SOW.pdf

DRAFT COPY

AIM-120

MISSILE RAIL LAUNCHER (MRL)

STATEMENT OF WORK (SOW)

TABLE OF CONTENTS

PARA TITLE PAGE

1.0 Scope 2

1.1 Technical Data Package (TDP) 2

1.2 Integrated Master Schedule (IMS) 2

1.3 Program Management 2

1.4 Production 2

1.5 Government Furnished Equipment (GFE) 3

2.0 Applicable Documents 3

3.0 Government Deliverables 3

3.1 TDP 3

3.2 Production 6

ANNEX A Applicable Documents 10

ANNEX B Contract Data Requirements List (CDRL) 11

ANNEX C List of Acronyms 12

1.0 SCOPE.

1.1 Technical Data Package (TDP). The contractor shall validate and amend the existing Government owned TDP in accordance with this Statement Of Work (SOW) for all Missile Rail Launcher (MRL) configurations listed in paragraph 1.4 of this SOW, in order to produce and deliver to the Government a complete TDP that reflects the most up-to-date MRL configurations. A launcher will be provided, as Government Furnished Equipment (GFE), in order to validate the TDP via a Physical Configuration Audit (PCA).

1.2 Integrated Master Schedule (IMS). The contractor shall perform work in accordance with the approved IMS covering all major milestones, events, and deliveries (Contract Data Requirements List [CDRL] A001, Integrated Master Schedule, DI-MGT-81650). An updated IMS shall be delivered as requested by the Government or anytime the contractor makes a change to the IMS.

1.3 Program Management. The contractor shall establish and maintain a program management organization with a single manager responsible for all aspects of the MRL program and shall maintain the management organization throughout the MRL production program.

1.3.1 Program Scheduling. The contractor shall conduct a schedule management program as an integral segment of the program management effort.

1.3.2 Program Management Reviews (PMR). The contractor shall prepare and present a semi-annual PMR to include an agenda and minutes. PMRs shall provide production status including potential delays and recovery plans, financial/schedule status, quality assurance status, logistics status, engineering/test issues, and program issues (CDRL A004, Conference Agenda, DI- ADMN-81249A; CDRL A005, Conference Minutes, DI-ADMN-81250A).

1.3.3 Proprietary Information. The TDP for this contract contains Proprietary Information for the LAU-129C/A, D/A, E/A, and F/A versions of the launcher. The proprietary documents include FPS-3057C Spray Application of Filled Elastomeric Coating Specification and 16PR15601 Alternate Mission Equipment Finish Process Specification. Access to these documents will require an agreement between the prime contractor and Lockheed Martin Aeronautics Co. The Government will not facilitate an agreement with Lockheed Martin and the prime contractor.

This will be the sole responsibility of the prime contractor.

1.4 Production. The contractor shall meet first article MRLs and subcomponents requirements and submit the TDP for approval in accordance with CDRL A002, Product Drawings, Models, Lists, DI- SESS-81000E, prior to production. The following MRL configurations may be procured:

MRL NSN TOP ASSEMBLY

DRAWING

AIRCRAFT

LAU-128 A/A 1440-01-316-1238 3820480-135 F-15

LAU-128 D/A 1440-01-545-7207 200625372 F-15

LAU-129 A/A 1440-01-315-4103 3820490-137 F-16

LAU-129 B/A 1440-01-513-7329 56G4100-1 F-16

LAU-129 C/A 1440-01-513-7354 56G4200-1 F-16

LAU-129 D/A 1440-01-513-7351 56G4200-2 F-16

LAU-129 E/A 1440-01-513-7352 56G4300-1 F-16

LAU-129 F/A 1440-01-513-7353 56G4300-2 F-16

1.5 GFE. To facilitate the TDP validation, production, and first article acceptance test Form, Fit, and Function (FFF) requirements, one of each of the following items will be provided to the contractor.

