FinalUHTSSOW.pdf

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

3 December 2009

Statement of Work (SOW) for

Universal Hydraulic Test Stand

(UHTS)

Prepared by

642d COMBAT SUSTAINMENT GROUP ENGINEERING DIVISION

380 RICHARD RAY BLVD

ROBINS AFB GA 31098-1638

TABLE OF CONTENTS

1. SCOPE

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 Integrated master plan (IMP)

3.1.3 Integrated master schedule (IMS)

3.1.4 Plant access

3.2 Program reviews

3.2.1 Post-award orientation conference (PAOC)

3.2.2 Technical design and program management reviews (PMRs)

3.2.3 PMR support

3.2.4 Conference room

3.2.5 Meeting agendas

3.2.6 Meeting minutes

3.3 System engineering

3.3.1 System safety

3.3.2 Corrosion control

3.3.3 Reliability and maintainability

3.3.3.1 Reliability

3.3.3.1.1 Basic reliability model

3.3.3.1.2 Basic reliability prediction

3.3.3.2 Maintainability

3.4 Logistics

3.4.1 Technical Order (T.O.) requirements

3.4.1.1 Technical Manual schedule and status report

3.4.1.2 T.O. verification

3.4.2 Provisioning

3.4.3 Reserved…………………………………………………………………………….. 8

3.4.4 Training/familiarization

3.5 Testing and evaluation

3.5.1 Design analysis

3.5.2 Preproduction test procedures and report

3.5.3 Aircraft Compatibility Test

3.5.4 User Operational Test and Evaluation (OT&E)

3.5.5 Refurbishment

3.5.6 Production acceptance procedure and report

3.5.7 Random Sampling

3.6 Configuration management and control

3.6.1 Configuration requirements

3.6.2 Engineering Change Proposals (ECPs)

3.6.3 Request for Deviation (RFD)

3.7 Welding

3.7.1 Welding Procedures

1. SCOPE

This document defines the tasks and support requirements for the procurement of Universal Hydraulic Test Stand (UHTS) as described by PD07WRGBZOENF10.

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.

Department of Defense Specifications

MIL-PRF-49506 Logistics Management Information

Department of Defense Standards

MIL-STD-882D Standard Practice for System Safety

Department of Defense Handbooks

MIL-HDBK-217F Notice 2 Reliability Prediction of Electronic Equipment MIL-HDBK-470A Designing and Developing Maintainable Products and Systems MIL-HDBK-472 Maintainability Prediction MIL-HDBK-1568 Material and Processes for Corrosion Prevention and

Control in Aerospace Weapons Systems

2.1.2 Other Government documents, drawings, and publications.

Department of Defense Manuals

TM 86-01K Air Force Technical Manual Contract Requirements

Data Item Descriptions (DIDs)

DI-SAFT-80101B System Safety Hazard Analysis Report DI-MGMT-80227 Contractor's Progress, Status and Management Report DI-MISC-80508B Technical Report/Study Services DI-NDTI-80603 Test Procedure DI-CMAN-80639C Engineering Change Proposal (ECP) DI-CMAN-80640C Request for Deviation (RFD)

DI-CMAN-80642C Notice of Revision (NOR) DI-NDTI-80809B Test/Inspection Report DI-ILSS-80872 Training Materials DI-CMAN-81218 Product Base Line Index (PBLI) DI-ADMN-81249A Conference Agenda DI-ADMN-81250A Conference Minutes DI-MFFP-81403 Corrosion Prevention and Control Plan DI-ALSS-81529 Logistics Management Information (LMI) Data

Product(s) DI-ALSS-81557 Supplemental Data for Provisioning (SDFP) DI-SAFT-81626 System Safety Program Plan

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia PA 19111-5094.)

2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DOD adopted are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents cited in the solicitation.

Reliability Information Analysis Center (RIAC)

NPRD-95 Nonelectronic Parts Reliability Data 1995

(Application for copies should be addressed to Reliability Information Analysis Center, 201 Mill Street, Rome NY 13440.)

