Iron Fist A-Kit DLA Production SOW.docx

SECTION C - DESCRIPTION/SPECIFICATIONS/WORK STATEMENT

Bradley Fighting Vehicle System (BFVS) Iron Fist A-kit Procurement

SECTION C - DESCRIPTION/SPECIFICATIONS/WORK STATEMENT

C.1 DESCRIPTION OF SUPPLIES

C.1.1 General Description Purpose. The purpose of this effort is to provide A-kits for the Iron Fist installation on the Bradley Fighting Vehicle.

Unclassified deliveries shall be sent to:

DODAAC: CK0WJQ

US Army Temple Distribution Facility Attn: Jesse Saenz (254-239-4930) 3831 Lucius McCelvey Temple, Texas 76504

C.1.2 Scope

C.1.2.1 The contractor shall produce BFVS Iron Fist A-kits (Part Number Part #57K7977).

C.1.2.2 Start of Work Meeting (SOWM). The contractor shall host and conduct a start of work meeting within 30 calendar days after contract award at their facility. The SOWM shall be available to be viewed live virtually using Government agreed upon technology. The contractor shall schedule the event with the Procuring Contracting Officer (PCO), and Product Manager (PdM) Bradley office at least 10 business days in advance of the meeting. The contractor shall participate with the Government to arrange a schedule and agenda for the meeting. The contractor shall deliver an agenda in accordance with CDRL A013, presentation materials in accordance with CDRL A014, and meeting minutes in accordance with CDRL A015.

C.1.2.3 Integrated Product Team (IPT) Meetings. The contractor shall conduct weekly IPT meetings virtually to provide the Government with the status of the Iron Fist A-kit production. The Contractor shall coordinate the IPT meeting agenda issues, topics, and schedules with the Government IPT members. The contractor shall discuss risks, issues, quality, and production readiness concerns. Meeting minutes shall be submitted IAW CDRL A014. The minutes shall contain schedules; detailed results and proceedings of discussions, assessments, and guidance; action items; an attendees roster; and all presentations. Action items shall be assigned prior to the close of the meeting.

C.1.2.4 Program Management - The contractor shall establish and maintain a program management approach to ensure that project quality, schedule, supportability, and technical objectives are met. The contractor shall provide program management to include support of program meetings; Integrated Product Team (IPT) and review meetings; ensure program compliance with the scope of work; project scheduling; risk identification, management, and mitigation; and review and approval of artifacts identified in the Deliverables section.

C.2.1 Requirements

C.2.1.1 Testing

C.2.1.1.1 The contractor shall submit CDRL A001 Ballistic Acceptance Test Report NLT 150 calendar days after contract award in accordance with quality assurance provision requirements in Attachment 0001 (Technical Data Package) to the Government for technical review.

C.2.1.1.1.1 First article ballistic tests shall consist of all the tests specified in MIL DTL-12560K for Class 4A Armor. Unless otherwise specified the first article ballistic test shall not be required provided (a) the manufacturer, within 37 months, has produced acceptable plates within the same nominal thickness ranges of Table VI, and (b) the production conditions are the same as for previously accepted plates. A supplier who has previously met the first article requirements shall furnish the procuring activity the firing record of the ballistic test plate and other pertinent data relative to compliance with first article. The results and data from these ballistic tests shall be provided in the First Article Ballistic Test Report (CDRL A001).

C.2.1.1.1.2 The contractor shall provide two ballistic test plates for each nominal thickness range (see Table VI) shall be randomly selected and submitted for ballistic testing to the Government for First Article Test to an Army Test and Evaluation Command (ATEC) approved test center . A request for test services (RFTS) will be required via the U.S. Army Test & Evaluation Command Decision Support System (ADSS) website (https://adss.atec.army.mil/public/rfts/testrequests/request.aspx) to receive approval to conduct testing.

C.2.1.1.1.3 Ballistic testing facility. Unless otherwise specified in the contract or purchase order, the ballistic test plates shall be forwarded to the Commander, USA ATC, ATTN: TEAT-SLV, Building 358, 6850 Lanyard Road, Aberdeen Proving Ground, MD 21005-5059 or to an approved Government facility for ballistic testing for first article or production acceptance.

C.2.1.1.2 Corrosion resistance testing for the coating system shall be IAW MIL-DTL-53072; specifically, section 4.2.3.1 and associated sub-sections for Application Validation. Salt fog testing of the entire end item is also required, and shall be IAW MIL-STD-810 method 509.7 salt fog with alternating 24 hour periods of wet and dry for a total of 96 hours total test duration. The results and data from these corrosion tests shall be provided in the First Article Corrosion Resistance Test Report (CDRL A002) due NLT 255 days after award.

C.2.1.1.3 The contractor shall submit Final Acceptance Inspection Record (FAIR) (CDRL A003) NLT 255 calendar days after contract award.

C.2.1.1.4 The contractor shall conduct a ballistic test on each lot of certified steel IAW with CDRL A001. A FAIR and corrosion testing shall be conducted if the contractor makes any changes to the manufacturing process, moves the manufacturing process to a new location within the current building or physically moves operations, makes a subcontractor change or a major design change IAW with CDRLs A002 and A003. The contractor shall inform the USG team prior to making any of these changes.