1.5.1 LAU-128

1.5.2 LAU-129

2.0 APPLICABLE DOCUMENTS. The specifications listed in Annex A of this SOW must be met and are part of the TDP.

3.0 GOVERNMENT DELIVERABLES.

3.1 TDP. The existing Government TDP includes some outdated information that must be validated and amended to reflect the most current configurations of the MRLs listed in paragraph 1.4 of this SOW. The contractor shall validate and amend the TDP as follows:

3.1.1 Technical Requirements: The following requirements are indicative, but not all inclusive, of the type of work that will be required throughout the performance of this tasking.

3.1.1.1 Data Lists Review. The contractor shall review the following and update the TDP for the LAU-128 (3820480) and LAU-129 (3820490) (CDRL A002, Product Drawings/models and associated lists, DI-SESS-81000E):

3.1.1.1.1 Part Number List

3.1.1.1.2 Government Specifications and Standards

3.1.1.1.3 Contractor Design Activity Specifications and Standards

3.1.1.1.4 Contractor Design Activity Drawings

3.1.1.1.5 Subcontractor Design Activity Drawings

3.1.1.2 Configuration Information Review. The contractor shall verify and update information for current production of LAU-128 (3820480) and LAU-129 (3820490), by reviewing the following:

3.1.1.2.1 Drawing notes

3.1.1.2.2 Drawing tables

3.1.1.2.3 Drawing parts lists

3.1.1.2.4 Engineering Change Proposals

3.1.1.2.5 Notices of Revisions (NORs)

3.1.1.2.6 Other associated unincorporated changes

3.1.1.3 Error Identification and Correction. The contractor shall identify errors in the supplied TDP (paragraph 3.1.1.1 and 3.1.1.2) for the LAU-128 (3820480) and LAU-129 (3820490) and revise each drawing to correct each identified error in accordance with paragraph 3.1.1.9.

3.1.1.4 TDP Submission. The contractor shall create and submit a revised TDP in the form of a completely new drawing package with all required changes incorporated versus just adding changes to the TDP provided. (CDRL A002, Product Drawings/models and associated lists, DI-SESS-81000E) The TDP will include processes and procedures for manufacturing and machining which are not generally available, but are essential to the design and manufacture of the LAU-128 (3820480) and LAU-129 (3820490).

3.1.1.4.1. 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). TDP data includes, but is not limited to, Computer Aided Design (CAD) data, CAD models, model based definition data sets, Gerber data and Master Bill of Materials (BOM). The 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. Vendor Item Control Drawings shall be used to specify the requirements for purchased items when such items have been approved for use in the design. They are to be used without alteration, selection, or source qualification (testing of an item prior to procurement action to ensure that it satisfies the specified requirements). The TDP shall be delivered in accordance with Air Force Product Data Specification drawing 9579776 Revision M (CAGE 98752), reference attached DD Form 1423 Block 16. (CDRL A002, Product Drawings/Models and Associated Lists, DI-SESS-81000E).

3.1.1.5 Quarterly Status Report (QSR). The contractor shall report the schedule and technical status in the QSR (CDRL A003, Quarterly Status Reports, DI-MGMT-80368A).

3.1.1.6 Engineering Data Guidance Conference. The contractor shall support and co-chair an Engineering Data Guidance Conference with AFLCMC/LZPEM for engineering data within 60 days after contract award. The conference shall be convened at a site and on a date agreed upon by the Government contracting officer and the contractor. (CDRL A004, Conference Agenda, DI-ADMN-81249A; CDRL A005, Conference Minutes, DI-ADMN-81250A) The contractor shall address, discuss and provide status on the following:

3.1.1.6.1 Understanding of all CDRL requirements, applicable Data Item Descriptions (DIDs), specifications, and standards.

3.1.1.6.2 TDP review requirements and schedules.

3.1.1.6.3 TDP delivery requirements and schedules.

3.1.1.6.4 Contractor's drafting practices, procedures, TDP drawing formats, and CAD programs.

3.1.1.6.5 The contractor's quality assurance procedures relating to TDP documents, including quality control of subcontractor and vendor data.