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. Beginning the first month after contract award and continuing until one month after first production delivery, the contractor shall prepare a monthly contractor's progress, status and management report due NLT the 5th day of the following month and forward the report to the address indicated on the DD1423. Contractor's progress, status and management report is not required after the first month of production delivery unless the contractor is unable to meet production requirements for any reason. If the contractor is unable to meet production requirements for the month, then the contractor shall prepare a contractor's progress, status and management report and forward the report to the Hydraulic Test Stand Program Office as soon as they are aware that production requirements cannot be satisfied for that month. The contractor will only submit the monthly contractor's progress, status and management for the months production requirements cannot be met in accordance with the contract terms unless otherwise specified by the contracting officer. This report shall identify the status of all portions of the contract and shall be identified in the contractor's milestone chart.

The program report shall include all events such as reviews, audits, tests, identification, and delivery of the contract line items.

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

3.1.3 Integrated master schedule (IMS). RESERVED

3.1.4 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.

3.2 Program reviews.

3.2.1 Post-award orientation conference (PAOC). The contractor shall attend a POAC as directed by the Contracting Officer. The Government will convene the POAC with the contractor at Robins AFB, GA.

3.2.2 Technical design and program management reviews (PMRs). Preliminary Design Review (PDR) and Critical Design Review (CDR). The contractor shall be responsible for conducting a PDR at Robins AFB within 90 days after the effective date of the first delivery order and a CDR within 180 days after the effective date of the first delivery order, or at any time proposed by the contractor and approved by the Government within 200 days after the effective date of the first delivery order. The CDR shall be held at the contractor’s facility. Both reviews will involve formal technical reviews of the proposed design and reviews of any program risks. The PDR shall address at a minimum: equipment layout drawings, environmental concerns, mechanical design, packaging (layout), system safety, dimensional data, manufacturability data, parts considerations, human engineering elements, corrosion aspects, reliability and maintainability aspects, and quality considerations. The CDR shall encompass at a minimum: all areas of the PDR, although at a much greater level of detail and completeness and any mockups or assemblies shall be made available for Government review as well. (DI-ILSS-81335, Design Review Data Package)

3.2.3 PMR support. The contractor shall participate in and support all reviews, audits, and meetings as requested by the PCO. Should the contracting officer require a program management review, it shall be held at the contractor’s facility.

3.2.4 Conference room. The contractor shall provide a conference room suitable for meetings of up to 30 Government representatives, plus contractor personnel in support of scheduled meetings.

3.2.5 Meeting agendas. The contractor shall publish an agenda for all meetings and conferences specified in 3.2.2. The contractor shall request from the Government any items or issues to be discussed or presented at the meetings and include as directed such items in the agenda. Agendas shall be submitted within 5 working days prior to any meeting. (DI-ADMN-81249A, Conference Agenda)

3.2.6 Meeting minutes. The contractor shall provide a written record of the discussions, decisions and action items identified at each meeting. The contractor shall submit meeting minutes no later than 10 days after the meeting in accordance with DD Form 1423. (DI-ADMN-81250A, Conference Minutes)

3.3 System engineering.

3.3.1 System safety. The contractor shall establish, conduct, document, and maintain a system safety program in accordance with 4.1 through 4.8 of MIL-STD-882D. 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. (DI-SAFT-81626, System Safety Program Plan; DI-SAFT-80101B, System Safety Hazard Analysis Report)

3.3.2 Corrosion control. The contractor shall establish, conduct, document, and maintain corrosion prevention and control program using MIL-HDBK-1568 for guidance. A corrosion prevention and control plan shall be developed. (DI-MFFP-81403, Corrosion Prevention and Control Plan)