C.2.2 RESERVED

C.2.3 Period of Performance

C.2.3.1 The contractor shall begin deliveries 365 days after award at a rate of 20 kits per month.

C.2.4 Quality l Requirements

C.2.4.1.1 Quality Manual. The contractor will develop and maintain a Quality manual to communicate management’s expectations to employees, demonstrate the contractors plan to conform to the requirements of the current ISO 9001 standard, demonstrate organizational roles and responsibilities and authorities are assigned, communicated and understood, and to provide a starting point for internal, Government and ISO Certification auditors. The contractor shall deliver CDRL A004 Quality Manual.

C.2.4.1.2 Subcontractor Quality Management System (QMS). The contractor shall develop a subcontractor quality assurance program including an associated plan that requires certification to current ISO 9001 standard for each subcontractor. The contractor shall develop a method to track ISO 9001 certification status for subcontractors within 60 business days following contract award and shall provide this information to the Government upon request. Subcontractors, who are not certified to the current ISO 9001 standard, will have 24 months to obtain certification. The contractor shall provide the status of subcontractor certifications on a monthly basis until all subcontractors are ISO 9001 certified. The Subcontractor Quality Assurance Plan shall ensure a developed, documented, implemented, and maintained system of quality procedures, work instructions, flow charts, and documented records for all products. The Subcontractor Quality Assurance Plan shall be available for Government review upon request. The contractor shall make available subcontractors quality performance information such as Parts Per Million (PPM) defects and On Time Delivery at the request of the Government. The contractor shall have a process to review and remove subcontractors who continue to have negative trends in performance. The contractor shall allow for PM MAV presence to perform joint on-site verification of a subcontractor that has a quality spill or that has multiple months of poor performance. The contractor shall deliver CDRL A006 - Subcontractor Quality Assurance Plan.

C.2.4.1.3 The contractor's documentation and acceptance of the subcontractor quality assurance system and quality procedures, work instructions, flow charts, and records shall be made available upon Government request. The Government reserves the right to perform quality audits at the contractors and subcontractor facilities.

C.2.4.1.4 Flow Down of Contract Quality Assurance Requirements to Subcontractors. The contractor shall flow down all Section C.9 quality requirements to suppliers, distributors, vendors or firms that furnish supplies or services directly to or on behalf of the contractor for all BFVS variants (Subcontractor). The contractor shall ensure that subcontractors understand and are compliant with contract requirements prior to releasing contractual documents and subsequent changes. The Government has the right to review or access contractual documents between the contractor and their subcontractors.

C.2.4.1.5 The contractor shall facilitate Program Office personnel and DCMA access to facilities, processes, data, and records, comprising all tiers of subcontractors. The contractor shall notify the Government and present a risk mitigation validation plan if they plan to change a subcontractor after passing FPT. Post-test hardware, software, and supply chain changes shall be subject to requalification by the First Article Test (FAT) process.

C.2.4.1.6 Advanced Product Quality Planning (APQP). The contractor shall operate in accordance with the Advanced Product Quality Planning manual, published by Automotive Industry Action Group (AIAG). The contractor shall flow down this requirement to their supply base. The guideline references the utilization of the following Quality Tools:

Process Failure Mode and Effects Analysis (PFMEA) Production Part Approval Process (PPAP) Measurement System Analysis (MSA) Control Plans Statistical Process Control (SPC)

C.2.4.1.7 PFMEA. The contractor shall create PFMEA for all processes (manufacturing and assembly) necessary to build the specific Government product/vehicle. The contractor shall provide PFMEAs to the Government when responding to an Engineering Change Proposal (ECP), Failure Analysis and Corrective Action Report (FACAR), or Product Quality Deficiency Report (PQDR). The contractor shall use AIAG FMEA manual (latest edition) as a guide to create the PFMEAs. Those potential failure modes and their effects that are deemed by the contractors team as high risk, must be controlled, mitigated, or eliminated. The responsibility, target completion dates, action results, and evidence of actions taken must be recorded for them to be considered complete and compliant to the requirements of this contract. The PFMEA must reflect the current processes being used at all times. The contactor shall ensure that all aspects of their product realization process, including receiving, material handling, production, test and inspect, labeling, shipping, and prototyping are covered by these PFMEAs. The contractor shall develop a process of continual improvement via PFMEA Risk Priority Number (RPN) reduction.

C.2.4.1.8 PFMEAs for other items (non-critical items, non-key subsystems) shall be made available to the Government on request. The contractor shall update these documents to reflect lessons learned, updated reliability predictions, and corrective actions. The contractor shall ensure that the documents are traceable to the engineering change level and process changes, and shall be included in the configuration management change process.

C.2.4.1.9 Production Part Approval Process (PPAP). The contractor shall ensure subcontractors demonstrate that their processes have the capability of meeting design and specification requirements prior to the presentation of product for Government acceptance. The product(s) shall be validated in accordance with the control plan developed by each subcontractor and approved by the contractor. The contractor shall use the current revision of the PPAP manual published by the AIAG for requirements and processes used for submission and approval of PPAPs at each level. The PPAPs must reach level 3, as defined in the AIAG, for all parts made by subcontractors as well as parts made in-house by the contractor prior to the presentation of the completed product for Government acceptance unless another PPAP level is approved by the Government on a case by case basis. Other PPAP levels may be authorized provided the contractor provides data supporting its request for approval of another PPAP level. The USG team will review and provide disposition. If approved the contractor shall utilize the Request for Variance (RFV) process. The contractor shall request approval from the Government to issue interim PPAP approval if it is not complete prior to DD250. The results of tests and verifications needed to meet FAT requirements on the TDP shall be part of the PPAP package. The contractor shall update the PPAP and FAT in the event a subcontractor is replaced. The contractor shall update the PPAP in the event a subcontractor moves the process, site, part, material, changes owners, changes processes from manual to automated, moves a part from internally built to externally built. The Government reserves the right to review production part approval documents and records at its discretion.

