I.5.a. 103122 Encl (7) Appendix_A.pdf

APPENDIX A

MINIMUM STANDARD QUALITY CONTRACT REQUIREMENTS FOR MATERIAL

PROCUREMENT, MODIFICATION, REPAIR OR OVERHAUL OF MATERIAL

NON-NUCLEAR LEVEL I MATERIAL SMICs L1, C1, S1 AND LEVEL I SUPPORT SMIC Q3, VG

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Appendix A

STATEMENT OF WORK (SOW) – SECTION C REQUIREMENTS

1. Scope

1.1 The material covered in this contract will be used in a crucial shipboard system. The use of incorrect or defective material would create a high probability of failure resulting in serious personnel injury, loss of life, loss of vital shipboard systems, or loss of the ship itself. Therefore, the material has been designated as SPECIAL EMPHASIS material

(Level I, Scope of Certification, or Quality Assured) and special control procedures are invoked to ensure receipt of correct material.

1.2 The Certifying Activity (CA) is the designated Level I certifying activity for all Level I systems and associated components supplied under this contract. The contractor will contact the CA in writing after award of contract and prior to commencement of any work to ensure all Level I prerequisites are addressed.

2. Applicable Documents

2.1 See Statement of Work (Section C), for specific System, Equipment, Material, and

Component Drawings and References.

Note - All applicable documents will be listed in a manner which will allow positive identification of the references and will indicate the revision/change level when the

Statement of Work (SOW) was prepared.

3. Requirements (per SEA 06P Letter, Ser 06/026, 19 June 2015)

3.1 Quality System Requirements - The Contractor furnishing items under this contract/purchase order shall provide and maintain a quality system in accordance with

MIL-I-45208, ISO9001:2008 (except as amplified or modified herein) with the calibration system requirements of MIL-STD-45662 or ISO10012 or ANSI-Z540.1. Quality systems in accordance with ISO9001:2000, ISO9001:1994, or ISO9002:1994 are acceptable alternates.

3.1.1 The Contractor's quality system and products supplied under the system are subject to evaluation, verification inspection, and acceptance/non-acceptance by the Government representative to determine the system's effectiveness in meeting the quality requirements established in the Contract/Purchase Order.

3.1.2 The Contractor's quality system shall be documented and shall be available for review by the Contracting Officer or his representative prior to initiation of production and throughout the life of the contract. The Prime Contractor shall, upon notification, make his facilities available for audit by the contracting

Officer or his authorized representative.

3.1.3 See CDRL DI-QCIC-81110 (Inspection System Procedures) - All suppliers of

Level I/SUBSAFE (LI/SS) material are required to submit a copy of their current documented quality system procedures to the Procurement Contracting Officer

(PCO) prior to award of any contract/purchase order. Suppliers that have a copy of their current quality system procedures on file at the Procuring Activity may request the PCO waive this requirement.

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Appendix A

3.1.4 This contract provides for the performance of Government Quality Assurance at source. The place or places of performance may not be changed without the authorization of the Procurement Contracting Officer. Upon receipt of this order, promptly notify the Government representative who normally services your plant so that appropriate planning for Government inspection can be accomplished. If you do not have an assigned Government representative, notify the nearest Defense Contract Management Agency (DCMA) Office. In the event that a local Government representative or DCMA Office cannot be located, our purchasing agent should be notified immediately.

3.1.5 Any changes made by the Contractor to a qualified quality system will require re-submittal to the PCO and concurrence by the Government Quality Assurance

Representative prior to adoption.

3.2 Contractor Inspection Requirements - The Contractor shall maintain adequate records of all inspections and tests. The records shall indicate the nature and number of observations made, the number and type of deficiencies found, the quantities approved and rejected and the nature of corrective action taken as appropriate. Inspection records shall be traceable to the material inspected.

3.2.1 The supplier's gages, measuring and test equipment shall be made available for use by the Government representative when required to determine conformance with Contract requirements. When conditions warrant, the supplier's personnel shall be made available for operations of such devices and for verification of their accuracy and condition.

3.2.2 All documents and reference data applicable to this contract shall be available for review by the Government representative. Copies of documents required for

Government inspection purposes shall be furnished in accordance with the instructions provided by the Government representative.

3.3 Subcontractor Inspection Requirements - The Government has the right to inspect at source, any supplies or services that were not manufactured or performed within the contractor's facility. Such inspection can only be requested by or under authorization of the Government representative. Any purchasing documents to a subcontractor must cite the applicable portions of the contractually invoked quality system (e.g. calibration requirements), plus any product requirements that apply to the supplies being purchased.

When the Government elects to perform source inspection at the subcontractor's facility, applicable purchase documents shall be annotated with the following statement: "A

Government inspection is required prior to shipment from your plant. Upon receipt of this order, promptly notify the Government representative who normally services your plant so that appropriate planning for Government inspection can be accomplished. If you do not have an assigned Government representative, notify the nearest Defense Contract

Management Agency (DCMA) Office. In the event that a local Government representative or DCMA Office cannot be located, our purchasing agent should be notified immediately."