3.3.3 Reliability and maintainability.

3.3.3.1 Reliability.

3.3.3.1.1 Basic reliability model. The contractor shall develop and maintain a basic reliability model for the system. All equipment and associated quantities comprising these parts shall be included in the model. All equipment, including those intended solely for item redundancy and alternate modes of operation, shall be modeled in series. A basic reliability block diagram shall be developed and maintained for the items with associated allocations and predictions in each reliability block. The basic reliability block diagram shall be keyed and traceable to functional block diagrams, drawings, and schematics, and shall provide the basis for accurate mathematical representation of basic reliability. Nomenclature of elements of the item used in the basic reliability block diagrams shall be consistent with that used in functional block diagrams, drawings, schematics, weight statements, power budgets, and specifications. The basic reliability model shall be documented in the design analysis (see 3.5.1) and reviewed at the design reviews.

3.3.3.1.2 Basic reliability prediction. The contractor shall prepare and maintain a basic reliability prediction for the system; it shall be based upon the associated basic reliability model (see

3.3.3.1.1). All equipment and associated quantities comprising these parts shall be included in the model except for documented exclusions approved by the procuring activity. Failure rate data (or equivalent reliability parameters) shall be consistent with the level of detail of the basic reliability model and availability of procuring activity approved relevant data sources for a comprehensive prediction (for example, software reliability, human reliability, storage reliability, etc.). The prediction shall be based upon the worst-case service use profile. All data sources for failure rates, failure distribution, and failure rate adjustment factors (for example, stress factors, duty cycle, etc.) shall be identified for each reliability block. Data sources shall be MIL-HDBK- 217F Notice 2, NPRD-95, or otherwise approved by the procuring activity. The basic reliability prediction shall be documented in the design analysis (see 3.5.1) and reviewed at the design reviews.

3.3.3.2 Maintainability. The contractor shall prepare and maintain a maintainability prediction for mean time to repair (MTTR) using MIL-HDBK-470A, Appendix D, and MIL-HDBK-472, Notice 1, for guidance. The model and failure rate data shall be consistent with that of the basic reliability prediction (see 3.3.2.1.2). The maintainability prediction shall be documented and reviewed at the design reviews.

3.4 Logistics.

3.4.1 Technical Order (T.O.) requirements. The contractor shall submit Operation and Operator Maintenance Instruction; Maintenance and Overhaul; and Illustrated Parts Breakdown (IPB) manuals in accordance with TM 86-01, Air Force Technical Manual Contract Requirements.

3.4.1.1 Technical Manual schedule and status report. The Technical Manual schedule and status report shall be in accordance with TM-86-01, Air Force Technical Manual Contract Requirements, and DI-MGMT-80227, Contractor's Progress, Status and Management Report.

3.4.1.2 T.O. verification. Technical order verification shall be in accordance with TM 86-01 at the contractor’s facility.

3.4.2 Provisioning. The contractor shall identify and recommend logical spare/repair parts sufficient to meet system/equipment operation and supportability in accordance with the Air Force Initial Provisioning Performance Specification (IPPS). MIL-PRF-49506 should be used as a guide. Format shall be consistent with existing Government Provisioning data system (D220).

(DI-ALSS-81529, Provisioning Technical Documentation: Provisioning Parts List (PPL) Topdown Sequence, Long Lead Items List (LLIL): LLIL-SAIP (Items recommended for Spares Acquisition Integrated with Production and not later than 165 days prior to contractor’s order need date or as determined at the PGC), Design Change Notices (DCNs): DI-ALSS-81557, Supplemental Data For Provisioning (SDFP))

3.4.3 Reserved.

3.4.4 Training/familiarization. The contractor shall provide an instructional media package on the test stands in accordance with DD1423 (DI-SESS-81526B, Instructional Media Package).