C.2.4.1.10 Measurement System Analysis (MSA). The contractor shall conduct MSA in accordance with methods outlined in the AIAG manual, Statistical Process Control Reference Manual. The contractor shall develop a system for identifying measurement systems that must be evaluated with defined MSA methodology. Prioritization of MSA activity shall be based on Special Characteristics (SC) and Critical Characteristics (CC) designations and suppliers analysis of risk. MSA reports shall serve as outputs of the MSA system. The measurement system shall specify requirements for calibration and MSAs for all measurement fixtures, measurement instruments, test equipment and gauges used to determine conformance of product at all stages of system design, build, test and delivery. Performing MSA's based on "family of tools" may be considered on a case by case basis by the Government.

C.2.4.1.11 The contractor shall develop measuring system outputs for: Calibration planning, Calibration history, gauges due and overdue for calibration, gauges identified for MSA activity and their status, gauge MSA data collection, and stability studies. MSA studies and reports shall be developed in contractor format, however, required content and pass/fail determination shall default to compliance with the current AIAG MSA publication if the use of an alternative study and report content, including pass/fail criteria, is not agreed upon by the Government.

C.2.4.1.12 Gauge tolerances must be as defined by Society of Automotive Engineers (SAE) / Deutsches Institut f\'fcr Normung (DIN) /International Organization for Standardization (ISO) or other national or international standards or as specified by the device manufacturer, or validated through study. Laboratories performing calibration on measurement devices, instruments, and gauges shall be compliant to ISO/IEC 17025 requirements for the competence of testing and calibration laboratories.

C.2.4.1.13 The contractor shall provide access to the Government for MSA activities for audit purposes. The Government reserves the right to be present at any activities conducted to support MSA. The contractor shall provide Government access to MSA reports and data upon request.

C.2.4.1.14 Control Plan. The contractor shall develop and maintain process control plans in accordance with the latest AIAG Manual that ensures compliance with requirements. The plans shall involve the entire production system including rework or retrofit work. The Control Plans shall include outputs from the PFMEA. The contractor shall address Special Characteristics, Critical Characteristics and Critical Safety Items, whether identified by the Government (e.g. Key Product Parameters) or the contractor, in the development of control plan content. Control Plans shall include specific response plans when undesirable measurement results are obtained. The response plans, in conjunction with the inspection/test frequency, shall prevent suspect material from leaving the contractors facility in the event of a nonconforming measurement. The contractor shall reflect the current processes in use.

C.2.4.1.15 Characteristics Definitions:

(1) Special Characteristics A product characteristic or manufacturing process parameter that can affect safety or compliance with regulations, fit, function, performance, requirements or subsequent processing of product.

(2)Critical Characteristics Those product features or process parameters that can affect compliance with government regulations or safe product function and which require specific supplier, manufacturing, assembly, installation, inspection, test, shipping or monitoring and inclusion on Control Plan.

(3) Critical Safety Items:

A part, assembly or support equipment whose failure, malfunction or absence could cause loss of life, permanent disability or major injury, loss of a system or damage to equipment, property or environmental harm.

(4) Statistical Process Control (SPC). The contractor shall develop and maintain a program for the training, use, and integration of statistics. The contractor shall utilize:

Descriptive Statistics to provide awareness of process outputs at a managerial level. These include tools such as Bar Charts, Line Charts, Pareto Diagrams, Pie Charts, etc.

Analytic Statistic tools to provide the basis for Descriptive Statistics. These include tools such as database crunching, ‘Analysis of Variation (ANOVA), Regression, MSA, and Correlation studies

C.2.4.1.16 Control Statistics provide triggers for action in real time. Typically, Control Statistic tools have features such as control limits, or employ other methods to alert the operators when adjustments may return the process to within the desired operating range.These include tools such as XbarR, XmR, control charts, etc.

C.2.4.1.17 The contractor shall utilize SPC as the basis for continual improvement and apply the Plan-Do-Check-Act cycle within the SPC System for all major processes: Plan Phase - Use Descriptive Statistics to assist with data-driven decision making and quality planning. Risk avoidance, such as Special Characteristic or Critical Characteristic control, shall also factor into the planning phase.

Do Phase - Implement Statistical Control tools in the processes identified during Descriptive Statistics reviews. The contractor shall implement control techniques to characterize the voice of the process and provide distinction of special cause and common cause variation. Check Phase - Assess the effectivity of the Control Statistic activity employed. Act Phase - Determine path forward.