3.1.1.6.6 The role of subcontractors and vendors who may deliver TDP documents under this contract.

3.1.1.6.7 The contractor's configuration management system, including methods for releasing documents, approving documents and incorporating changes into documents.

Note: Engineering Data Guidance Conferences may be held in conjunction with other meetings or conferences.

3.1.1.7 In-Process Review (IPR) of the TDP. The contractor shall host, support and co-chair IPRs of the engineering drawings, associated lists, and other documentation to be included in the TDP. IPRs shall be conducted only after the contractor's quality assurance personnel have completely reviewed the data and determined that data are of sufficient quality that Government time will be effectively utilized during the review. As a minimum, an IPR will be scheduled when data has reached the 40 and 80 percent completion point based on the number of drawings and shall be held, when possible, in conjunction with other reviews as required. The contractor shall notify AFLCMC/LZPEM a minimum of 60 days prior to the anticipated date of completion point. An IPR shall focus on the contractor's progress in the preparation of the TDP. 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 to perform the IPRs effectively. (CDRL A004, Conference Agenda, DI-ADMN-81249A; CDRL A005, Conference Minutes, DI-ADMN-81250A) The contractor shall correct all discrepancies identified during the IPRs. All subcontractor/vendor data shall be made available for review. The Government may schedule separate IPRs at their discretion

3.1.1.8 Relationship of Contractor with Subcontractors/Vendors. The contractor shall levy on sub-contractors and sub-vendors the same requirements for TDPs as are levied on them by this contract. This requirement shall apply at all tiers of sub-contractor/vendor levels associated with the program.

3.1.1.9 Engineering Data Updates and Revisions. The contractor shall (and shall cause subcontractors and vendors to) update and maintain engineering data for the TDP and shall incorporate all changes in accordance with the following:

3.1.1.9.1 All Class I engineering changes which affect FFF shall be incorporated into the applicable engineering data format prior to delivery of data.

3.1.1.9.2 All Class II engineering changes which do not affect FFF shall be incorporated into applicable engineering data format.

3.1.1.9.3 Revisions to existing engineering drawings, models, and associated lists and other documentation to be included in the TDP, for which the contractor is the current design activity, shall result in the delivery of the entire revised document and associated data file. If price adjustments are needed after award for the production prices, due to approved Engineering Change Proposals, then the contractor shall submit a proposal in accordance with FAR 15.408, III. Formats for Submission of Line Item Summaries, B.

Change Orders, Modifications and Claims. There will be no price adjustments until after TDP approval. (CDRL A006, Engineering Change Proposals, DI-SESS-80639D).

3.2 Production. The contractor shall manufacture, inspect, test, and deliver MRLs that conform to the component level requirements and perform as required to meet the functional, allocated, and product configuration baselines in accordance with the approved TDP. This includes drawings listed, the engineering data lists, specification and standards, and this SOW.

3.2.1 First Article Acceptance Test (FAAT). MRL contractors shall perform a FAAT as specified in Part II of specification DS32050-116 on the LAU-128A/A and LAU-129A/A MRL configuration at the beginning of production. A test report shall be submitted upon completion of FAAT testing. (CDRL A007, First Article Qualification Test Plan and Procedures, DI-NDTI- 81307A; CDRL A008, Equipment Inspection and Testing Report, DI-NDTI-81583A).

3.2.1.1 Power Supply First Article Acceptance Test. In the event an unqualified source is chosen for power supply fabrication, FAAT testing shall be performed in accordance with specification DS32050-550, Part I and II. (CDRL A007, First Article Qualification Test Plan and Procedures, DI-NDTI-81307A; CDRL A008, Equipment Inspection and Testing Report, DI-NDTI-81583A).