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Appendix A

3.3.1 The prime contractor's program shall include procedures to assess the capability of the prospective suppliers to produce the products or supply the services in accordance with the contract, prior to the issuance of any purchase document.

3.3.2 Each sub-tier supplier of material or services for items in Section 3 of this contract shall be subjected to a periodic review or audit by the Prime to determine the continued capability of the supplier to control the quality of the products or services specified in the purchase order or contract.

3.3.3 The prime contractor shall ensure that the purchased product conforms to specified purchase requirements and this contract. The type and extent of control applied to the supplier and the purchased product shall be dependent upon the effect of the purchased product on the end item represented by this contract.

3.3.4 The prime contractor shall evaluate the requirements of the contract and select suppliers based on their ability to supply the product in accordance with the prime contractor's requirements and the contract. Criteria for selection and evaluation shall be established. Records of this effort shall be available for review by the government.

3.3.5 The prime contractor's supplier quality assurance program shall provide for a review of purchase documents to assure applicable quality requirements are included or referenced in the documentation for compliance by the supplier.

3.4 Government Furnished Material and/or Equipment (GFM/GFE) - When material or equipment is furnished by the Government, the Contractor shall develop documented control procedures that require at least the following:

3.4.1 Visual examination upon receipt to detect damage during transit.

3.4.2 Inspection for completeness and proper type.

3.4.3 Verification of material quality received.

3.4.4 Periodic inspection and precautions to assure adequate storage conditions and to guard against damage from handling and deterioration during storage

3.4.5 Functional testing, either prior to or after installation, or both, as required by the

Contract to determine satisfactory operation.

3.4.6 Identification and protection from improper use or disposition.

3.4.7 Reporting to the Government, any GFM or GFE property found damaged, malfunctioning, or otherwise unsuitable for use. In the event of damage or malfunction during or after installation, the supplier shall determine and record probable cause and necessity for withholding the material from use.

3.4.8 For GFE material, and as required by the terms of the bailment agreement, the supplier must establish procedures for adequate storage, maintenance, and inspection of bailed Government material. Records of all inspection and maintenance performed on bailed property shall be maintained.

3.4.9 Material returned to the contractor shall be handled as GFM.

PROCUREMENT, MODIFICATION, REPAIR OR OVERHAUL OF MATERIAL

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Appendix A

3.5 Traceability and Certification Requirements - To assure that correct materials are installed in Level I/SUBSAFE systems, it is imperative that traceability be maintained from the material to the material certification test report and other required Objective Quality

Evidence (OQE). The material certification report must completely and accurately reflect that the material supplied meets the specified requirements.

3.5.1 Parts of an Assembly requiring Traceability and Certification – Quantitative chemical and mechanical analysis is required for the parts listed below unless specifically stated otherwise:

Part - (See attached Parts/Material List)

Material - (See attached Parts/Material List)

3.5.2 The following provides the minimum requirements for maintaining material traceability and supplements the requirements specified in DI-MISC-81020 and elsewhere in the contract/purchase order. The Contractor shall develop written procedures that implement the material control requirements stated herein.

3.6 Material Traceability - The certification data report shall be identified through a unique traceability number, heat-lot number, or heat-treat number for metallic material or batch of non-metallic material, as applicable, which shall also be marked on the material. This traceability marking on the material shall provide direct traceability to the material's chemical composition and mechanical properties certification data. For material produced by batch, continuous cast, or continuous pour processes, samples shall be taken no less than once in every eight hours of operation for the purpose of validating proper chemical composition and mechanical properties. Traceability shall be maintained through all process operations including any subcontracted operations, to the finished component.

3.6.1 Material Marking for Traceability and Identification - The following are the minimum marking requirements. Additional/alternate marking requirements, if applicable, will be specified elsewhere in the contract/purchase order. In addition to the marking requirements on applicable drawings and/or specifications, marking for traceability is required. All traceability markings shall be permanently applied in accordance with MIL-STD-792 (except as specified below). An alternate marking method is permissible provided it is an available option in the contractually invoked specification or drawing, except in instances where the material has been modified by this contract/purchase order and differs from that specified in the specification or drawing.

3.6.2 Traceability markings for items with precision machined or plated surfaces, or material with suitable marking surface areas less than 3/8 inches square (either

3/8" x 3/8" or an area equal to 0.1406 inches square) shall be applied to a durable tag and the tag securely affixed to the material.

3.6.3 Traceability markings shall be maintained through assembly, and whenever possible shall be visible after assembly. For items where the marking is not visible after assembly, a durable tag shall be securely attached to the item identifying the part number, piece number, traceability number, and the location of the permanent mark.