C.2.4.1.18 The contractor shall implement SPC in all critical processes of product realization including product development, purchasing, manufacturing, field analysis, external product failures, continual improvement, safety, and cost of quality. Critical phases are determined via the outputs of the Planning Phase, and identification of the appropriate statistical tools shall be included in the (process) control plans. Metrics used to illustrate progress shall include the target established for the process. Efforts shall be made to improve the process capability and the process potential capability of critical processes.

C.2.4.1.19 The contractor shall use methods of data organization, data gathering, data analysis, and conclusions drawn from this data, in accordance with the accepted and agreed to methods outlined in the AIAG manual. The contractor shall reference the most current published edition.

C.2.4.1.20 Process data and completed control charts shall be treated as controlled documents and retained for the life of the contract. The Government reserves the right to view all process control charts and their continual improvement plans, when requested. The Contactor shall ensure that objective measures are identified to evaluate.

C.2.4.1.21 The performance and value of quality activities to the customer. The contractor shall retain data records as prescribed in the contract associated with readiness, customer satisfaction, and factors that can adversely affect component and organizational performance.

C.2.4.1.22 Corrective Action Reports (CARs). The contractor shall provide CARs to the Government when responding to ECP, FACAR, PQDR or instances where a corrective action is prescribed by this contract or current ISO 9001 standard. The contractor shall deliver Corrective Action Reports IAW Attachment 0002 Corrective Action Report (CAR) Form and CDRL A005 CAR.

C.2.4.1.23 Problem Solving, Corrective Action, and Preventative Action. The contractor shall implement and maintain a corrective action, problem solving, and preventive action system. Corrective action initiated as result of a quality spill (e.g. non-conforming parts shipped or placed on a vehicle, system, or article) will have a containment process in place within 1 business day of identification of the spill. Information including affected lots, affected vehicles, systems, or articles, supply chain, and clean point shall be made available to the Government upon request.

C.2.4.1.24 Product Quality Deficiency Report (PQDR). The contractor shall investigate, provide failure analysis and corrective action to all PQDRs (Standard Form 368) generated against supplies produced under this contract. USG will provide the contractor with reasonable access to solve problems where exhibits are found to be non-conforming or fail to operate. Should an exhibit of the item in question be required, the contractor shall submit an exhibit request electronically to the Government PQDR Action Officer and DCMA Support Point. Upon receipt of the request, the DCMA Support Point will electronically process the request. All corrective actions taken by the contractor shall be at no additional cost to the Government. PQDR corrective actions which require a configuration change must be approved by the Government PCO. All PQDR investigation reports and associated corrective actions shall be approved by the PQDR Action Officer before the Government considers a PQDR closed. PQDRs will not be closed in Product Data Reporting and Evaluation Program (PDREP) until the corrective action(s) delivered by the contractor or its suppliers are officially approved by The Government IAW C.2.4.1.24 and CDRL A005 CAR.

C.2.4.1.25 Consequences of Missing Deadlines. PQDRs shall have root cause and Government-approved corrective actions in place within 30 business days of the occurrence or discovery of Category I process or product deficiency and within 40 business days of the occurrence or discovery of Category II process or product deficiency. Category I and II are defined in AR 702-7-1. The Government reserves the right to withhold payments if PQDR acceptance criteria, deliverables and timelines are not met.

C.2.4.1.26 PQDR Corrective Actions. The contractor shall provide supporting documentation such as internal assessments, data from suppliers analyses (e.g. FEA, FMEA), test data, certifications, drawings, and digital photographs to resolve the problem and prevent it from reoccurring. The contractor shall document PQDR(s) as a customer complaint against their QMS.

C.2.4.2 Paint

C.2.4.2.1 Production Paint Process Validation. The contractor shall perform paint process validation testing IAW the requirements of this section prior to painting any parts, components, systems, or assemblies that shall be delivered. Testing results serve as Objective Quality Evidence (OQE) of compliance with MIL-DTL-53072 and TT-C-490 requirements. Testing results will be made available to the Government upon request. The contractor shall re-validate their paint process(es) if any changes to the validated process(es) occur. For the purposes of this contract, a coating process is defined as any unique combination of substrate material, surface preparation method, pretreatment material and application method, coatings (primers and topcoats), and coating application methods. Variations in any of these options represents a different coating process which requires validation.

C.2.4.2.2 Production Representative Specimens. The contractor shall produce and test six (6) production representative specimens for validation testing of each paint process. The contractor shall be clean, pretreat, prime, and topcoat all specimens as during production in a representative environment. Compliance with surface profile and coating thickness (dry film thickness) requirements shall be verified on all produced specimens. Corrosion resistance requirements shall be verified on three (3) “X” scribed, and adhesion shall be verified on the remaining three (3) unscribed specimens.

C.2.4.2.3 Testing Requirements. Surface profile shall be measured IAW ASTM D4417, method B or C. Coating thickness (dry film thickness) shall be measured by taking five (5) randomly spaced spot measurements per test specimen IAW SSPC-PA2 for primers and topcoats. Adhesion and corrosion resistance shall be tested IAW MIL-DTL-53072. Evaluation of corrosion resistance test specimens shall be performed IAW ASTM D1654, Procedure A, Method 1. Hydrogen embrittlement testing shall be performed on three specimens IAW TT-C-490 when required by the selected pretreatment method(s). Corrosion resistance and hydrogen embrittlement testing shall be performed by an ISO/IEC 17025 or Nadcap accredited laboratory. At a minimum, OQE for paint tests shall include all report requirements as defined within the test standard. OQE for adhesion and corrosion resistance tests shall include photographs of all test specimens before and after testing. The Government reserves the right to request additional information to verify compliance with the requirements of this section.

