.

(DI-MGMT-80227, Contractor's Progress, Status and Management Report, A001)

3.1.4 Integrated master plan (IMP). The contractor shall implement and maintain the proposed IMP for this program. (DI-MGMT-80004, Management Plan, A002)

3.1.5 Integrated master schedule (IMS). A baseline IMS shall be developed at the start of the program in accordance with DI-MGMT-81861, A003, Format 6. The contractor shall implement and maintain the IMS using the original baseline schedule as an unchanging reference. The IMS shall be provided in both Microsoft Project and PDF formats as an attachment to the monthly status report (see 3.1.3). (DI-MGMT-81861, Integrated Program Management Report (IPMR), A003)

3.2 Conferences and program reviews.

3.2.1 Post Award conference. The Government will convene a post award conference with the contractor at Robins AFB, GA within 45 working days after contract award. The Procuring Contracting Officer (PCO) will coordinate the actual date, time, and location of the conference with the contractor.

3.2.2 Technical reviews.

3.2.2.1 Design reviews.

Design review location and schedule. The contractor shall host and conduct a preliminary design review (PDR) within 180 calendar days after the contract is awarded. The contractor shall host and conduct a critical design review (CDR) within 270 calendar days after the contract is awarded. The design reviews shall be held at the contractors location/facilities. The PCO will coordinate the actual date, time, and location of the reviews with the contractor.

Design review content. The contractor shall provide copies of PDR and CDR presentation 25 calendar days prior to PDR and CDR to the Government for review. The PDR and CDR shall include formal technical reviews of the proposed design; program risks shall be reviewed on a technical and schedule basis. Each review shall include, but is not limited to, the following:

preliminary calculations; any necessary design studies or analyses including the design analysis as required in 3.3.5 preliminary drawings, including equipment layout drawings (packaging), order of manufacturing, manufacturing inspection tables and jigs/tooling, components, and information electrical and mechanical design environmental control thermal design aspects training materials lists of materials, parts, and processes human engineering elements corrosion control maintainability production capability and manufacturing quality considerations

Final drawings, final calculations, and any mockups or any assemblies shall be made available for the Government review as well. All applicable comments from the PDR shall be incorporated into the CDR design documentation.

3.2.2.2 Test readiness review (TRR). The contractor shall host a test readiness review (TRR) 14 days prior to the start of the developmental test and evaluation (DT&E) of the trailers. The TRR shall assess test objectives, test methods and procedures, scope of tests, and determine if required test resources have been properly identified and coordinated to support planned tests. Further, the contractor shall support a Government TRR prior to operational test and evaluation (OT&E), via electronic support such as email or teleconference. Similar to the DT&E TRR, the OT&E TRR shall assess test objectives, test methods and procedures, scope of tests, and determine if required test resources have been properly identified and coordinated to support planned tests.

3.2.2.3 Technical review documentation. The contractor shall prepare all necessary detailed status reports for the technical review meetings, conference agendas, and conference minutes. The contractor shall prepare formal documentation of the PDR, CDR, and TRR. (DI-MISC-80508, Technical Report/Study Services, A004)

3.2.3 Program Management Review support. The contractor shall participate in and support all reviews, audits, and meetings as requested by the PCO or the contractor. Program Management Reviews shall be conducted quarterly or as required at a mutually agreeable location or via teleconferences.

3.2.4 Conference room. The contractor shall provide a conference room suitable for meetings of up to 10 Government representatives, plus contractor personnel, in support of scheduled meetings at the contractor’s facility.

3.2.5 Meeting agendas. The contractor shall publish an agenda for all meetings and conferences specified in 3.2.2 and 3.2.3. The contractor shall request from the Government any items or issues to be discussed or presented at the meetings, and shall include such items in the agenda. Agendas shall be submitted not less than five working days prior to any meeting. (DI-ADMN-81249, Conference Agenda, A005)

3.2.6 Meeting minutes. The contractor shall provide a written record of the discussions, decisions, and action items identified at each meeting. Minutes shall include presentation material.

(DI-ADMN-81250, Conference Minutes, A006)

3.3 Systems engineering.

3.3.1 Environment, Safety, and Occupational Health (ESOH).

3.3.1.1 System safety. The contractor shall establish, conduct, document, and maintain a system safety program in accordance with MIL-STD-882. The contractor shall document their approach for analyzing, eliminating, or minimizing ESOH hazards during all phases of the program. The contractor shall initiate changes in the system design based on safety analysis results such that the associated risk is reduced to a level acceptable to the Government. An initial system safety hazard analysis shall be provided 14 days prior to the PDR; updated versions of the analysis shall be provided 14 days prior to the CDR, 14 days prior to the TRR, and with the trailer test report(s).