PROCUREMENT, MODIFICATION, REPAIR OR OVERHAUL OF MATERIAL

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Appendix A

3.6.4 Fasteners shall be marked in accordance with the applicable specification. The method of marking shall be types I, II, III, V, VIII or IX of MIL-STD-792 except for grades 410, 416 and 431 in the H condition and grades 8, 630, A574, and 4340 which shall be marked by method II when marking is applied after the final heat treatment. Traceability marking must be legible after the application of protective compounds.

3.6.4.1 Marking is required for all fasteners regardless of size and shall include the material symbol, the manufacturer's identification symbol, and the traceability marking. Material grade marking for ASTM-

A574 shall be “STM” in lieu of No Marking as stated in MIL-DTL-

1222, unless the material is Grade 4340, which shall be marked

“4340”. Marking shall be applied on the head of headed fastener (top preferred, side location if necessary). Self-Locking screws shall also be marked with six dots approximately .032 diameter, raised or depressed by approximately .010 equally spaced in a circular pattern on the top perimeter of the head of the fastener.

3.6.5 Marking Location - Permanent marking shall be legible and shall be located so as to not affect the form, fit, and function of the material. When applicable, marking location shall be as shown on the drawing, except that Ball Valve Balls shall be marked in the waterway/airway.

3.6.6 Seat Marking - Each seat must be permanently marked in accordance with MIL-

STD-792, type I and as stated below, except for Teflon seats, which shall only be tagged. Type IX marking may be substituted for type I provided the minimum character size scribed by the marking tool is approx. 3/32-inch-high to insure legibility. Permanent marking is NOT permitted on Teflon seats.

TEFLON seats shall be tagged. All other seats shall be marked on the outer cylindrical surface.

3.6.6.1 Seat marking requirements shall maintain complete traceability to certification OQE. Seat marking shall be either a heat/lot or batch number, a vendor traceability number/code, or a combination thereof and shall be unique to the material certification.

3.6.7 Pipe, Tube, and Metal Bar shall have both permanent marking and temporary marking applied as specified below.

3.6.7.1 Permanent marking - Permanent traceability marking shall be marked on each end of each pipe, tube, and metal bar. (MONEL and K-

MONEL bar: 3/4 inch to 1 inch rods and 7/8-inch hex bar may be marked on the surface near the end of bar/rod, and rod less than 3/4 inch and hex bar less than 7/8 inch may be bundled and tagged or boxed with the traceability marking on the tag or box). All traceability marking shall be permanently applied in accordance with

MIL-STD-792. An alternate marking method is permissible provided it is an available option in the contractually invoked specification, PROCUREMENT, MODIFICATION, REPAIR OR OVERHAUL OF MATERIAL

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Appendix A except in instances where the material has been modified by this contract/purchase order, and differs from that specified in the specification. Electric arc marking or impression marking is strictly prohibited on thin wall tubing (wall thickness of less than 0.125 inch).

3.6.7.2 Temporary Marking - Temporary Marking shall consist of: Name or

Trademark of Manufacturer, specification and grade (as applicable), size, contract number, and the traceability marking. Pipe and tube marking shall also include SML (for seamless). Marking shall be in accordance with the material specification and SAE-AMS-2806, SAE-AMS-2807, SAE-AMS-2809, Table I of SAE-AMS-STD-185, or ASTM-B666 as applicable. Application shall be in accordance with MIL-STD-792, type A (temporary ink stenciling). An alternate method is permissible for MONEL and K-MONEL bar provided it is an available option (temporary marking only) in the applicable material specification, except that hot finished rod with rough ground surface 3/4 inch and under may be bundled and tagged or boxed with the traceability marking on the bag or box. Contamination levels for ink stenciling shall be as outlined in paragraph 5.2 of MIL-STD-792.

3.6.8 Permanent markings are not required for consumable material (weld filler material, etc.). Traceability shall be by a label attached to each unit container.

The unit container identification label shall include, in addition to the contract number and the National Stock Number (NSN), all markings required for identity and traceability. Each container in the lot must contain material from the same traceability number or heat/lot, as defined in the applicable specification. Identification marking shall be the Type designation in accordance with the applicable detail specification.

3.6.8.1 For covered welding electrodes, the Type designation or classification number shall also be applied to the electrode covering within the space 2 1/2 inches from the grip end of the electrode. The marking shall consist of at least one complete type designation or two or more partial type designations that can be read or positively interpreted as the intended designation. The two partial type designations shall consist of at least the top portion and the bottom portion of the designation.

3.6.8.2 Individual cut length bare welding rods shall be identified in accordance with the applicable commodity specification. In the absence of specific specification marking requirements, at least one legible type designation/classification number shall be applied to each rod, either by stamping or by tagging (i.e. flag tagging).