3.4.4.1 Operation and maintenance orientation. The contractor shall plan for and conduct a “hands-on” operation and maintenance orientation for the using activities to familiarize the users with the UHTS at each aircraft compatibility test location and operational test and evaluation inspection locations listed in 4.8.18.1 and 4.8.22 of PD07WRGBZOENF10. Additionally, there will be one “hands-on” operation and maintenance orientation class held at the contractor’s facility. Operation and maintenance orientation at each compatibility test location and operational test and evaluation inspection location shall take place within 5 days prior to start of aircraft compatibility tests and operational test and evaluation inspection at each location. The operation and maintenance orientation class at the contractor’s facility shall be held within 90 days of start of production shipment of the UHTS. The orientation shall include but not be limited to: operational familiarization, ease of maintaining the unit for both corrective and preventative efforts, support and test equipment review, unit safety features, application of technical manual to modes and effects, troubleshooting, fault isolation, and theory of operation.

The contractor shall provide all required reference material in accordance with paragraph 3.4.4.2 herein for up to 30 USAF personnel. Copies of the latest draft effort in developing the TO for the UHTS, shall also be available. (DI-ILSS-80872, Training Materials)

3.4.4.2 Operation and maintenance familiarization/orientation material. The contractor shall develop an interactive multimedia system (program media) on CD ROM or DVD to be used during the operation and maintenance orientation and for use in the field for familiarization of operational and maintenance personnel at the organizational level. MIL-HDBK-29612-3A shall be used as a general guide, although contractor format is acceptable. This program media shall be in sufficient detail to provide the technician adequate skills to operate and provide general maintenance for the up-keep of the UHTS in the field. The program media shall also be in sufficient detail to allow the Air Education and Training Command (AETC) to formulate a training course for future use. The program media shall be compatible with existing USAF personal computers (Microsoft Windows based operating systems) and consist of all materials (e.g., software, firmware) necessary to execute the material. Approximately 30 copies of the draft version program media shall be available for use at the classroom operation and maintenance orientation for USAF personnel. Feedback from the USAF personnel attending the operation and maintenance orientation shall be gathered and used to develop the final version of the program media to be used for organizational level familiarization. The program media shall be subject to final Government approval before final delivery. Final delivery of two copies of the program media shall be made to WR-ALC. One copy of the program media shall be sent with each UHTS as pack up data. Note: excluding the first article/preproduction UHTS, no UHTS delivery acceptance will occur without completed and Government accepted orientation material. (DI- ILSS-80872 and MIL-HDBK-29612-3A)

3.4.4.3 Government rights. The contractor shall extend to the Government unlimited usage rights for the duplication and distribution of the operation and maintenance familiarization/orientation material (program media) identified in 3.4.1 and 3.4.2 herein.

3.5 Testing and Evaluation.

3.5.1 Design analysis. A design analysis of the system and each subsystem shall be performed to verify compliance with this SOW and the PD07WRGBZOENF10. The analysis shall include, but is not limited to, a system safety and hazard analysis (see 3.6, 3.6.1, 3.6.2, 3.6.3, 3.6.4, 3.8.4, 3.8.4.1, 3.10.1, 3.10.2, 3.13, 3.16.2.6, 4.6, 4.8.17 and 4.8.20.3 of PD07WRGBZOENF10); a basic reliability model (see 3.3.3.1.1) and predictions (see 3.3.3.1.2); and an air transportability analysis (see 4.8.9.2 of PD07WRGBZOENF10). An initial design analysis shall be provided at the PDR; updated versions of the analysis shall be provided at the CDR, at the start of preproduction testing, and with the preproduction test report. (DI-MISC-80508B, Technical Report/Study Services)

3.5.2 Preproduction test procedures and report. The contractor shall submit detailed preproduction test procedures to the Government for approval in accordance with the DD1423.