(DI-SAFT-81626, System Safety Program Plan (SSPP), A007; DI-SAFT-80101, System Safety Hazard Analysis Report (SSHAR), A008)

3.3.1.2 Hazardous materials. The contractor shall manage hazardous materials, including those embedded in the system or used during operation or maintenance, as an element of the Systems Engineering process. The system shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. The use of hexavalent chromium is also prohibited. The contractor shall list any hazardous materials, as defined in AFI 32-7086 Hazardous Materials Management, to be delivered under this contract, including locations, quantities, and special handling and disposal procedures. This information shall be documented in the design analysis (see 3.3.5) and reviewed at the technical reviews; it shall be in accordance with

FED-STD-313.

3.3.2 Corrosion control. The contractor shall establish, conduct, document, and maintain a corrosion prevention control program; it shall be documented in a corrosion prevention and control plan in accordance with 4.1 of MIL-STD-1568. The initial corrosion prevention and control plan shall be provided 14 days prior to the PDR; the second submission of the plan shall be provided 14 days prior to the CDR. (DI-MFFP-81403, Corrosion Prevention and Control Plan, A009)

3.3.3 Reliability-Centered Maintenance (RCM) analysis. The contractor shall perform RCM analysis in order to develop preventive maintenance tasks and intervals in accordanc with 4.6.16 of PD15WRWNZEA05. The RCM analysis and the preventive maintenance tasks and intervals shall be documented in the design analysis (see 3.3.5) and reviewed at the technical reviews.

3.3.4 Risk management. The contractor shall develop, implement, and conduct a risk management program; criteria can be found in the Risk Management Guide for DoD Acquisition https://www.acq.osd.mil/se/docs/2017-rio.pdf , Risk is defined as:

A measure of future uncertainties in achieving program performance goals within defined cost and schedule constraints. It has three components: a future root cause, a likelihood assessed at the present time of that future root cause occurring, and the consequence of that future occurrence.

A future root cause is defined as, “The reason, which, if eliminated or corrected, would prevent a potential consequence from occurring. It is the most basic reason for the presence of a risk.” A consequence is defined as, “The outcome of a future occurrence expressed qualitatively or quantitatively, being a loss, injury, disadvantage, or gain.” A related term is an issue, defined as, “A problem or consequence which has occurred due to the realization of a root cause. A current issue was likely a risk in the past that was ignored or not successfully mitigated.” The risk management process deals with identifying and mitigating risks so that they do not become issues.

The risk management process model includes the following activities, performed on a continuous basis:

Risk Identification

Risk Analysis

Risk Mitigation Planning

Risk Mitigation Plan Implementation

Risk Tracking

Risk identification, risk analysis, risk mitigation planning, risk mitigation plan implementation, and risk tracking shall be included as an attachment to the monthly status report (see 3.1.3).

3.3.5 Design analysis. A design analysis of the system and each subsystem shall be performed to verify compliance with this SOW and each applicable requirement of the PD. The analysis shall include, but is not limited to, the following:

system safety hazard analysis (see 4.6.5 of the PD) electro-static discharge analysis (see 4.6.7 of the PD) service life analysis (see 4.6.8 of the PD) dimensional drawing (see 4.6.11.1 of the PD) structural analysis (see 4.6.11.5 of the PD) loading analysis (see 4.6.11.6 of the PD) air transportability analysis (see 4.6.12.1 of the PD) tie-down provision analysis (see 4.6.12.3 of the PD) lifting provision analysis (see 4.6.12.4 of the PD) surface transportability analysis (see 4.6.12.5 of the PD) maintainability analysis (see 4.6.16.1 of the PD) parking brake and service brake analysis (see 4.6.17.1.3 of the PD)

A Material Safety Data Sheet (MSDS) shall be provided for each hazardous material identified for use in the program (see 3.3.1.2 herein). An initial design analysis shall be provided 14 calendar days prior to the PDR; updated versions of the analysis shall be provided 14 working days prior to the CDR, 14 working days prior to the TRR, and with the first article test report. (DI-MISC-80508, Technical Report/Study Services, A00A)