3.2.1.2 Class I ECP Change. Applicable elements of a FAAT shall be performed prior to production incorporation of Class I ECP changes. The extent of testing will be determined by AFLCMC/EBR dependent upon the complexity of the ECP and the type launcher. (CDRL A007, First Article Qualification Test Plan and Procedures, DI-NDTI-81307A; CDRL A008, Equipment Inspection and Testing Report, DI-NDTI-81583A).

3.2.2 Periodic Sampling Test (PST). PSTs are specified in Part II of specification DS32050-116 and are required for this contract. Sampling results will be documented in a test report (CDRL A010, Test Inspection Report, DI-NDTI-80809B)

3.2.3 Environmental Stress Screening (ESS). The contractor shall perform ESS in accordance with DS32050-116. The ESS program shall include all MRL system hardware; i.e., MRLs and spares/replacement parts. The contractor shall update ESS test procedures and provide ESS reports to the Government upon request (CDRL A008, Equipment Inspection and Testing Report, DI-NDTI-81583A).

3.2.4 Buildup Inspection (BI). The contractor shall accomplish a BI on one of each LAU-128 and LAU-129 MRL configuration during each contract year beginning after First Article Test

Acceptance. The contractor shall notify the government, both AFLCMC/EBRMM and 409 SCMS/GUME, at least 60 calendar days prior to the start of BI. The government reserves the right to be present for the BI.

3.2.4.1 BI Procedures. The buildup inspection shall be performed as follows:

(1) The launcher sub-assemblies shall be inspected and subjected to initial qualification tests before being incorporated into the next higher assembly during launcher buildup.

Qualification/functional tests are those as specified in DS32050-116. The Government reserves the option to require inspection and qualification/functional test of each sub-assembly prior to continuing with the buildup.

(2) The launcher sub-assemblies to be inspected and tested include but shall not be limited to:

(a) Detent Assembly

(b) Launcher Power Supply

(c) Aft Dampener Assembly

(d) AIM-120 Umbilical Assembly

(e) Forward Fairing Fastener Assembly

(3) Correction of deficiencies, corrective action implementation, re-assembly, and re-test of defective items identified by the buildup inspections shall be at no cost to the Government.

(4) Upon completion of the buildup, the contractor shall provide an initial assessment of actions required to correct any deficiencies identified by the BI’s. (CDRL A010, Test/Inspection Report, DI-NDTI-80809B).

3.2.5 MRL Test Asset Refurbishment. All MRLs used in First Article Acceptance Tests, Periodic Sampling Tests, and Buildup Inspections shall be refurbished and re-tested, as required, to a deliverable condition within 30 days after approval of the applicable test report.

3.2.6 Government-Industry Data Exchange Program (GIDEP). The contractor shall participate in the GIDEP to the extent necessary to receive alerts from the GIDEP Operations Center, Fleet Missile System Analysis and Evaluation Group, Corona, CA 91720. The contractor shall use the alerts from the GIDEP Failure Experience Data Bank for the purpose of identifying and deleting and/or limiting those proposed parts versus data coded from the list which has been identified as being defective or requiring to be limited. The contractor shall use lessons-learned documentation or similar equipment to prevent repeating the same mistakes on the MRL program. (CDRL A011, GIDEP Alert/Safe-Alert Report DI-QCIC-80125B).

3.2.7 Source Controlled Items.

3.2.7.1 Qualification of New Sources. Efforts to qualify a new source are the sole responsibility of the contractor. FAAT testing at the component level shall be successfully completed prior to delivery of production hardware. If component level first article test requirements are not specified as part of this contract, the item shall be included in an all-up launcher tested in compliance with DS32050-116, Part II and Addendum to DS32050-116, Part II. (CDRL A012, Test Inspection Report, DI-NDTI-80809B; CDRL A008, Equipment Inspection and Testing Report, DI-NDTI-81583A).