3.7 See CDRL DI-MISC-81020 (Chemical and Mechanical) and CDRL DI-MISC-80678 when applicable (i.e., SEAT MATERIAL) - Material Certification - In addition to the brian.wohler Highlight

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Appendix A certification data requirements specified in DI-MISC-81020, the following material certification requirements apply:

3.7.1 Metallic Material - Quantitative chemical and mechanical analysis of material traceable to traceability markings is required. Material certification test reports shall include the class, form, condition, grade, type, finish, and/or composition, as applicable, of the material supplied.

3.7.2 Non-Metallic Material - The Contractor shall furnish the applicable test reports for each heat/lot/batch of seat material. Material certification test reports shall include, in addition to the specification, the class, form, grade, type, process, and/or composition, as applicable, of the material supplied.

3.7.3 When required, see CDRL DI-MISC-81020 (QUALITY CONFORMANCE/

REQUIRED TESTS) - Certification is required for each test performed under

Quality Conformance listed in the applicable paragraph of the military specification (or Table 5 of AWS specifications).

3.7.4 Re-identification and re-certification of metallic material is required when the material is subjected to a process which alters its properties. If the starting material or raw stock is processed in a manner that will not affect its chemical composition or mechanical properties, the original certifications for the chemical composition and mechanical properties, as required by the material specification, are acceptable. Re-certification of the chemical or mechanical properties is required if a process is used during fabrication that alters the original properties of the material (e.g. alloying, heat treating, or forming). In these instances, the properties of the material must be re-determined and documented to reflect the altered condition. The altered material shall be uniquely re-identified. The properties thus determined and documented, are required for final certification and shall conform to the material specification or the contract/purchase order requirements. When only the mechanical properties are altered, the original certification for chemical composition shall be over-stamped and/or annotated with the unique traceability marking used with the altered material as shown below:

Traceability No.

(Marking on finished item)

Is fabricated from raw material

Heat No. and

Heat Treat No.

(When Applicable)

(Name and Signature of Authorized Co. Rep) Date

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Appendix A

3.7.5 Material certification data forwarded by the manufacturer shall contain a signed certification that the report results represent the actual attributes of the material furnished and indicate full compliance with all applicable specification and contract requirements. Transcription of certification data is prohibited.

3.7.6 Statements on material certification documents must be positive and unqualified.

Disclaimers such as "to the best of our knowledge" or "we believe the information contained herein is true" are not acceptable.

3.7.7 If material is received without the required certification papers or with incorrect/missing data on the certification papers, the material will be rejected.

3.8 Material Handling - The written material control process shall include the following:

3.8.1 All raw materials shall have traceability markings (except as specified below).

3.8.2 Stored raw materials requiring traceability shall be segregated to preclude intermingling with materials not requiring traceability.

3.8.3 When traceability markings will be removed by a manufacturing or fabrication process, the marking shall be recorded prior to removal and be immediately restored upon completion of the process. If this cannot be done or is impractical, an appropriate material control procedure (such as a bag and tag, tagging, and/or tote box control) must be employed. The material control procedure must provide a method of positive control to preclude commingling of heats/lots or loss of traceability. The traceability marking shall be reapplied upon completion of the final manufacturing process.

3.8.4 Brazing or weld filler metals for strength welds forming or integral with pressure containing components or assemblies requiring traceability shall be verified to be the correct material, and type or grade, as applicable, prior to consumption.

At a minimum, material verification shall consist of inspection of material test reports for conformance to specified requirements. Control of welding and brazing filler metals shall be maintained to the point of consumption to assure use of the correct type and grade. Markings and traceability requirements do not apply to brazing and weld filler metals after consumption. It is the responsibility of the prime contractor to ensure conformance with the above requirements on welds performed by their subcontractors.

3.8.5 Purchase orders for raw material shall specify that the material be traceable to material certification test reports by traceability markings on the material and identified on the test reports. The certification data requirements contained in

DI-MISC-81020 shall be invoked by the prime contractor on all subcontractors supplying Level I material.

3.8.6 The material control process shall include requirements for the maintenance of traceability for items sent out for subcontracted operations. If such operations would remove traceability markings, purchase or work orders shall specify a method and marking location for remarking. The contractor shall also ensure

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Appendix A that subcontractor production controls are adequate to preclude commingling of materials during processing.

3.9 Receiving inspection

3.9.1 Products and services produced by sub-tier suppliers for incorporation in the contract end item shall be subject to inspection or audit at the time of receipt by the prime prior to further processing within the prime contractor's plant or shipment to another location.

3.9.2 Receiving Inspection shall include as a minimum;

3.9.2.1 Verification that the traceability marking on the material agrees with that on the certification test reports.

3.9.2.2 Verification that certification test reports are legible and complete.

3.9.2.3 Verification that the contents of the certification test reports are in compliance with the contractually invoked specifications and requirements.