3.3.6 Finite element analysis (FEA). The Contractor shall evaluate the equipment/all major structural components under worse case loading conditions using an FEA program, and provide a report to the Government for review and acceptance. The FEA program used to support analysis shall be identified to the Government and referenced within the report. All assumptions, materials selected, analysis/verification techniques [for example, element type(s), mesh types, size(s) and plots, loads, boundary conditions, and real world results/data, etc.] shall be presented and identified within the report for each item analyzed. Empirical or hand calculations shall be presented to verify computer model and analysis output. The Government will identify, with support by the Contractor, items requiring FEA. The Contractor shall supply all CAD models used to conduct FEA in native and neutral (IGES, STEP, etc) file format. (DI-GDRQ-81256, Mathematical Model Finite Element Structure Report, A00B; DI-GDRQ-81257, Mathematical Model Finite Element Analysis Report, A00C)

3.3.7 Correlating finite element model to ground testing. Results from the FEA, per paragraph 3.3.6, shall be reviewed post first article testing. The computer-based model and FEA shall updated/corrected, as necessary, in order to achieve software solution convergence to within +/- 6% of values resulting from instrumented first article testing. (DI-MISC-80508, Technical Report

– Study/Services, A00D)

3.3.8 Fatigue analysis. Post delivery of requirements per 3.3.7, the Contractor shall conduct fatigue analysis of critical components subject to cyclic loading in order to estimate equipment failure timeframes, order of failure within the equipment, etc. Material endurance limits shall account for effects such as, but not limited to the following (DI-MISC-80508, Technical Report – Study/Services, A00E):

size effect loading effects surface finish surface treatments temperature environment

S-N curves or constant life fatigue data for the applicable materials shall be used to drive fatigue life expectancy. Stress concentration factors, S-N curves, or constant life fatigue data used shall be obtained from Government-accepted publications (for example, Metallic Material Properties Development and Standardization Handbook). To prevent premature failure caused by repeated loads, the design and manufacturing methods of all parts and the techniques by which they are assembled and installed shall be such that applied or residual tensile stresses and stress concentrations are minimized. The contractor shall be responsible for researching and proposing load transmissions/history that map to Air Force field use and account nuclear certifications requirements in accordance with AFI 63-125, AFI 91-103, and AFI 91-107 as appropriate. The contractor shall provide detail explanation for load history selection and provide rationale as to why it is considered representative of service life loading conditions and expectations.

3.3.9 Damage tolerance and repair report (DTARR). The Contractor shall generate and deliver a DTARR to the Government. The Contractor shall propose to the Government and coordinate any items recommended for DTARR evaluation. This report shall include, but not be limited to, the following (DI-SESS-81485, Durability and Damage Tolerance (DADT) Test Report, A00F):

account for maximum allowable limits in regards to corrosion, material deformation, surface scratches, cracking, gouges, missing material, misdrills, holes, fastener hole elongation, etc., for each structural member experiencing critical loading during travel and operation incorporate comprehensive instruction(s) of repair procedures for the types and locations of damage typical of use

Individual FEA-generated von Mises stress plots, principal stress plots, as well as associated displacements and strains, shall be presented for each structural component detailed within

3.3.8. Load distribution and loading applied to each member, along with associated rationale, shall be provided for each scenario within the report.

The FEA/CAD program used to determine damage tolerance shall be identified to the Government and included within the report. All simplifications and assumptions (and associated rationale), materials and mechanical properties selected, and analysis/verification techniques [for example, element type(s), mesh types, size(s) and plots, loads, boundary conditions, and real world results/data, etc.] shall be presented and identified within the report for each item analyzed.

Empirical or classical stress analysis shall be presented within the appendix of the report to verify the FEA data output.

3.3.10 Aircraft transportability certification. The contractor shall support the independent Government analysis of air transportability for the trailers. The contractor is responsible for providing all data described in PD15WRWNZEA05 and this SOW to the procuring activity in order to obtain all necessary aircraft transportability certifications. This data shall be provided with the CDR and the preliminary first article test data.

3.3.11 MHU-141V2 nuclear surety certification. The contractor shall support the independent Government analysis of nuclear surety certification for the MHU-141V2 trailer. The contractor is responsible for providing all data described in PD15WRWNZEA05 and this SOW to the procuring activity in order to obtain all necessary aircraft transportability certifications. This data shall be provided with the PDR, CDR, preliminary first article test data, and final first article test report.