C.2.4.2.4 Paint Quality Control. Following validation of the production paint process(es), the contractor shall execute paint quality control testing for those paint process(es) and generate OQE to ensure compliance with MIL-DTL-53072 and TT-C-490 requirements for painted parts, components, systems, or assemblies that will be delivered throughout the duration of this contract. The contractor shall notify the Government COR via email within five business days of any adhesion, corrosion resistance, or hydrogen embrittlement quality control testing failures. The Government reserves the right to inspect Objective Quality Evidence at contractor facilities.

C.2.4.2.5 Paint Quality Control Testing Requirements and Frequency. The Contractor shall perform quality control testing following the methods and requirements of 2.4.2.3 at the frequencies outlined in this section unless otherwise approved by the Government. The Contractor shall verify surface profile (roughness) at least once every 4 hours of production for each unique surface profile and blasting media used. The Contractor shall verify coating thickness (dry film thickness) at least once each day of production for each coating process. The Contractor shall verify adhesion at least once each day of production for each coating process. The Contractor shall verify corrosion resistance at least once every 60 calendar days for each coating process. When required by the applicable finish system for the substrate family, the Contractor shall verify hydrogen embrittlement at least once every 120 calendar days for each applicable pretreatment method.

C.2.4.3 Welding

C.2.4.3.1 Welding Design C.2.4.3.1.1 Armor Base Material All accepted armor grade steel shall be limited to materials qualified under the latest revision of MIL-A-11356, “Armor, Steel, Cast, Homogeneous, Combat Vehicle Type” (CST), MIL-DTL-12560, “Armor Plate Steel, Wrought, Homogeneous” (RHA), or MIL-DTL-46100, “Armor Plate, Steel, Wrought, High Hardness” (HHA).

Fabrication using MIL-DTL-46186, “Armor Plate, Steel, Wrought, Very High Hardness” (VHA) or MIL-DTL-32332, “Armor Plate, Steel, Wrought, Ultra High Hardness” (UHA) shall require use of special techniques (see MAV Weld Code -Steel) and shall require approval by the PCO and the technical authority prior to use. Any other steel utilized as armor shall be approved by the PCO prior to use and shall be subject to the guidelines of armor materials for procedure qualification (see Welding Procedure Qualification section). Unless otherwise specified, armor base steel material shall be welded in the fully quenched and tempered condition.

Accepted, weldable, armor grade aluminum shall be restricted to the thicknesses, alloys, and armor classes qualified in the latest revisions of:

MIL-DTL-32262 “Armor Plate, Aluminum Alloy 6055 Weldable and Alloy 6061, Unweldable Applique” MIL-DTL-32341 “Armor Plate, Aluminum, Alloy 2139 Weldable and Alloy 2195 and 2060 Unweldable Applique”, MIL-DTL-32505 “Armor Plate, Aluminum, Alloy 7017 Weldable and 7020 Applique”, MIL-DTL-45225 “Aluminum Alloy Armor, Forged”, MIL-DTL-46027 “Armor Plate, Aluminum Alloy, Weldable 5083, 5456, and 5059”, MIL-DTL-46083 “Aluminum Alloy Armor, Extruded, Weldable”, MIL-DTL-46118 “Aluminum Alloy Armor, 2219, Rolled Plate and Die Forged Shapes” or MIL-DTL-46192 “Aluminum Alloy Armor Rolled Plate (1/2 to 4 Inches Thick), Weldable (Alloy 2519)”.

Any other aluminum utilized as armor shall be approved by the PCO prior to use and shall be subject to the guidelines of armor materials for procedure qualification (see Welding Procedure Qualification section).

C.2.4.3.1.2 High Strength Steel High strength steel is defined as any S-3, S-4, S-5 or S-11 steel with a yield strength greater than 90ksi (620MPa). This includes some grades of high strength low alloy (HSLA) steels, high yield strength (HY) steels, as well as many quenched and tempered steels.

C.2.4.3.1.3 Non-armor Grade Steel Steel not manufactured and qualified to a specification for armor grade steel (see Armor Base Material), covered by a base material group number per tables of the following: MAV Weld Code -Steel, NAVSEA S9074-AQ-GIB- 010/248 “Requirements for Welding and Brazing Procedure and Performance Qualification”, or the Welding Procedures Qualified by Employer section of AWS B2.1/B2.1M “Specification for Welding Procedure and Performance Qualification” and Annex C thereof, or the Ferrous and Nonferrous P-Numbers Grouping of Base Metals Table of ASME BPVC Section IX.

C.2.4.3.1.4 Armor Welding Design Joint designs for Class I welds IAW MAV Weld Code -Steel or MAV Weld Code – Aluminum shall require the approval of the PCO upon request. For specific joint design recommendations and calculations, see the latest version of MIL-STD-22, “Welded Joint Design” and NAVSEA S9074-A1-GIB-010/1628, “Fillet weld and partial penetration groove tee weld size, strength and efficiency determination”, as applicable. All joint designs and joint design calculations, including finite element analysis (FEA) results, shall be delivered to the PCO for review upon request. Square groove, plug, or slot welds shall not be used for Class I joint designs without adequate supporting data, including a test plan for demonstrating weld soundness, which shall be submitted to the PCO for approval prior to use.

