H-65_Tyonek_Wire_Harness_Buildup_SOW_Final.docx

Enclosures Enclosures

STATEMENT OF WORK (SOW)

For The Manufacturing of 89 MH-65E Aircraft Wire Harnesses For Tyonek Manufacturing Group, Inc.

2/11/2019

Table of Contents

Enclosure 5- GFE 12

General Information Introduction This Statement of Work (SOW) defines the effort required to provide aircraft wire harnesses for the MH-65E helicopter improvement program.

Background The wiring harness currently installed on all 98 Coast Guard MH-65 helicopters is, for the most part, original to the airframes. First introduced to the fleet in 1985, the wiring harnesses are becoming a mission degrader due to its age, inconsistent configurations and multiple repairs of various quality.

In conjunction with a Service Life Extension Project (SLEP) and Programmed Depot-Level Maintenance (PDM) the new wire harness will be part of an airframe conversion from the current MH-65D to a modernized MH-65E. This conversion will be described herein as Echo Conversion.

Scope The U.S. Coast Guard (USCG) Aviation Logistics Center (ALC) has a requirement to fabricate 89 aircraft wire harnesses for the MH-65 Dolphin Short Range Recovery (SRR) helicopter. The USCG shall provide a Technical Data Package (TDP) with the harness design. The contractor shall provide engineering, design corrections as required, procurement of materials, and fabrication of the wire harness in accordance with (IAW) the TDP with deliveries to pace PDM cycles.

Applicable Documents The following is a list of documents referenced in this SOW:

· SAE AS50881F, SPECIFICATION FOR WIRING, AEROSPACE VEHICLE

· NAVAIR 01-1A-505, JOINT SERVICE GENERAL WIRING MAINTENANCE MANUAL

· SAE-AMS-DTL-23053, DETAIL SPECIFICATION: INSULATION SLEEVING, ELECTRICAL, HEAT SHRINKABLE, GENERAL SPECIFICATION

· MIL-PRF-46846, RUBBER SYNTHETIC HEAT-SHRINKABLE

· TMGI-QP-0002, TYONEK CONFIGURATION MANAGEMENT

· ASTM D3951-15, AMERICAN SOCIETY FOR TESTING AND MATERIALS

· MIL-STD-2073-1E, STANDARD PRACTICE FOR MILITARY PACKAGING

· AS9100 REV D, QUALITY MANAGEMENT SYSTEM – REQUIREMENTS FOR AVIATION, SPACE AND DEFENSE ORGANIZATIONS

· ISO 9001:2015, INTERNATIONAL ORGANIZATION FOR STANDARDIZATION QUALITY MANAGEMENT SYSTEMS

· IPC-A-610, ASSOCIATION CONNECTING ELECTRONIC INDUSTRIES, ACCEPTABILITY OF ELECTRONICS ASSEMBLIES TRAINING AND CERTIFICATION PROGRAM

· J-STD-001, ASSOCIATION CONNECTING ELECTRONIC INDUSTRIES; TRAINING AND CERTIFICATION PROGRAM

· ICP/WHMA-A-620, ASSOCIATION CONNECTING ELECTRONIC INDUSTRIES; TRAINING AND CERTIFICATION PROGRAM

· MIL-HDBK-522, DEPARTMENT OF DEFENSE HANDBOOK: GUIDELINES FOR INSPECTION OF AIRCRAFT ELECTRICAL WIRING INTERCONNECT SYSTEMS Work Requirements Requirements

1. The Contractor shall use the data from Enclosure 2 to provide eighty nine (89) MH-65E wire harnesses delivered IAW schedule in Enclosure 3.

2. The Contractor shall provide all harnesses IAW SAE AS50881F, Specification for Wiring, Aerospace Vehicle; and or NAVAIR 01-1A-505, The Joint Service General Wiring Maintenance Manual, workmanship standards for military aircraft.

3. The Contractor shall use PN 966-67-3, bracket, to be provided by the government, in wire harness subassembly DWG 968-67-3, MH-65 E 25AJ1 Pilot Cyclic Disconnect.

4. All unused contact cavities shall be treated in accordance with SAE AS50881F.

5. Final assembly harnesses shall include dust caps on all unmated connectors IAW SAE AS50881F and or NAVAIR 01-1A-505.

6. All wire harnesses shall be built IAW TDP. All materials, including connectors, splices, junction, shield termination, tape protection materials and all types sleeving shall be of the type and standard called for on each drawing of the TDP. All build processes shall be IAW SAE AS50881F and NAVAIR 01-1A-505. The Contractor shall not substitute or deviate from methods or materials. The Contractor may suggest alternative to materials and build methods IAW the Configuration Management section of this SOW. No changes to the TDP are allowed without written approval and must conform to SAE AS50881F and NAVAIR 01-1A-505 workmanship practices.