Data such as FEA, fatigue analysis, DTARR, brake, steering, and mobility test data will be used to determine surety of the trailer.

3.4 Logistics.

3.4.1 Technical Order (TO) requirements. The contractor shall develop and deliver technical manuals in accordance with TM-86-01. The manuals’ technical accuracy and content shall be verified before final acceptance by the Government. Note: excluding the first article trailers, no trailer delivery acceptance will occur without completed and Government accepted technical manuals. (TM-86-01, Air Force Technical Manual Contract Requirements, B001)

3.4.1.1 TO content. In addition to the normal TO content required in accordance with TM-86-01, the following special data shall also be included:

a. The information contained on the transportation data plate as it is presented on the plate (see 3.3.3.3 of the PD).

b. Upon receipt of the Air Transport Certification Letter from Air Transportability Test Loading Agency (ATTLA) at WP-AFB, the Air Transport Certification Letter file number without revision letter shall be incorporated into the Technical Manual (see 3.6.1 of the

PD).

c. A description of the pintle hook’s fastener type and the fastening torque (see 3.8.11 of the

PD).

d. Complete wiring information such as wire running lists (size, type, designation, to/from, connectors, etc.), wiring diagram, wiring schematic for the trailer shall be included

3.4.1.2 In-process review of Technical Data (T.O.) data. The contractor shall host, support, and co-chair an IPR of the T.O. data at the 30%, 75% and 100% milestone review. The IPR shall be conducted only after the contractor's quality assurance personnel have completely reviewed the T.O. data and determined that data are of sufficient quality that Government time will be effectively utilized during the review. IPR may be scheduled when possible, in conjunction with other reviews (for example, IPR of Engineering Drawings). The contractor shall notify the procuring activity a minimum of 30 working days prior to the anticipated date of completion point.

The IPR shall focus on the contractor's progress in the preparation of the TDP. The contractor shall support and provide the necessary resources, that is, meeting agenda, conference room, applicable data, minutes, and appropriate personnel available to answer any questions to perform the IPR effectively. The contractor shall correct all discrepancies identified in the IPR. All subcontractor/vendor data shall be made available for review. If the quantity of subcontractor/vendor data is of sufficient magnitude, the Government may schedule a separate IPR at the subcontractor's/vendor's facility. (DI-ADMN-81249, Conference Agenda, B002;

DI-ADMN-81250 Conference Minutes, B003)

3.4.2 Provisioning. The contractor shall identify all parts in a top-down break down format to meet system and equipment operation and supportability in accordance with the Air Force Initial Provisioning Performance Specification (IPPS). GEIA-HB-0007 shall be used as a guide. Format shall be consistent with existing Government Provisioning data system (D220). (DI-SESS-81758, Logistics Product Data, Provisioning Parts List (PPL) D001, Design Change Notices (DCNs), Statement of Prior Submission (SPS)); DI-SESS-81874, Engineering Data for Provisioning

(EDFP) D002)

3.4.2.1 Provisioning Guidance Conference. A Provisioning Guidance Conference (PGC) shall be scheduled by the Prime Provisioning Activity (PPA) and should be held within 45 days after receipt of contract. The PGC is normally held at AFGLSC PPA for approximately two days to ensure both the contractor and the Government understand the provisioning requirements on contract. If a PGC is not desired, the contractor shall submit a written request for waiver of the PGC to the PPA. In the event a waiver is approved, a mutual understanding of the Provisioning requirements must be communicated in some forum in which the AFMC Form 718 (Provisioning Performance Schedule (PPS)) must be documented/completed, signed by both the Government and contractor, and a contract modification issued, if required. (DI-ADMN-81249, Conference Agenda, D003; DI-ADMN-81250 Conference Minutes, D004)

3.5 Inspection (testing and evaluation). Inspection, test, and evaluation of the trailers shall occur in two main phases, first article testing and conformance testing. First article testing is used to show how the trailer design meets all physical and performance requirements of PD15WRWNZEA05. The contractors primary responsibility for first article testing shall be DT&E; the Government’s primary responsibility during first article testing shall be OT&E; some sharing of responsibility is expected to occur, primarily in the area of compatibility testing.

Conformance testing is sole responsibility of the contractor and used to show how production trailers conform to the Government approved design and exhibit the required level of quality.