3.10 Discrepancy reporting

3.10.1 Nonconforming products from sub-tier suppliers shall be identified and processed in accordance with the prime contractor's procedures for controlling nonconforming products. The prime contractor shall report the receipt of any nonconforming products to the responsible sub-tier supplier in accordance with established procedures. Nonconforming material records will be maintained and available for review by the government Quality Assurance Representative

(QAR).

3.11 Final Inspection - The following inspections shall be performed prior to Government inspection and acceptance.

3.11.1 Metallic Material Sampling - Material shall be inspected for form, fit, and function. Lot acceptance shall be based on zero defects and lot rejection based on one defect. The sample size shall be in accordance with the sampling plan(s) in the applicable military specification or standard, federal specification or standard, or drawing to which the material was manufactured. In the absence of such sampling plans, sampling inspection shall be per ANSI/ASQ-

Z1.4, general inspection level II (for sample size selection code), table IIA (for sample size). SMALL LOT SIZES - For lot sizes of fifty or less, the minimum sample size shall be eight units. For lot sizes of eight or less, the sample size shall be one hundred percent of the lot.

3.11.2 Metallic material - The Manufacturer may elect to use Statistical Process

Control (SPC) to assure product quality in lieu of the above attribute sampling plan, provided that the SPC methodology/system used provides acceptable products to the Government. However, the Government/Navy Receipt

Inspection Activity may perform their acceptance inspection of the material using the attribute sampling plan outlined above.

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Appendix A

3.11.3 Metallic material - All data concerning material verification (chemical, mechanical or physical properties), traceability (material certifications to material marking), and nondestructive test (NDT) certifications for material shall be 100% inspected. The certification test reports shall also be 100% inspected for completeness and legibility.

3.11.4 Non-Metallic Material - Sampling for certification of non-metallic material shall be on the basis of one set of test specimens from each heat/lot or batch.

3.11.5 All welding electrodes/inserts shall be sample inspected in accordance with the applicable welding electrode/insert specification, except the unit containers shall be 100% inspected for traceability marking and that the markings are legible.

3.11.6 All material requiring traceability shall be 100% inspected for traceability marking and that the marking is legible.

3.12 See CDRL DI-MISC-80678 (Special Emphasis C of C) - The Contractor shall prepare and submit a certificate of compliance certifying that the items/components furnished under this contract comply with the requirements of the procurement document, including any/all invoked specifications and drawings. The certificate of compliance must show traceability to the marking applied on each individual item, and shall contain the following information:

3.12.1 Contractor's name, address, and date.

3.12.2 The contract/purchase order number (i.e. N66604-11-P-FA12).

3.12.3 The National Stock Number (NSN). The 18 character National Stock Number for Special Emphasis material includes the two digit COG, the four digit FSC, the 9 digit NIIN, and the two digit SMIC (i.e. 1H 4820 014532156L1).

3.12.4 Lubricants, sealants, anti-seize, and/or thread locking compounds ("N/A" when

Not Applicable).

3.12.5 Cure date ("N/A" when Not Applicable).

3.12.6 Manufacturer's compound number ("N/A" when Not Applicable).

3.12.7 When weld procedure submittal is required by the contract, a statement that the approval date of the qualification data precedes any production or repair welding performed on this Contract ("N/A" when Not Applicable).

3.12.8 A statement to the effect that all items furnished on this contract are in full compliance with the specifications and requirements

3.12.9 Contractor's or authorized personnel's signature.

3.13 Configuration Control - The Contractor shall maintain the total equipment baseline configuration. Baseline configuration is the configuration documentation formally designated by the Government at a specific time during an items life cycle. The configuration baseline, plus approved changes to the baseline, constitutes the current approved configuration documentation. For items of proprietary design, Contractor

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Appendix A drawings showing the latest assembly configuration shall be provided to the Government in electronic (C4) format. Definitions are provided elsewhere in the Contract/Purchase

Order.

3.13.1 Waivers/Deviations - All waivers and deviations, regardless of significance or classification require review and approval by the Contracting Officer. Waivers and Deviations shall be designated as Critical, Major, or Minor. The

Contractor shall provide a copy of this request to the QAR. Requests for

Waivers/Deviations shall be submitted to the PCO.

3.13.1.1 A waiver is defined as a written authorization to accept an item, which during manufacture, or after having been submitted for

Government inspection or acceptance, is found to depart from specified requirements, but nevertheless is considered suitable for use as is or after repair by an approved method.

3.13.1.2 A deviation is defined as a specific written authorization (granted prior to the manufacture of an item) to depart from a particular requirement(s) of an item's current approved configuration documentation for a specific number of units or a specified period of time, and to accept an item which is found to depart from specified requirements, but nevertheless is considered suitable for use "as is" or after repair by an approved method.

3.13.1.3 A Critical Waiver/Deviation consists of a departure involving safety.

3.13.1.4 A Major Waiver/Deviation consists of a departure involving:

Performance.

Interchangeability, Reliability, Survivability, Maintainability, or

Durability of the item or its repair parts.