3.2.7.2 Manufactured by Previously Qualified Vendors. Vendors included on source control drawings which have not produced the item to the requirements of the source control drawing for a period of thirty-six months shall be required to complete first article testing at the component level. If component level first article test requirements are not specified and a qualification test is specified, the qualification test is required. If no qualification or first article testing is specified at the component level, the first article testing of the all-up launcher in compliance with DS32050-116, Part II and Addendum to DS32050-116, Part II will be considered sufficient first article testing of the included components. When an approved source changes the manufacturing process, location, design, or materials, the design activity shall be notified to determine if re-qualification is required. (CDRL A012, Test Inspection Report, DI-NDTI-80809B; CDRL A008, Equipment Inspection and Testing Report, DI-

NDTI-81583A).

3.2.8 Production Management.

3.2.8.1 Special Test Equipment (STE). The contractor shall provide (build or acquire) and maintain fully production capable STE in sufficient quantities to produce hardware in accordance with the contract delivery schedule. Operating procedures for STE and/or STE modifications shall ensure compliance with the tests specified in DS32050-116, Part II and Addendum to DS32050-116, Part II and will be made available to the Government upon request (CDRL A009, Acceptance Test Plan, DI-QCIC-80553A).

3.2.8.2 Process Control Requirements. The contractor shall develop and document procedures to plan, monitor, and control production, installation, and servicing processes.

Pertinent STE issues shall be included in the production control plan. The contractor shall identify capacity rate analysis, individual test cycle time, and proposed total operating hours per day for each item of STE. (CDRL A013, Assembly and Subassembly Manufacturing Quality Report, DI-QCIC-80562).

3.2.8.3 Risk Management. The contractor shall develop a manufacturing process risk management plan and integrate it into production control. The contractor shall identify all key manufacturing processes, establish process capability, requirements, and process control requirements for each and document them in the risk management plan. (CDRL A014, Contractor’s Risk Management Plan, DI-MGMT-81808). The contractor shall develop and refine process capability controls using MIL-HDBK-683 as a guide where appropriate. The manufacturing process risk management plan shall be made available to the Government upon request.

3.2.8.4 Subcontract Management Plan. The contractor shall maintain and implement a subcontract management plan for subcontract, vendor, and affiliate management. This plan shall have procedures and resolution of production risk, production surveillance, and timely reporting of production problems or delays which may adversely affect the program. The subcontract management plan and subcontractor structure shall be made available to the Government upon request (CDRL A014, Contractor’s Risk Management Plan, DI-MGMT- 81808).

3.2.9 Configuration and Data Management.

3.2.9.1 Configuration Management (CM). The contractor shall define the designation and implementation of CM responsibilities in order to meet the SOW CM requirements.

Functional, operational, and organizational relationships in the performance of CM tasks shall be addressed and a CM manager will be designated. The contractor shall document in detail the organizational responsibilities and associated procedures for control and implementation of the CM program in a hardware CM Plan. (CDRL A015, Supplier’s Configuration Management Plan DI-SESS-80858C).

3.2.9.1.1 Change Proposals. The contractor shall be responsible for properly designing, testing, and qualifying any modifications pertaining to applicable specifications and/or baseline drawings. The contractor may use MIL-HDBK-61A as a guide when proposing and implementing changes via Engineering Change Proposals (ECPs) and Notices of Revision (NORs). These changes that are submitted for production units shall be only issues that arrive after the approved TDP. If issues do arise after the approved TDP that require pricing changes to the production units then the contractor shall submit a proposal in accordance with FAR 15.408, III. Formats for Submission of Line Item Summaries, B.

Change Orders, Modifications and Claims only after the ECP is approved. (CDRL A006, Engineering Change Proposals, DI-SESS-80639D; CDRL A016 Notice of Revision, DI-

SESS-80642D)

3.2.9.1.2 Change Approval Authority. AFLCMC/EBRE is the approval authority for all Class I and II ECPs (As defined in EIA-649B and EIA-649-1 CM Standards and Mil- HDBK-61A) on the LAU-128 and LAU-129 version launchers.