3.5.1 First article.

3.5.1.1 First article test plan. The contractor shall develop a detailed first article test plan. The test plan shall address all requirements identified in the PD and this SOW. (DI-NDTI-80566, Test Plan, A00K)

3.5.1.2 First article test procedure. After Government approval of the test plan, the contractor shall develop detailed first article test procedures, which shall address all requirements identified in the PD and this SOW. The test procedures shall build upon and be a progression from the test plan.

The test procedures shall include items such as: data record sheets, charts, graphs, identification of test instruments by manufacturer, model number, and serial number, interconnections, planned instrumention locations, etc. along with applicable pass/fail criteria. The test procedures shall address modeling and simulation (M&S); if M&S is not applicable, the test procedures shall be so noted. (DI-NDTI-80603, Test Procedure, A00L)

3.5.1.3 First article testing. Testing and verification of the trailers shall be performed in accordance with section 4.0 of PD15WRWNZEA05. First article testing of the trailers shall occur with two phases: phase one DT&E and phase two, trailer compatibility (a subset of DT&E performed by the Government) with OT&E. Excluding any preliminary contractor testing, official first article phase one testing shall be completed within a 90 calendar day period. Phase two first article testing (compatibility and OT&E) shall also be completed within a separate 90 calendar day period. The contractor's shipping responsibility shall be as specified in the contract and shall include at a minimum: all liability and costs incurred to move all equipment to and from locations for testing and/or demonstration purposes. Each first article trailer shall be furnished with the accessories identified in PD15WRWNZEA05 for test activities. Additionally, the contractor shall ensure that a kit of common repair parts is available during phase one and phase two first article testing so that minor breakdowns do not delay the test beyond repair time required to return the trailers to serviceable condition. No official phase one or phase two first article testing shall occur prior to Government approval of test procedures and successful completion of the required TRRs.

DT&E (contractor testing). After Government approval of the first article test procedures and the TRR, the contractor shall schedule and perform the DT&E. The contractor shall notify the Government of the date, time, and location of testing 30 days prior to the start of testing to allow for successful completion of TRR and travel arrangements. The testing may be witnessed by one or more Government representatives.

3.5.1.3.1.1 Test instrumentation. The contractor shall instrument the trailer during all tests that occur during phase one testing. Instrumentation is required to correlate finite element models (FEMs) used to determine internal loads, local stresses and strains, and deflections with instrumentation measurements obtained during structural ground tests. Instrumentation and test loads can directly impact correlation efforts and it is prudent to carefully evaluate their contribution during the test planning effort. The contractor shall ensure the first article is instrumented at 15 locations (minimum); these locations shall be agreed upon by the Government and critical areas based on FEA (see 3.3.6). Potential considerations, though not exhaustive, for instrumentation and test loading requirements are provided below:

Instrumentation:

Types

• Rosette, axial, shear, deflection, etc.

Quantity

• Number of channels, consideration for back-up gages, etc.

Locations

• Left side and right side, primary load paths, back-to-back, etc.

Provisions for Additional Instrumentation

• Spare channels, extra data storage capacity, etc.

Calibration

• Manufacturer requirements, thermal compensation, etc.

Accuracy

• Manufacturer certification, range of applied loading, etc.

Linearity Checks

• Automated evaluation and reporting of issues Data Collection Sample Rate

• Storage buffer, rate during applied loading, etc.

Data Storage

• Capacity, time history, load cell feedback, etc.

Test Loading:

Load Levels and Increments

• Maximum % limit load, % limit load increments, hysteresis check

Load Case Selection

• Loading conditions which provide meaningful instrumentation measurements, etc.

Load Application and Distribution

• Whiffle trees, formers, hard points, etc.

Test Article Restraint

• Boundary conditions, constraints, load introduction fixtures, transition structure, etc.