The test procedures shall address all requirements identified in the PD and this SOW for such tests. The test procedures shall include data record sheets, charts, graphs, identification of test instruments by manufacturer, model number, and serial number. Upon Government approval of preproduction test procedures, the contractor shall promptly schedule the contractor’s in-plant testing. Thirty (30) days prior to actual in-plant preproduction testing, the contractor shall notify the Government of the date, time, and location of the testing. The contractor shall submit two preliminary preproduction test reports: the first one shall be submitted to the Government for approval upon completion of the contractor’s in-plant preproduction tests; the second preliminary preproduction test report shall be submitted to the Government for approval upon completion of the aircraft compatibility test (DI-NDTI-80603A, Test Procedure; DI-NDTI- 80809B, Test/Inspection Report).

3.5.3. Aircraft Compatibility Test. Upon Government approval of the contractor’s preliminary test report on in-plant testing, the contractor shall promptly transport the four preproduction units to the following locations, in consecutive order, for aircraft compatibility testing:

Nellis AFB, NV Travis AFB, CA

The contractor shall be responsible for all costs and logistics associated with transporting the four units to the locations. During aircraft compatibility testing at each location, the contractor shall be responsible for providing all materials, fluid, fuel, supplies, test equipment, tools, and labor necessary to perform the aircraft compatibility tests. The contractor’s personnel shall not handle or operate any part of the aircraft. The contractor shall assist government personnel, as needed, to complete the necessary test to ensure compatibility. The government will ensure that the required aircraft is available for the testing period at each location, and will provide personnel to operate the aircraft to which the UHTS units will be connected. Actual compatibility tests are expected to take no more than 5 working days at each location, however, Air Force mission requirements may result in delays to testing schedule. Therefore, the contractor shall be prepared and available to conduct the aircraft compatibility testing for a period of no more than 15 calendar days at each location, excluding time required for transportation of the units between locations. The contractor shall complete all aircraft compatibility tests in no more than 60 calendar days after completion of all in-house testing, such time includes the shipping of the four units from the contractor’s facility to Location 1, and shipping the UHTS units from Location 1 to Location 2. The contractor shall be responsible for providing personnel to conduct approximately 1 day of on-site operational training and orientation on the UHTS units to government personnel at each of the locations prior to the onset of testing.

3.5.4 User Operational Test and Evaluation (OT&E). Upon Government approval of the contractor’s preliminary test report on aircraft compatibility tests, the contractor shall promptly transport the four preproduction units to the first OT&E location. Thereafter, the contractor shall be responsible for transporting the four preproduction units from each OT&E location to the next location until such time that OT&E is complete. The following locations have been selected for the four OT&E sites:

Travis AFB, CA Nellis AFB, NV McChord AFB, WA Moody AFB, GA

The contractor shall be responsible for all costs and logistics associated with the transporting of the preproduction units. Air Force users will conduct all tests. The contractor shall provide a spare parts kit with each item shipped for the user OT&E containing all items required to conduct scheduled maintenance during the test as well as common repair parts predicted to be needed during the OT&E. At each OT&E location, the contractor shall provide on-site orientation to AF users relative to operation and maintenance on each unit type (diesel and electric) for no more than three calendar days. The contractor shall ensure that a minimum of a 70% reviewed technical manual and instructional media package on each unit type is available for orientation purposes during OT&E. Subsequently, the contractor shall provide telephone and electronic mail support during the duration of OT&E at each location. In situations where telephone and/or electronic mail support are insufficient to resolve problems with the unit, the contractor shall provide on-site support for resolution. All support, regardless of on-site, telephonic, or electronic mail, shall be available no later than 48 hours of notification, exclusive of weekends and official Government holidays during OT&E. OT&E will take place for approximately 30 days at each location, for a total approximate time of 120 days, excluding time required for transportation of the units between locations. All tests shall be completed, reviewed and accepted by the government before preproduction acceptance.

3.5.5 Refurbishment. No later than 30 calendar days after completion of OT&E and upon Government direction, the contractor shall be responsible for sending all preproduction units to the contractor’s facility for refurbishment. One preproduction item of each type shall be retained at the contractor’s facility until the last shipment on the last delivery order or as otherwise directed by the contracting officer. The remaining preproduction items shall be shipped to the location specified in the contract. The contractor shall be responsible for any repairs that may be necessary to restore the items to a serviceable condition while retaining configuration integrity.