C.2.4.3.1.5 High strength steel welding design Joint designs for Class II welds IAW MAV Weld Code -Steel shall require the approval of the PCO upon request. For specific joint design recommendations and calculations, see the latest version of MIL-STD-22 and NAVSEA S9074-A1-GIB-010/1628, as applicable. All joint designs and joint design calculations, including finite element analysis (FEA) results, shall be delivered to the PCO for review upon request. Square groove, plug, or slot welds shall not be used for Class II joint designs without adequate supporting data, including a test plan for demonstrating weld soundness, which shall be submitted to the PCO for approval prior to use.

C.2.4.3.1.6 Non-armor welding design Joint designs for non-armor welds shall meet the design and fabrication requirements in the prescribed standards listed in Attachment 001, Welding Standards. All joint designs and joint design calculations, including finite element analysis (FEA) results, shall be delivered to the PCO for review upon request.

C.2.4.3.1.7 Weld Joint Design All weld joint designs shall be in accordance with engineering best practices and shall be the responsibility of the entity’s design engineering activity.

C.2.4.3.2 Welding Documentation C.2.4.3.2.1 Welding Standards Welds shall be free from defects indicative of poor workmanship. All welding shall be in accordance with (IAW) the documents listed in Attachment 001, “Welding Standards”, Table 1. The revision or edition (year) to be used shall be the year in effect at the time of the solicitation release date.

C.2.4.3.2.2 Alternate Welding Standards Subject to Procuring Contract Office (PCO) written engineering approval, the Contractor may utilize alternate standards or codes once the Contractor or Contractor's suppliers have demonstrated that the equivalent or better quality and performance can be obtained by their use. It is the Contractor's responsibility to demonstrate such equivalence to the Government. If the Contractor's component supplier shall not release specific proprietary information, the Government reserves the right to conduct an on-site review of the Contractor's supplier(s) quality system and welding operations to verify the capability of producing acceptable welds. The Government reserves the right to approve/disapprove the use of any and all such alternative welding standards and specifications. The demonstrated equivalent shall be verified prior to fabrication of any deliverable item under contract.

C.2.4.3.2.3 Welding Procedure Qualification The Contractor shall develop CDRL A008, Procedure Qualification Records (PQRs) CDRL A009, Welding Procedure Specifications (WPS) -that shall be uniquely identified with a traceable identifier IAW the welding standard(s) as specified in Attachment 001, “Welding Standards”. The Contractor shall follow the appropriate welding standard(s) scope to qualify the welding procedures. The Contractor and suppliers shall document and prepare welded test assemblies and section subsequent test specimens out of the procedure qualification test as to then test, write, qualify, and obtain the procedure qualification record IAW the appropriate standard(s). The use of prequalified weld joints and prequalified welding procedures as specified in American Welding Society (AWS) D1.1 does not preclude the submittal of said written prequalified welding procedures. The use of prequalified joint designs and prequalified base materials and extent thereof must also be properly specified within a qualified WPS.

C.2.4.3.2.3.1 Revised Welding Procedures If applicable, the Contractor shall deliver revised welding procedures to the Government for approval as part of the Procedure Qualification Records A008 and Welding Procedure Specifications A009. The Government reserves the right to apply a disposition to all revised weld procedures. The Contractor shall obtain Government approval of all revised procedures prior to their use to fabricate production weldments. If a Contractor will not release proprietary information, the Government reserves the right to conduct an on-site review of the Contractors quality system and weld processes to verify capability to produce acceptable welds.

C.2.4.3.2.4 Previous Procedure Qualification Welding procedures that have been previously qualified by a Contractor to meet the requirements of other standards, specifications, codes, or earlier revisions of the standard(s) listed in Attachment 001, “Welding Standards” for which records are available and qualifications have been maintained, are acceptable for use with the approval from the PCO and may be used by the Contractor to satisfy a WPS under this contract Procedure Qualification Records A008, and Welding Procedure Specifications A009. The Contractor shall submit a written request containing all previously approved welding procedures and their supporting documentation to use the previously qualified welding procedure to satisfy contract requirements. For procedures that involve armor grade materials, the welding specification and weld classification cross reference table from MAV Weld Code -Steel, or MAV Weld Code – Aluminum, shall be used to determine the new weld classification from the earlier revisions of those standards or canceled standards. The Contractor shall address all essential variables specified in the applicable welding standard(s) and include the information on the PQRs. The PCO may require requalification on a case-by-case basis where any of the following apply:

There are specific concerns about the adequacy or accuracy of the welding procedures, the ability of the personnel to produce acceptable works, or those procedures which do not meet the requirements of the applicable fabrication document.

The existing qualification does not meet the requirements of the earlier revision of the document originally qualified to.

Any exceptions made to a previous procedure that does not meet the requirements of the earlier revision of the document originally qualified to.

A non-favorable quality history regarding weld quality on a previous contract where the procedures were used.