3.5.1.3.1.2 Test daily situation reports (SITREPs). Throughout the developmental test and evaluation portion of the first article testing, the contractor shall submit a daily situation report (SITREP) that shall cover all monitored daily test activities. Examples are:

Test logs

Observed data to include: Observations, comments, anomalous conditions, or other items completed for each trailer unit

Recorded data as applicable to the type of equipment

Records of preventive maintenance activities performed

Daily Failure Reporting and Corrective Action System (FRACAS) status updates to include total number of failures occurred. Resolutions of previous failures and implementation of corrective actions applicable to the Reliability Growth Test (RGT)

FRACAS

For RGT, tracking of reliability growth to include the reliability growth curve for the number of hours completed

(DI-MGMT-80227, Contractor's Progress, Status and Management Report, A00M)

OT&E (Government testing). Following successful completion and Government approval of all phase one first article testing, the trailers shall be subjected to phase two first article testing consisting of (A) compatibility testing and (B) OT&E. See 4.3 thorugh 4.3.8 of PD15WRWNZEA05 for Government compatibility tests. As noted in 3.2.2.2 herein, a follow-on TRR shall be held (in which the contractor shall participate in but not lead) to ensure all pre-work has been completed PRIOR to start of phase two testing. USAF personnel will conduct all tests;

however on-site contractor support shall be available for the compatibility portion of the testing for one (1) week. Further, during the OT&E, on-site support shall be provided within five business days of notification for the duration of the testing period. On-site OT&E support shall only be used after exhaustion of electronic support via telephone, fax, email, etc. All OT&E shall be completed within 90 calendar days (excluding shipping time to the location). Down time due to breakage or parts failure will not count towards the total test time at either location. Copies of the latest draft effort in developing the TO for the trailers shall be available for Government use during the OT&E. All tests shall be satisfactorily completed and approved prior to first article acceptance.

3.5.1.3.2.1 OT&E locations. One MHU-110V2 trailer shall be shipped to Moody AFB, GA;

concurrently, one MHU-141V2 shall be shipped to Seymore Johnson AFB, NC. These locations shall intiate the OT&E. OT&E shall start at Moody AFB, GA with Government and contractor personell on-site; following the five business day event, staff will transition to Seymore Johnson AFB, NC for another five day OT&E start. After successful OT&E start at Moody AFB, GA and Seymore Johnson AFB, NC, the contractor shall ship one additional MHU-110V2 and one additional MHU-141V2 to Nellis AFB, NV for the second portion of OT&E. Both Government and contractor staff shall be present for initial five business day start up period. Shipping time between Moody AFB, GA/Seymore Johnson AFB, NC and Nellis AFB, NV shall be staggered in case any compatibility issues arise at Moody AFB, GA/Seymore Johnson AFB, NC; this avoids needless logistics. Note that the total OT&E time at each base is 90 days and that total OT&E time will slightly exceed 90 days total due to the staggered start. Additionally, a third MHU- 141V2 trailer shall be shipped to Barksdale AFB, LA for Governemnt only compatibility testing;

no contractor support is needed for this test; maximum duration shall be 30 days; this test shall not commence until after successful OT&E start up at Moody AFB, GA/Seymore Johnson AFB, NC, and Nellis AFB, NV.

3.5.1.3.2.2 OT&E follow-on. If significant deficiencies are noted during the OT&E or the Government recognizes the need for significant changes, an abbreviated follow-on OT&E may be required to verify successful implementation/integration of any noted deficiency corrections or changes. In the event such a need arises, one of the original OT&E locations will be reutilized and the abbreviated testing shall take place over a duration not to exceed 45 days.

3.5.1.3.2.3 OT&E report. The Government will generator and provide to the contractor a preliminary recommendation and final OT&E report.

First article test report. The contractor shall prepare and submit a preliminary first article test report within 30 calendar days of completion of contractor’s portion of DT&E. The test report shall document all testing performed, including results of any unsuccessful test attempts.

Completed analysis, certification, inspection, and demonstration results shall be presented with the test data requirement. No further testing (such as compatibility/OT&E) shall occur until the preliminary test results are submitted and approved. This preliminary first article test report will comprise the bulk of the OT&E TRR in an effort to ensure all developmental work is complete prior to commencement of compatibility and operational testing. The contractor shall prepare and submit a final first article test report within 30 days of successful completion of the compatibility/OT&E. The final copy shall include all data submitted in the preliminary version plus identify any issues and corrections that occurred during the compatibility/OT&E testing and any required OT&E follow-on testing. See 4.0 of PD15WRWNZEA05 for further details of these tests. (DI-NDTI-80809B/T, Test/Inspection Report, A00N)

3.5.1.4 First article approval.First article approval shall not be granted until satisfactory completion and Government approval of all testing and associated analysis and reporting. MHU- 141V2 first article approval shall not be granted until successful completion of nuclear surety certification—failure of the MHU-141V2 to obtain nuclear surety certification shall result in failure of the MHU-141V2 first article. Note the MHU-110V2 and MHU-141V2 trailer first article are planned and anticipated to be given separately rather than concurrently due to the additional nuclear surety certification required of the MHU-141V2 trailer.