Health or Safety.

Effective Use or Operation.

Weight, Stability, or Structural Integrity.

System design parameters as schematics, flows, pressures or temperatures.

Compartment arrangements or assigned function.

3.13.1.5 A Minor Waiver/Deviation consists of a departure which does not involve any of the factors listed as critical or major.

3.13.1.6 All Waivers/Deviation requests shall include the information listed below:

a. A complete description of the contract requirement affected and the nature of the waiver/deviation (non-conformance), including a classification of Critical, Major, or Minor.

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Appendix A

b. Number of units (and serial/lot numbers) to be delivered in this configuration.

c. Any impacts to logistics support elements (such as software, manuals, spares, tools, and similar) being utilized by

Government personnel or impacts to the operational use of the product.

d. Information about remedial action being taken to prevent reoccurrence of the non-conformance.

3.13.2 ECPs - The Government will maintain configuration control and change authority for all modifications or changes affecting form, fit, function, or interface parameters of the Equipment and its sub-assemblies. The Contractor shall submit an Engineering Change Proposal (ECP) to the Contracting Officer for any Class I or II changes that impact the Equipment covered by this contract. An Engineering Change (EC) is defined as a change to the current approved configuration documentation of a configuration item at any point in the life cycle of the item. An Engineering Change Proposal (ECP) is defined as a proposed Engineering Change and the documentation by which the change is described, justified, and submitted to the Government for approval or disapproval. A Class I ECP is approved by the Government's Configuration

Control Board and authorized with a contract modification. A Class II change is typically reviewed for concurrence in classification by the local government representative, unless otherwise specified elsewhere in the contract/purchase order. ECPs shall be prepared in Contractor format, and shall include the following information:

3.13.2.1 The change priority, change classification (Class I or Class II), and change justification.

3.13.2.2 A complete description of the change to be made and the need for that change.

3.13.2.3 A complete listing of other Configuration Items impacted by the proposed change and a description of the impact on those CIs.

3.13.2.4 Proposed changes to documents controlled by the Government.

3.13.2.5 Proposed serial/lot number effectivities of units to be produced in, or retrofitted to, the proposed configuration.

3.13.2.6 Recommendations about the way a retrofit should be

accomplished.

3.13.2.7 Impacts to any logistics support elements (such as software, manuals, spares, tools, and similar) being utilized by Government personnel in support of the product.

3.13.2.8 Impacts to the operational use of the product.

3.13.2.9 Complete estimated life-cycle cost impact of the proposed change.

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Appendix A

3.13.2.10 Milestones relating to the processing and implementation of the engineering change.

3.14 Mercury Free - Mercury or mercury containing compounds shall not be intentionally added or come in direct contact with hardware or supplies furnished under this contract.

Mercury contamination of the material will be cause for rejection.

4. Procedure Requirements

4.1 The following information provides amplifying detail and aids to clarify the requirements established in Section 3. These specific procedure requirements are necessary to ensure the Certifying Activity has adequate information to support Level I certification.

4.2 Quality System Requirements - In addition to the Quality Systems identified in Paragraph

3.1, ISO 9001:2015 is an acceptable alternate.

4.3 Contractor Inspection System Requirements - The contractor will furnish the following specific procedures to the Certifying Activity (CA) prior to production, when required.

4.3.1 Inspection Plan - A Step-by-Step method with inspection/verification points that contains the following:

a) Part Name

b) Identification of each characteristic to be inspected

c) Acceptance and reject criteria

d) Actual dimension recordings

4.3.2 Dynamic Test/Balance Procedure - will include the following:

a) Test Requirements

b) Set up of Unit in Test Stand

c) Gages used

d) Applied Loads

e) Step-by-step Method

f) Applied Cycle Times

g) Recording of Test Results

h) Time Periods for Test

4.3.3 Hydrostatic Pressure Test Procedure in accordance with applicable Test

Requirement Specification or Manual (i.e., NAVSEA 0387-LP-046-8000;

NAVSEA S9505-AF-MMA-010; NAVSEA S9086-RK-STM-010; NAVSEA

S9086-RJ-STM-010) unless otherwise specified by the basic contract.

a) Test Requirements

b) Test Rig Configuration

c) Applied Loads

d) Step-by-step Method

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e) Applied Cycle

f) Recording of Test Results

g) Time Periods for Test

4.3.4 Non-Destructive Test Procedures (NDT) in accordance with NAVSEA T9074-

AS-GIB-010/271 for:

a) Visual

b) Magnetic Particle

c) Dye Penetrant

d) Radiography

e) Ultrasonic

4.3.5 Welding

a) Fabrication welding of machinery, piping and pressure vessels will be in accordance with NAVSEA S9074-AR-GIB-010/278.

b) Fabrication and welding of HY-80/100/130 Submarine Hull structure will be in accordance with NAVSEA T9074-AD-GIB-010/1688.

c) Welding procedures, welding procedure qualification test data, and welder Qualification data will be in accordance with NAVSEA S9074-

AQ-GIB-010/248. Weld procedure and qualification test data will be submitted to the Certifying Activity for approval prior to welding.