C.2.4.3.2.5 Welding Repair Procedures The Contractor shall provide a written weld repair procedure (WRP) identifying proper technique and approach to correct defective products IAW Welding Repair Procedure A010. The Welding procedures for the repairs shall be IAW the applicable welding standard(s) in Attachment 001, “Welding Standards”. A repair is defined as the reprocessing of nonconforming material IAW approved written procedures and operations to reduce, but not completely eliminate, the nonconformance. The purpose of repair is to bring nonconforming material into a usable condition. Repair is distinguished from rework in that the item after repair still does not completely conform to all of the applicable drawings, specifications or contract requirements.

C.2.4.3.2.6 Welding Equipment The Government reserves the right to review welding equipment calibration program documents, calibration records and/or process documents upon request.

C.2.4.3.2.7 Welder & Welding Operator Qualification Before assigning any welder or welding operator to perform welding covered by this contract the Contractor shall obtain certification that the welder or welding operator has passed qualification tests as prescribed by the standards listed in Attachment 001, Welding Standards. The Contractor shall submit these qualifications in the Welder Qualification Records (WQR) A011. A qualified WPS shall be used for each welder or welding operator qualification plate. Qualifying as a welder shall not qualify the individual as a welding operator or vice versa. A welder’s performance qualification is measured in their ability to create a test plate which meets the acceptance criteria of the welding document. A welding operator’s performance qualification is measured in their ability to successfully operate the welding equipment and produce a test plate which meets the acceptance criteria of the welding document. The results of testing this plate in accordance with the welding standard requirements shall be documented in a WQR and shall be uniquely identified with a traceable identifier. A person tending a robotic work cell loading and unloading parts shall not require qualification. Robotic qualification is required for the Programmer (operator) who has set up and input the arc motion, work motion devices, torch path, and all associated welding parameters into the robot controller teach pendant and specific weldment part program. If the duties of the robot tender include additional responsibilities such as visual inspection and process monitoring, the robot tender shall have appropriate training for that task.

C.2.4.3.3 Inspection and Testing Requirements C.2.4.3.3 1 Inspection and Testing Requirements The Contractor shall clearly identify all joints on the weld drawings that require nondestructive testing (NDT) IAW AWS A2.4 “Standard Symbols for Welding Brazing and Nondestructive Examination”. The certified inspector shall determine compliance of the weld to the requirements of the welding standard(s) listed in Attachment 001, “Welding Standards”.

C.2.4.3.3 2 Frequency of NDT examination All welds shall require some form of NDT to be performed IAW the applicable welding standards listed in Attachment 001, “Welding Standards”. Welds to be covered shall be inspected prior to being made inaccessible.

A sampling plan shall be developed for all NDT activities IAW MIL-STD-1916, “DoD Preferred Methods for Acceptance of Product”. If an alternate acceptance method is requested, the requirements and procedure shall be IAW MIL-STD-1916.

For welding done IAW MAV Weld Code -Steel, the verification level (VL) for Class I and Class II welds shall be VL-VI, Class III welds shall be VL-V and Class IV shall be VL-II.

For welding done IAW MAV Weld Code – Aluminum, the verification level (VL) for Class I welds shall be VL-VI, Class II welds shall be VL-V and Class III shall be VL-II.

C.2.4.3.3 3 Visual Testing (VT) All welds shall be visually inspected IAW the applicable welding standards listed in Attachment 001, Welding Standards. For the purpose of this contract, weld quality and workmanship shall be verified by Certified or Authorized Visual Inspectors trained to perform the specific functions they are assigned (see CVI and AVI sections). Certified Visual Weld Inspectors shall have the authority to sign as a visual weld inspector.

Authorized Visual Inspectors may visually inspect welds, but shall not have the authority to sign off as a visual weld inspector. Regardless of qualifications, the welder or welding operator shall not have the ability to approve the final inspection on their own work.

C.2.4.3.3 4 Hold Time Prior to NDT For all non-austenitic high strength steels, CST (MIL-A-11356), RHA (MIL-DTL-12560), and HHA (MIL-DTL- 46100) armor grade steels greater than 0.3” (8mm) in thickness, the final NDT examination for acceptance shall be conducted no less than the following, after the weld has cooled to ambient temperature. For all VHA or UHA, the final NDT examination for acceptance shall be conducted no less than the following, after the weld has cooled to ambient temperature, regardless of thickness.

24 hours when performing UT, 36 hours when performing RT, or 48 hours when performing VT, PT, or MT.

The required visual inspection should be completed in a manner that suits production. Therefore, preliminary VT and post 48-hour hold VT are advisable prior to UT or RT. Preliminary NDT examinations are advisable to avoid production related delays, by identifying defects not related to delayed hydrogen cracking. Any defects found during the preliminary NDT may be addressed before the hold period is complete.

Restarting the hold period is necessary if thermal repair processing is used. Any defects identified and addressed following the first hold period shall be subject to an additional hold period. Alternative strategies to mitigate delayed hydrogen cracking must be supported by data and shall be submitted to the procuring contract officer for review for acceptability prior to amending the length of this hold time.

C.2.4.3.3 5 NDT Acceptance Criteria for Armor.

When NDT is required for armor grade materials, the acceptance criteria shall be IAW MAV Weld Code -Steel for steel armor and MAV Weld Code – Aluminum for aluminum armor. When the results of an inspection process or indications are inconclusive, the weld shall be inspected by another NDT method.