7. USCG will have change control rights for all drawings. The Contractor shall submit all redlines to the Contracting Officer’s Representative (COR) for adjudication. Vendor may create its own part number (P/N) for the assembly. ALC will designate an NSN as well as serial number.

8. All hardware (nuts, bolts, and washers) shall be left loose and labeled for aircraft installation. All items shall be new and not refurbished.

Government Furnished Equipment (GFE) A notional GFE list is provided. Should additional GFE be required to ensure timely delivery of harnesses, the Contractor shall provide a written request for consideration to the KO. The Government procurement cost shall be used as the cost for any GFE. GFE price shall be deducted from the price of the intended harness cost.

Wire Harness Deliverables MH-65 wire harnesses, complete and kitted IAW the TDP, Enclosure 2, and this SOW, are required to be delivered to ALC in conjunction with aircraft PDM/Echo Conversion induction which is every 17 calendar days.

First Article (FA) delivery is required per the schedule and will undergo an acceptance and evaluation period of two weeks at the ALC.

Following FA acceptance, the first production wire harness shall be delivered immediately, with remaining deliveries reflected in Enclosure 3.

Early deliveries must be coordinated in advance and approved by the COR due to limited climate controlled storage at the ALC and to allow for possible minor changes (see section 2.8) to the TDP/production between contract option years.

Contract Deliverables Requirements List (CDRL) CDRLs are outlined in Enclosure 1.

Performance Reports The Contractor shall develop and deliver a monthly electronic performance report IAW CDRL 0004. This simple report shall detail harness builds in progress, anticipated delivery schedule and detail any constraints to supply or configuration management.

Post Award Conference (PAC) The Contractor shall conduct a PAC. The meeting shall be held within 30 calendar days After Receipt of Order (ARO). This PAC may be by either teleconference or on site at ALC. The contractor, at a minimum, shall present points of contact, general schedule, initial risk evaluation, initial action items, and status of initial actions such as parts procurement, work-area setup, and TDP evaluation. The Contractor shall provide meeting minutes within 10 business days to Government IAW CDRL 0001.

Integrated Product Team (IPT) Meetings The contractor shall support weekly IPT meetings after the PAC and continuing until first article delivery, then monthly IPTs through the remaining eighty eight (88) harness builds. The contractor shall document and publish IPT meeting minutes (CDRL 0003) within 3 business days following the meetings. Minutes shall include at a minimum: meeting notes, an updated Integrated Master Schedule (IMS), open/closed project action items, risks and risk reduction efforts.

Configuration Management and Engineering Changes The Contractor shall designate a single point of contact for all configuration management (CM) functions. The contractor shall maintain configuration control IAW EIA649B. The Contractor shall provide a copy of the internal process instruction that aligns with requirements within this SOW at the time of the PAC, including samples of update/change forms and verify CM. The contractor shall impose and enforce these CM requirements on all subcontractors and execute to an IMS that includes a detailed schedule for hardware vendors.

Over the course of the contract design changes to improve the reliability, maintainability, or operational performance of the wire harness is expected to be found. These changes will be incorporated into appropriate drawings and shall be provided to the Contractor for buildup and schedule impact consideration. Changes shall be implemented at no cost to the Government if it is minor in nature and provided prior to the specific harness’ buildup. Examples of these changes include but are not limited to: wire-length changes to more accurately meet termination areas, connector changes, or wire subassembly organization/routing. If more than minor, the Contractor shall provide a quote that reflects the Contractor’s costs on the initial harness change and any incremental charge on following harnesses. The quote shall include an itemized breakdown of all labor and material costs. If more than minor in nature and requiring an increase in cost, authorization for the contractor to incorporate the change will be by a modification to the contract and applicable task orders. The Contractor shall incorporate minor, no-cost changes with written approval from the COR. Changes that are more than minor shall not be completed until written authorization from the KO is received.

The Contractor shall provide the Government a system which allows for deviation, redline changes or alternate material usage to the TDP in Enclosure 2. This system shall utilize electronic forms through e-mail. The Contractor has three (3) business days to acknowledge Government change requests. For requests that are considered more than minor in nature, the Contractor shall provide a cost estimates within two (2) business days to the Government. The Contractor may also submit deviation, redline changes or alternate material usage to the TDP requirements via electronic forms through e-mail. If more than minor, this request shall include a cost estimate. The Government has five (5) business days to accept or deny the request. Requests that do not receive acknowledgment within the allotted time will be considered denied. Resubmissions are accepted.