The contractor shall be responsible for all costs and logistics associated with delivery of the preproduction items to the contractor's facility for refurbishment.

3.5.6 Production acceptance procedure and report. The contractor shall test each production item in accordance with 4.2 of the PD utilizing a subset of the preproduction test procedures. The contractor shall enclose an acceptance test report for each production item. (DI-NDTI-80809B, Test/Inspection Report)

3.5.7 Random Sampling. At the direction of the Government, the contractor will perform additional tests that are specified below on one production unit selected by the DCMA Quality Assurance Evaluator or as directed by the Contracting Officer. Random sampling shall occur at least two times, but not more than four times per option year.

The Government will notify the contractor and DCMA ACO of the requirement to perform additional testing on a random unit. Upon notification, the contractor will have 7 calendar days to establish a testing date with the DCMA office and 642 CBSG Contracting Office. Testing shall be accomplished within 21 days of notification and Government personnel will be present to witness the testing.

Testing will coincide with the delivery schedule and the contractor will make available a minimum of 5 units for testing; however, only one unit will be selected for the random sampling test.

Test Failure: In the event the random sample fails any part of the testing, production will immediately cease until the root cause of the failure is identified and the contractor presents a plan of action to restore performance to meet the technical specifications identified in the purchase description. Additionally, the contractor shall verify that all previously shipped units do not have the same failure. Should a UHTS unit be verified to have that failure, the contractor shall repair the unit to meet the technical specifications.

Test Report: The contractor shall prepare a test report of the results and include all documentation to support a pass or failure of the test. The report will be verified and signed by a Government representative and forwarded to the 642 CBSG contracting office.

Random Sampling Testing: The contractor will perform the following additional tests as described in the PD on one randomly selected unit:

Test no.

Test PD Test paragraph

PD Requirement paragraph

T1 Hydrostatic test 4.8.1 3.11.10, 3.11.12

T2 Operational test

4.8.2 3.3, 3.9, 3.7.1, 3.7.1.1a-k, 3.10, 3.11, 3.18, 3.12, 3.13, 3.15, 3.15.1, 3.18.4, 3.23

T15 Flow test 4.8.4.1 3.11.2

T16 Cycling test 4.8.4.2 3.11.3

T17 Fluid temperature test 4.8.4.3 3.11.4

T19 Low pressure system pressure test

4.8.4.5 3.11.12

T45 Endurance test

(amended to 100 hrs)

4.8.10.1 3.3, 3.9, 3.7.1, 3.7.1.1a-k, , 3.11, 3.18

3.6 Configuration management and control.

3.6.1 Configuration requirements. After the preproduction item acceptance, the contractor shall establish and maintain configuration control. The accepted preproduction items shall serve as the manufacturing standard. All of the documents used to produce and define the accepted preproduction items shall be identified in a Product Base Line Index. The list shall identify the applicable version number as required. (DI-CMAN-81218, Product Base Line Index (PBLI))

3.6.2 Engineering Change Proposals (ECPs). After the Product Baseline is released, the contractor shall incorporate all changes to master drawing baseline via approved ECPs. A Notice of Revision (NOR) shall be submitted with each ECP. (DI-CMAN-80639C, Engineering Change Proposal (ECP); DI-CMAN-80642C, Notice of Revision (NOR)).

3.6.3 Request for Deviation (RFD). The contractor shall prepare an RFD whenever a departure from the contractually-specified baseline is proposed for a specific number of units or for a specific time. (DI-CMAN-80640C, Request for Deviation (RFD))

3.7 Welding

3.7.1 Welding procedures. The contractor shall prepare and qualify all welding procedures in accordance with DD1423 (DI-MISC-80875, Welding Procedures). The contractor shall provide all welding procedures utilized on the test stand to the government for approval.