C.2.4.3.3 6 NDT Acceptance Criteria for High Strength Steel When NDT is required for high strength steel, the procedures and acceptance criteria shall be IAW MAV Weld Code -Steel.

C.2.4.3.3 7 NDT Acceptance Criteria for Non-Armor When NDT is required for non-armor material(s) the acceptance criteria shall be as stated in the applicable standard of Attachment 001, “Welding Standards”. The acceptance criteria can differ based on the design loads and types of forces. The Contractor shall state what joints are critical load bearing members and clearly identify these weldments for inspection purposes. In the case of critical structures, the acceptance criteria for cyclic loads will be as stated in the applicable welding standard from Table 1 of Attachment 001, “Welding Standards”.

C.2.4.3.3.8 Non-Destructive Testing (NDT) Personnel Qualification.

Individuals performing any method of NDT shall meet the qualification requirements for the applicable NDT level of certification American Society for Nondestructive Testing (ASNT) Recommended Practice No. SNT-TC- 1A, ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel ANSI/ASNT CP-189 or Aerospace Industries Association (AIA)/National Aerospace Standard (NAS) Standard Practice NAS410, except as listed in the sections for Certified Visual Inspector Qualification and Authorized Visual Inspector Qualification. The required NDT level shall be determined by the contractor’s NDT written practice.

Alternately, any certification through ASNT Central Certification Program (ACCP) shall be recognized as certified at the NDT level of examination. The Contractor shall make available all NDT personnel qualification records upon request by the Government.

For NDT methods not covered by ASNT SNT-TC-1A, ANSI/ASNT CP-189 or NAS410, personnel shall qualify to comparable levels of competency by the administration of examinations for the particular method involved. A certified NDT Level III shall be responsible for the validity of the examinations and overall personnel qualification and certification (PQ&C) program.

C.2.4.3.3.9 Certified Visual Inspector Qualification. Certified Visual Inspector (CVI) shall be based on:

Current certification in IAW AWS QC1, “Standard for AWS Certified Welding Inspectors” as a Certified Welding Inspector (CWI) or Senior Certified Welding Inspector (SCWI).

Current certified welding inspectors qualified by the Canadian Welding Bureau (CWB) to Level II or the Level III requirements IAW with Canadian Standards Association (CSA) W178.2, “Certification of Welding Inspectors”.

Current Level II Visual Inspection (VT) certification or greater IAW the American Society of Nondestructive Testing (ASNT) CP-189, “ASNT Standard for Qualification and Certification of Nondestructive Personnel.

Items (a)-(c) shall be verified through submission Visual Weld Inspector Training Program A007.

C.2.4.3.3.10 Authorized Visual Inspector Qualification. Authorized Visual Inspector (AVI) shall be based on:

An entity’s internal or in-house AWS B5.1 or B5.2 qualified welding Inspector shall not be qualified to sign off on welds that would require a CVI or equivalent signature. An Associate Welding Inspector or a Welding Inspector Specialist who meets the minimum requirements of AWS B5.1 or AWS B5.2, respectively, shall be competent to perform visual inspection with the approval of the Government. A Welding Inspector Assistant, qualified under AWS B5.2 shall only perform inspection duties while under the supervision of a Government approved Welding Inspector Specialist, an ASNT SNT-TC-1A level II or greater, or any certified visual weld Inspector IAW above requirements of Certified Visual Inspector Qualification section a)-(c) or, Welding Inspectors that are only qualified to ASNT SNT-TC-1A shall not be qualified to sign off on welds that would require a CVI or equivalent signature. An Inspector who is qualified as an ASNT VT level II IAW the requirements of ASNT SNT-TC-1A, shall be competent to perform visual inspection with the approval of the Government. An ASNT VT Level I Inspector qualified IAW ASNT SNT-TC-1A, shall only perform inspection duties while under the supervision of a Government approved Associate Welding Inspector, Specialist, an ASNT SNT-TC-1A level II or greater, or any certified visual weld Inspector IAW the requirements of the section for Certified Visual Inspector Qualification (a)-(c).

Previous certification IAW with the section for Certified Visual Inspector Qualification precludes the need for the additional training specified and allows for immediate qualification as an AVI. Those qualified in this manner shall be restricted to within two years following the expiration of their certificates. In cases where the external qualification has lapsed, then the vision test must be passed before being able to perform as an AVI.

Items (a)-(c) of this section shall be verified through submission through Visual Weld Inspector Training Program A007.

C.3.1 Deliverables

C.3.1.1 The contractor shall submit all Request for Variances on DD Form 1694 (RFVs) describing a departure from the requirements specified in the TDP IAW (CDRL A012).

SECTION D: PACKAGING AND MARKING

D.1 PACKAGING

(a) The preservation, packing, and marking requirements for this contract/order shall be accomplished in accordance with the requirements in the specification/standard defined below.

(b) The following requirements shall apply:

(1) LEVEL OF PRESERVATION: MILITARY

(2) LEVEL OF PACKING: A

(3) QUANTITY PER UNIT PACKAGE: 001

(4) SPECIFICATION/STANDARD: MIL-STD-2073-1E

(c) The specification/standard cited is intended to give a clear and accurate description of the technical packaging requirements for the item being procured, including the procedure by which it can be determined that the requirements have been met. Specific instructions and/or tailoring of the specification/standard is detailed in the supplemental instructions below.