4.3.6 Weld Repair Procedure - Repairs of out of tolerance conditions will be approved by the Certifying Activity prior to performing any repairs on components and/or assemblies to be presented to the government for acceptance and use. The procedure will include:

a) Repair Area

b) Repair Method

c) Step by Step Repair Process

d) Test Requirements

e) Acceptance Criteria

4.3.7 Special Requirements

Note – Any specific technical/operational requirement not clearly identified in this Appendix or the Engineering Drawings will be clearly defined in the

Statement of Work (SOW).

4.4 Government Furnished Material/Contractor Furnished Material Requirements - The following information provides specific procedure, inspection, and test record requirements to support Level I certification. For each assembly, component, delivered

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Appendix A item, the contractor will furnish one (1) copy of the following documents correlated to the contract number and serial number assigned to the component/assembly:

4.4.1 For Government-Furnished Material

a) Certification that material furnished was used in the assembly it was supplied for use.

b) Documented list of all material used in such furnished assembly. For each piece, the list will include the drawing number, piece number, and component serial letter.

4.4.2 For Contractor-Furnished Raw Material

a) For contractor-supplied raw material used in the manufacture of components, the contractor will supply documented verification of raw material by alloy families by one of the following methods.

Note: Level I material must use option (2) or (3).

(1) Use simple, direct and rapid material analysis methods or a combination of methods (e.g., visual, hardness test, magnetic properties test, acid spot tests, and metal comparator tests).

(2) Supply material certification reports of physical properties and chemical composition traceable to material in compliance with

DI-MISC-81020.

(3) Supply Issue Release/Receipt Document DD FORM 1348-1A for material received from the Navy Supply System.

4.4.3 Verification of Assembly - A torque record reflecting actual torque applied and lubricant used when drawing, or special notes specify such records.

a) Torque Records will include; torque wrench/device serial number, range, calibration date, calibration due date, identification of lubricants

(if applicable). NOTE - Running torque will be required to determine final torque, if fasteners are 5/8 inch or less and have a self-locking feature. Whenever running torque is required the use of a dial type torque wrench is required (Snap or beam type torque wrenches will not be used.). Torque Wrench chosen will be within 20-90% of the torque wrench range for the required torque.

b) For all other instances, the vendor will provide a certificate of compliance attesting to conformance with all drawing and specified requirements.

c) Components removed from equipment/assemblies/ subassemblies must be identified and documented.

d) Components installed into equipment/assemblies/ subassemblies must be identified and documented.

e) O-rings utilized in SUBSAFE assemblies/subassemblies/piece parts must be documented, reporting the type O-ring used, Part number, PROCUREMENT, MODIFICATION, REPAIR OR OVERHAUL OF MATERIAL

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Appendix A results of visual inspection of O-ring, cure date, and quantity used.

Including shelf-life expiration date.

f) Ensure that all O-rings were manufactured and supplied by a QPL

Vendor when applicable by specification.

4.4.4 Weld Records - Including Identification of weld procedure, joint, base material, filler material, heat treatments.

a) When required by the applicable fabrication specification (NAVSEA

S9074-AR-GIB-010/278 or NAVSEA T9074-AD-GIB-010/1688) and welder qualifications as required under this contract in accordance with

NAVSEA S9074-AQ-GIB-010/248.

4.4.5 Non-Destructive Testing (NDT) Inspection Test Reports.

a) Report must include identification of procedure used, joint inspected, plan number, piece number, equipment and NDT Personnel

Qualification compliance to NAVSEA T9074-AS-GIB-010/271.

b) Radiographic film must be marked in relation to contract number, serial number, and location of the film on the part being tested.

c) Film must be accompanied by a shooting sketch and an acceptance statement signed by a Government qualified reader.

4.4.6 Pressure/Performance Test Reports.

a) Gage serial number, range, calibration date, pressure requirement, actual pressure, duration of test, and medium used.

b) Pressure test gauges will be selected such that the test pressure falls within 50-90% of the gauge range. (Note - Test gauge range is greater than the test pressure but not more than twice that of the maximum test pressure).

4.4.7 Hydrostatic Testing

a) Hydrostatic testing will be conducted per the applicable specification and/or requirement, and will be accomplished prior to certification.

b) The test data will be maintained by the contractor and the actual results submitted to the Certifying Activity.

c) The hydrostatic and post-test inspection of the part/assembly for leaks and damage will occur on the same day.

Note: The following are examples

Hydrostatic Pressure Testing

Joint Tightness Testing

Dynamic Testing.