3.2.9.1.3 Deviation/Waivers. Request for deviations/waivers may be prepared in accordance with MIL-HDBK-61A. Deviations shall be submitted to AFLCMC/EBRE for processing to the appropriate approval authority. Major/Critical waivers must be reviewed and approved by the appropriate USAF agency (CDRL A017, Request for Variance DI-SESS-80640D).

3.2.9.1.4 Engineering Release System. The contractor shall maintain control over the manufacture and acceptance of all configuration items through an engineering release system. MIL-HDBK-61A may be used as a guide.

3.2.9.2 Data Management. The CDRL, DD Form 1423, identifies the delivery instructions which the contractor must perform to assure timely delivery of quality data. It does not relieve the contractor from complying with Federal Acquisition Regulation (FAR) data requirements that appear in the contract.

3.2.9.2.1 Data Submission. The contractor shall accompany all CDRLs with a transmittal letter that summarizes pertinent information concerning the CDRL submittal. The contractor shall develop and maintain a system/process for monitoring CDRL data preparation, submittals and tracking.

ANNEX A

APPLICABLE DOCUMENTS

DESIGNATION TITLE

16PR15601 Alternate Mission Equipment Finish Process

DS32050-116, Prime Item Development & Product Fabrication Specification, AIM-120 Parts I & II Launcher

DS32050-550, Critical Item Product Fabrication Specification, Power Supply Part II

PS60602-712 Environmental Stress Screening for AIM-120 Production and APREP FAR and supplements Federal Acquisition Regulation

FPS-3057C Spray Application of Filled Elastomeric Coating

MIL-HDBK-683 Statistical Process Control Implementation and Evaluation Aid

MIL-HDBK-61A(SE) Configuration Management Guidance

MIL-PRF-49506 Logistics Support Analysis

MIL-STD-882D System Safety Program Requirements, Notice 1

ANNEX B

CONTRACT DATA REQUIREMENTS LIST (CDRL)

CDRL # TITLE DATA ITEM DESCRIPTION

A001 Integrated Master Schedule DI-MGT-81650

A002 Product Drawings/models and associated lists DI-SESS-81000E

A003 Quarterly Status Reports DI-MGMT-80368A

A004 Conference Agenda DI-ADMN-81249A

A005 Conference Minutes DI-ADMN-81250A

A006 Engineering Change Proposals DI-SESS-80639D

A007 First Article Qualification Test Plan DI-NDTI-81307A and Procedures

A008 Equipment Inspection and Testing Report DI-NDTI-81583A

A009 Acceptance Test Plan DI-QCIC-80553A

A010 Test Inspection Report DI-NDTI-80809B

A011 GIDEP Alert/Safe-Alert Report DI-QCIC-80125B

A012 Test Inspection Report DI-NDTI-80809B

A013 Assembly and Subassembly Manufacturing DI-QCIC-80562

Quality Report

A014 Contractor’s Risk Management Plan DI-MGMT-81808

A015 Supplier’s Configuration Management Plan DI-SESS-80858C

A016 Notice of Revision DI-SESS-80642D

A017 Request for Variance DI-SESS-80640D

ANNEX C

LIST OF ACRONYMS

ACRONYM MEANING

BI Buildup Inspection

BOM Bill of Materials

CAD Computer Aided Design

CDRL Contract Data Requirements List

CM Configuration Management

ECP Engineering Change Proposals

ESS Environmental Stress Screening

FAAT First Article Acceptance Test

FAR Federal Acquisition Regulation

FFF Form, Fit, Function

GFE Government Furnished Equipment

GIDEP Government-Industry Data Exchange

Program

IMS Integrated Master Schedule

IPR In-Process Review

MRL Missile Rail Launcher

NOR Notice of Revision

PCA Physical Configuration Audit

PMR Program Management Review

SOW Statement of Work

STE Special Test Equipment

TDP Technical Data Package