Physical Configuration Audit (PCA) and Manufacturing Inspection The Contractor shall host, at the contractor’s facility, a PCA of the first article prior to packaging for delivery at a time coordinated later with the Government. The Contractor shall prepare a Configuration Audit Summary Report IAW CDRL 0005, to report the audit results and take appropriate action to resolve any discrepancies noted. The Contractor shall host the Government for additional audits as required. The Government does not require additional reports beyond the FA audit.

The contractor shall provide access to their facility and processes to facilitate inspections of production harnesses. Government inspectors reserve the right to inspect manufacturing and kitting processes at the Contractor facility at a minimum of once a quarter. The Government reserves the right to conduct more frequent inspections as needed.

Travel The contractor will be authorized travel expenses consistent with the substantive provisions of the Joint Travel Regulation (JTR) and the limitation of funds specified in this contract. All travel requires Government approval/authorization and notification to the COR. The Government will fund the following travel to complete initial aircraft survey to aid in harness development. Any other required travel will be on a reimbursable basis as approved by COR.

Inspection and Acceptance FA final Government acceptance will be conducted at ALC after receipt and satisfactory inspection results. Final inspection and acceptance of production harnesses shall be performed at destination (ALC) by local receiving personnel and will consist of count, condition and verification that all required documentation has been provided. ALC considers components Ready for Issue (RFI) upon acceptance. Components determined to be non-RFI upon installation may be returned to the contractor with a Quality Deficiency Report.

Product Quality Deficiency Reports and Warranty Claims The Contractor will be electronically notified of product quality deficiencies for any issues related to the manufacturing, kitting, or inaccuracies to configuration attributing to Contractor’s work. The contractor shall respond with acknowledgement and schedule to resolve any noted deficiencies within two (2) business days of electronic communications.

Packaging, Marking, and Shipping The contractor shall package, handle, ship and transport equipment in accordance with American Society for Testing and Materials (ASTM) D3951-15 and/or Military Standard-2073-1E. Each complete harness shall have a serial number that corresponds to the ALC work order number anticipated for installation. Serial numbers for the individual kits shall be the same as the complete harness serial number. This serial number shall be provided by the COR. All kits will be separately packaged then shipped in one container. The method of packaging shall be consistent once established.

The contractor shall ensure that all deliverables, when packed in separate shipping containers, will be capable of being transported on standard transportation systems, commercial or military carriers. The contractor shall preserve, package, and mark the containers to ensure complete delivery at destination without damage or deterioration due to the hazards of shipping, handling or storage. The contractor shall kit deliverables according to kitting instructions in Enclosure 4.

Packaging material shall not consist of popcorn, shredded paper, Styrofoam of any type, or peanut packaging. All shipping containers/packages shall be marked for delivery in accordance with the contract. All parts and assemblies, which require special care during packing, handling or shipping shall be identified and marked appropriately. A copy of the packing slip shall be affixed to the exterior of the package or shipping container and shall contain the following information:

Nomenclature National Stock Number Contract Number Part Number Master Serial Number Contractor’s Name and Address Assembly date for new components Each kit within the shipment shall have the following labels Kit Number Master Serial Number Inventory and Documentation IAW CDRL 0006, each harness delivery shall include both hard and electronic copies of the harness inventory as delivered and results of the acceptance test plan IAW section 2.16. Electronic copies shall be sent to the COR.

Quality Management System All work and work products shall be in accordance with the Contractor’s AS9100 Rev D-certified and ISO 9001:2015-certified Quality Management System (QMS). A copy of this QMS shall be provided to the government at the PAC IAW CDRL 0002.

The Contractor is responsible for performing or having performed all inspections and tests necessary to substantiate that the supplies furnished under this contract conform to contract requirements, including any applicable technical requirements for specified manufacturers’ parts.

The Contractor shall perform a 100% Quality Assurance (QA) inspection throughout all stages of wire harness manufacturing IAW ISO 9001:2015, AS9100 Rev D, and AS9110 Rev C Processes and Procedures prepared on AS9102 form. Wiring terminations and installation, soldering and connections shall meet standards IPC-A-610, J-STD-001, and ICP/WHMA-A-620 and shall be performed by certified personnel. All inspection documents shall be maintained and provided to the Government upon request. The Government maintains final QA inspection and acceptance authority.

Contractor QA inspection criteria procedures shall be equivalent to DoD Electrical Wiring Interconnect System (EWIS) Inspection Guidance contained in MIL-HDBK-522. USCG reserves the right to verify equivalence to military aerospace EWIS inspection criteria. Any Contractor QA procedures which are found to be lacking will be corrected and remedied to a point of equivalence prior to the manufacturing process being initiated.