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Appendix A

4.4.8 Inspection Records

a) The inspection records will show the results of actual measurements inspected and will include the inspector's signature and date, identification of the instrument or measuring equipment used, the calibration date, and due date.

b) The inspection records are to be maintained on Objective Quality Evidence

Data Sheets (OQEDS) supplied by the contractor.

(1) ACTUAL measurements are required for the following categories:

Dimensions with a tolerance of +/- .005 or less”

Straightness of .010” per foot or less

Geometric characteristics (forms, profile, orientation, location, run out, etc.) with a tolerance of .010” or less

Finishes 32 or less.

Angles +/- ½ degree or less

(2) All fasteners to be used in Level I or submarine hull integrity applications will be procured in accordance with MIL-DTL-1222, Specification 688-

1864 or as otherwise approved by NAVSEA (e.g., NAVSEA approved drawing, NAVSEA Technical Manual, etc.)

Note – Fastener Inspection criteria may vary significantly based on application. Engineering Agents and the Certifying Activity will ensure the correct inspection system (i.e., System 21, 22, 23, or other criteria) is clearly defined in the engineering drawings or specified in the Statement of Work (SOW).

(3) Sampling inspection is permitted under this contract and will be in accordance with ANSI/ASQ-Z1.4. A sampling plan identifying the parts and the sample size must be submitted to the Certifying Activity for approval prior to completion of inspection.

(4) Electrical test reports as required by Drawing or Specification.

(5) Repair OQE of components/assemblies will include:

Repair Procedure

Description and Location of Defect

Method of Repair

Inspection Results

(6) Complete inspection report showing the results of visually inspecting O-rings used in the assembly.

This report will have attached the individual O-ring packages that the

O-rings were supplied in and will show the cure date of each O-ring.

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Appendix A

(7) All of the supplied documents will have complete traceability to the hardware for inspection purposes.

Therefore, whenever applicable, records will show: contract number, name of contractor, plan number, revision letter, piece number, serial letter/number of finished piece, item nomenclature, material degree of control, and MIC number, (if Level I).

(8) Documented list of all material used in each finished and delivered assembly.

Include a qualification summary sheet that will summarize and correlate all of the Objective Quality Evidence to support product quality.

4.5 Traceability and Certification Requirements:

4.5.1 Prior to applying any special finishes to final machined parts and prior to final assembly of component parts, the contractor will contact the CA to arrange for the semi-quantitative analysis material swipe to be performed by CA on the finished LEVEL I component.

4.5.2 For components and assemblies, certification is required for all materials used to fabricate the pressure containing parts of the component. This includes the fasteners used to hold these pressure containing parts together. All tests required by the specification and contract or purchase order must be performed and results reported as required by the contract or purchase order including without limitation, the specification(s) and drawing(s).

4.5.3 All pipe and tube furnished must be certified as seamless unless specifically allowed in the contract.

4.5.4 Information on test reports may be corrected by the originator only if records are available to support the change. Corrections shall be made by drawing a single line through the erroneous information and entering the correct information. The responsible official must identify the basis of making the change, sign and date adjacent to the correction. Initials and date are acceptable if the official's full signature and legible identifying information already appears on the page. The record used to justify the change must be attached to the corrected test report.

4.6 Material Marking:

4.6.1 Material Identification Control (MIC) numbers shall be assigned by (the

Certifying Activity). Each Level I finished component will be marked with drawing number, piece number, component, serial number, and MIC number.

These markings shall be applied using a permanent method described in MIL-

STD-792. The contractor may not alter or remove the MIC number once applied.

a) MIC marking of the LEVEL I component(s) or assembly must be accomplished in the presence of a representative from CA representative.

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b) The MIC number must remain associated with the material at all times.

4.7 Material Storage and Handling Requirements:

4.7.1 Storage areas and containers for Level I material will be distinctly identified and marked.

4.8 Material Shipping Requirements:

4.8.1 Prior to all material shipments, Government Source Inspection (GSI) is required to be completed by the cognizant Defense Contract Management Agency

(DCMA) office and all Objective Quality Evidence Data (OQED) associated with the delivered material as specified under this contract/ delivery order will be accepted by DCMA Representative and the assigned Certifying Activity (CA) prior to shipment of material.

a) The Certifying Activity must receive all OQED electronically (7) working days prior to delivery of material.

b) The Certifying Activity will provide the OQED disposition via e-mail (5) working days after receipt of the OQED.

c) Material will only be shipped after an acceptance disposition of the OQED by the Certifying Activity.

d) Material shipped without an acceptance disposition by the Certifying

Activity or source inspection/acceptance by DCMA, will be returned to the contractors facility at the expense of the contractor.

4.8.2 Shipping containers for equipment/material designated as Level I will be marked with “Level I” on sides and front.

4.9 Mercury Free Requirements:

4.9.1 Mercury-Free Certification Report - The contractor will deliver a mercury-free certification for all parts furnished under this contract.