3.5.1.5 First article restoration. All first article trailers used for DT&E shall be returned to a serviceable condition prior to commencement of OT&E. Trailers undergoing environmental testing shall have the entire electrical system replaced to avoid nuisance faults. Trailers undergoing stopping, steering, and mobility testing shall have the steering joints, brake calipers, brake rotors, brake pads, brake fluids, flexible hoses, master cylinder, and wheel bearings replaced to avoid nuisance faults. Cosmetic scratches, knicks, dings, and dents shall not be addressed between DT&E and OT&E. The contractor shall be responsiblke for and shall have 30 days after completion of phase one DT&E testing to restore the first article in accordance with the above.

After completion of all test events and Government approval of the first article, each first article trailer shall be restored to like new condition and be returned to a “zero-hour/zero-mile” condition.

The contractor shall be responsible for any repairs that may be necessary to restore the first article trailers to a serviceable, “like new” condition while retaining configuration integrity. The contractor shall document all and any work accomplished/necessary to complete restoration of the first article, and present the information to the Government. These trailers shall be inspected to the same workmanship standards as new production trailers, and be offered with the same warranty coverage as new production trailers. The contractor shall be responsible for all costs (including shipping) associated with trailer restoration/refurbishment activities.

3.5.1.6 First article disposition. The first article trailers are not planned to be expended or damaged to the extent they are no longer serviceable. As such, all first article trailers shall become part of the contract production quantity and shall be shipped to the location(s) specified in the contract.

One each MHU-110V2 and one each 141V2 shall be retained at the contractor facility until the last shipment on the last delivery order; the other first article trailers shall be shipped as and when directed by the procuring activity.

3.5.2 Production acceptance test procedure and report. The contractor shall develop production acceptance test procedures based on the requirements specified in 4.4 of PD15WRWNZEA05.

The contractor shall test each unit in accordance with the approved production acceptance test procedures. The contractor shall prepare and enclose a test report for each trailer with the unit pack up data. (DI-NDTI-80603, Test procedure, A00Q; DI-NDTI-80809, Test/Inspection/Report, A00P )

3.6 Configuration management.

3.6.1 Configuration requirements.

3.6.1.1 Baselines.

Functional baseline. The functional baseline is PD15WRWNZEA05.

Allocated baseline. All of the documents used to produce and define the accepted CDR configuration shall constitute the allocated baseline.

Product baseline. All of the documents used to produce and define the accepted first article trailers shall be identified in a Product Base Line Index (PBLI). The list shall identify the applicable version number as required. (DI-CMAN-81218, Product Base Line Index (PBLI), A00R)

3.6.1.2 Production release. The contractor assumes all risks in initiating production before the PCO has determined that the first article has met all requirements, DT&E has been successfully completed, compatibility/OT&E (and any deficiencies from the compatibility/OT&E have been corrected) has been successfully completed, the final first article report with all associated analysis/data has been accepted, and nuclear surety of the MHU-141V2 trailer has been obtained.

Production release is acknowledgment by the Government that the contractor has satisfied all requisites to proceed with delivery of hardware to be furnished under the contract. Regardless of obtainment of production release, delivery of production trailers shall not occur prior Government acceptance/approval of TOs and successful delivery of said TOs. Note that TOs cannot be approved without successful completion of provisioning.

3.6.2 Engineering Change Proposals (ECPs). Notwithstanding any other provision in the contract, no contractor or subcontractor's change in design, fabrication, assembly, part, material, process, or source of supply shall be made to the allocated or product baseline unless such change is submitted in writing by ECP and approved by the procuring activity. Any request for change shall be accompanied by complete documentation supporting the need for the change. A system safety impact statement shall be provided as part of the submittal; it shall quantify and qualify the system safety risk identified and how it impacts the system safety risk already identified for the system.

A Notice of Revision (NOR) shall be submitted with each ECP. Should the Government approve an ECP, the contractor shall be responsible for submitting updated TOs and the system safety hazard analysis report (see 3.3.1.1) to reflect the changes made in the ECP. (DI-SESS-80639, Engineering Change Proposal (ECP), A00S; DI-SESS-80642, Notice of Revision (NOR), A00T).