Acceptance Test Report Beyond the requirements of section 2.15, each harness shall have a point-to-point and 100% Bulk Check analysis. IAW CDRL 0006 an electronic version of this documentation shall be sent to the COR and a hardcopy shall be included in each harness’ packaging.

The following shall be used as a minimum for testing criteria:

1. Insulation resistance/circuit isolation:

a. Any EWIS without voltage/current sensitive devices connected shall have an insulation resistance test parameter of 100 megohms or greater at 500 VDC.

b. Any EWIS with voltage/current sensitive devices (relay/contactor coils, inductors, resistors, capacitors, diodes, transistors, blowers, motors, etc.) connected that can be safely tested shall have an insulation resistance of 10 megohms or greater at 28VDC or the device maximum voltage rating, whichever is lower, unless the programmer determines a higher voltage is safe and necessary.

2. Continuity/discontinuity for the conditions listed below:

a. Any point-to-point EWIS without voltage/current sensitive, resistive, inductive, capacitive, and/or switching devices connected shall have a continuity resistance of 2 ohms or less at 1 amp.

b. Any EWIS with voltage/current sensitive devices (relay/contactor coils, inductors, resistors, blowers, motors, etc.) connected that can be safely tested shall have a continuity resistance within 10 percent of the device manufacturer specification, unless variation is otherwise specified, utilizing voltage/current settings not to exceed the device manufacturer ratings while maintaining accuracy.

c. Any EWIS with capacitive devices connected that can be safely tested shall have a capacitance within 10 percent of the device manufacturer specification, unless variation is otherwise specified, utilizing voltage/current settings not to exceed the device manufacturer ratings while maintaining accuracy.

d. Any EWIS with voltage/current sensitive devices (diodes, transistors, etc.) connected that can be safely tested shall have a continuity resistance within 10 percent of the device manufacturer specification, unless variation is otherwise specified, voltage/current settings not to exceed the device manufacturer rating while maintaining accuracy. Diodes shall also be tested for discontinuity of 100 kilohms or greater at the diodes rated voltage.

e. Any EWIS that has mechanical switching devices (relay, contactors, switches, circuit breakers, etc.), whether electrically or manually operated, shall have a contact continuity resistance of 4 ohms or less at 1 amp and a contact discontinuity resistance of 10 megohms or greater at 28 VDC.

f. Coaxial and triaxial EWIS non-shielded conductors with no voltage/current sensitive devices (relay/contactor coils, inductors, diodes, transistors, etc.) connected shall have a continuity resistance of 8 ohms or less at 1 amp.

g. Coaxial and triaxial EWIS non-shielded conductors with voltage/current sensitive devices (relay/contactor coils, inductors, diodes, transistors, etc.) connected that can be safely tested shall have a continuity resistance within 10 percent of the device manufacturer specification unless variation is otherwise specified, voltage/current settings not to exceed the device manufacturer ratings, while maintaining accuracy.

h. Coaxial and triaxial EWIS shielded conductors shall not be tested with high voltage/current parameters. Shields shall be tested for less than 8 ohms point-to-point continuity, but shall not be tested/scanned for insulation or isolation due to the possibility of connector shells shorting to other circuits and therefore creating false errors.

i. Shielded pair wiring shields/drains attached to connector housings shall not be tested with high voltage/current parameters. Shields on these cables are normally tied to ground at some point in the circuit and bulk checks are not performed on ground circuits.

Supporting Information Points of Contact The following individuals are the designated points of contact for the project. Additional points of contract will be provided to ALC for further distribution.

Primary/ COR:

CWO Kenneth Irsik SRR Projects

USCG ALC

Kenneth.M.Irsik@USCG.MIL

(252) 335-6843

Alternate / ACOR:

LCDR James Conner SRR Projects

USCG ALC

James.O.Conner@USCG.MIL

(202) 475-3805

Technical Contact Should any technical or logistical concerns arise, direct and expedient communication is expected. The following individual is the designated Technical Manager point of contact for technical discussion. Should either Government Technical Manager not be available, communication with our primary point of contact noted in Section 3.1 is expected.

Primary:

CWO Kenneth Irsik SRR Projects

USCG ALC

Kenneth.M.Irsik@USCG.MIL

(252) 335-6843

Secondary:

Mr. John Foster SRR Projects

USCG ALC

John.L.Foster@USCG.MIL

(252) 232-8273 Enclosure 1 – Contract Deliverables Requirements List Enclosure 2 – Government Furnished Information Enclosure 3 – Wire Harness Delivery Schedule Enclosure 4 – Kitting Enclosure 5 - GFE