3.6.3 Request for Deviation (RFD). The contractor shall prepare an RFD whenever a departure from the contractually-specified base line is proposed for a specific number of units or for a specific time. (DI-SESS-80640, Request for Variation (RFV), A00U)

3.6.4 Engineering data. The Contractor shall develop/produce/maintain and deliver a TDP that accurately depicts the final product. The TDP shall represent the approved, tested, and accepted configuration of the defined delivered item(s). This shall include software and all test requirement documentation data required to test systems, subsystems and/or components. Vendor Item Control Drawings per ASME Y14.24 shall be used to specify the requirements for purchased items when such items have been approved for use in the design and are used without alteration, selection or source qualification (testing of an item prior to procurement action to ensure that it satisfies the specified requirements). TDP data includes, but is not limited to, Computer Aided Design (CAD) data, CAD models, model based definition data sets, 3D data, Gerber data, and Master Bill of

Materials (BOM). 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 or any third party. All engineering product definition data created using Government funding 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 delivery and format shall be in accordance with DI-SESS-81000E/T, Product Drawings/Models and Associated Lists.

Additionally, the Contractor shall support and provide the necessary resources, i.e., meeting agenda, conference room, applicable data, minutes, and appropriate personnel available to answer any questions for the Engineering Data Guidance Conference and all supporting In-Process Reviews during development of the TDP. Refer to: TDP Instruction package included with DI- SESS-81000E/T (C001) and (C002, DI-ADMN-81249A, Conference Agenda for Engineering Data Guidance Conference; C003, DI-ADMN-81250B, Conference Minutes for Engineering Data Guidance Conference; C004, DI-ADMN-81249A, Conference Agenda for IPR of the TDP; C005, DI-ADMN-81250B, Conference Minutes for IPR of the TDP).

3.6.4.1 Model-based TDP (MTDP). The Contractor shall provide a Model-based TDP for the respective system, subsystem, assembly, subassembly, or part pertaining to PD15WRWNZEA05.

If a specification is cancelled, superseded, or obsolete, a replacement specification that meets the design requirements shall be identified and used. Marking notes shall be updated to specifically address the complete marking instructions in MIL-STD-130. The new MTDP shall also incorporate any outstanding Change Orders against the existing TDP. Existing TDPs for which the USAF is not the current design activity shall not be revised unless otherwise directed by the Government.

MTDPs shall consist of a fully annotated (see MIL-STD-31000B) native model created in SolidWorks 2013 (or later version) , a fully annotated 3Di PDF derived from the native model, and a .stp file derived from the native model. The native model file (.sldprt, .sldasm, etc.) created in SolidWorks shall serve as the master from which all neutral files (e.g. STEP, IGS, JT, STL, PRC, PDF, etc.) are derived. MTDPs shall not include 2D drawings unless specifically authorized by the Government.

3.6.4.1.1 3D Models. Native 3D models created for items with an existing TDP shall be accurate to, and contain no-less than, the information present in the existing TDP. At a minimum, neutral file formats (e.g. STEP, IGS, JT, STL, PRC, PDF, etc.) shall be produced/producible from all native 3D models with no errors. Native 3D models shall accurately depict the items they define in both product structure, geometry, metadata, and management information. All 3D models shall be mono-detail. For any existing drawings containing insufficient information to fully define the part, a 3D model shall be created that captures the: envelope boundaries of the part or assembly, any interface requirements, and all other information from the original drawing.

3.6.4.1.1.1 Notes and Dimensions. Native 3D models shall be dimensioned and fully annotated (see MIL-STD-31000B) in accordance with ASME Y14.5 and ASME Y14.41. All notes within native 3D models shall be in accordance with ASME Y14.100. However, terms that refer to 2D mediums (e.g. DRAWING, PARTS LIST, etc.) shall be replaced with “MODEL”, as needed, to translate any standard notes for use in the context of 3D models. Instructions within these standards and any articles they reference that are only applicable in the context of 2D drawings are not required.

3.6.4.1.1.2 Material. The correct material shall be assigned to all native 3D models. The properties of the assigned material shall be accurate and at a minimum, shall include the density of the material.

3.6.4.1.1.3 Standard Views. All dimensions, tolerances, notes, lists, tables, figures, annotations, and other information necessary to define an item to the appropriate level shall be presented in various views within the native 3D model…