M67854-16-R-1122.pdf

CODE

(Hour)

PAGE(S)

until local time

X

A

X B

X C X D

EX

X

G

F 51 - 56

57 - 64

H 65 - 71

RATING PAGE OF PAGES

7. ISSUED BY

(Date)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other authorized official written notice.

Previous Edition is Unusable 33-134 STANDARD FORM 33 (REV. 9-97)

Prescribed by GSA

FAR (48 CFR) 53.214(c)

DO-A90 1 71

(If other than Item 7)

15A. NAME 16. NAME AND TITLE OF PERSON AUTHORIZED TO

AND

ADDRESS

SIGN OFFER (Type or print)

OF

OFFEROR

AMENDMENT NO. DATE

15B. TELEPHONE NO (Include area code) 17. SIGNATURE15C. CHECK IF REMITTANCE ADDRESS

IS DIFFERENT FROM ABOVE - ENTER

SUCH ADDRESS IN SCHEDULE.

18. OFFER DATE

1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

2. CONTRACT NO.

M67854 8. ADDRESS OFFER TO

See Item 7

9. Sealed offers in original and copies for furnishing the supplies or services in the Schedule will be received at the place specified in Item 8, or if handcarried, in the depository located in

CAUTION - LATE Submissions, Modifications, and Withdrawals: See Section L, Provision No. 52.214-7 or 52.215-1. All offers are subject to all terms and conditions contained in this solicitation.

10. FOR INFORMATION

CALL:

A. NAME (NO COLLECT CALLS)

11. TABLE OF CONTENTS

SOLICITATION/ CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/ COSTS

2 - 11

X I CONTRACT CLAUSES

DESCRIPTION/ SPECS./ WORK STATEMENT X

PACKAGING AND MARKING

12 - 24

J LIST OF ATTACHMENTS

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

26 - 27

X K

REPRESENTATIONS, CERTIFICATIONS AND

OTHER STATEMENTS OF OFFERORS

CONTRACT ADMINISTRATION DATA 29 - 32 X

SPECIAL CONTRACT REQUIREMENTS

OFFER (Must be fully completed by offeror)

X M

L INSTRS., CONDS., AND NOTICES TO OFFERORS

EVALUATION FACTORS FOR AWARD

NOTE: Item 12 does not apply if the solicitation includes the provisions at 52.214-16, Minimum Bid Acceptance Period.

is inserted by the offeror) from the date for receipt of offers specified above, to furnish any or all items upon which prices are offered at the price set opposite each item, delivered at the designated point(s), within the time specified in the schedule.

13. DISCOUNT FOR PROMPT PAYMENT

(See Section I, Clause No. 52.232-8)

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments

AMENDMENT NO. DATE

to the SOLICITATION for offerors and related documents numbered and dated):

FACILITY

12. In compliance with the above, the undersigned agrees, if this offer is accepted within calendar days (60 calendar days unless a different period

SOLICITATION, OFFER AND AWARD

X

(X) SEC. DESCRIPTION (X) SEC. DESCRIPTION PAGE(S)

PART I - THE SCHEDULE

26. NAME OF CONTRACTING OFFICER (Type or print) 27. UNITED STATES OF AMERICA 28. AWARD DATE

EMAIL:TEL: (Signature of Contracting Officer)

CODE CODE

B. TELEPHONE (Include area code) C. E-MAIL ADDRESS

AWARD (To be completed by Government)

19. ACCEPTED AS TO ITEMS NUMBERED 20. AMOUNT 21. ACCOUNTING AND APPROPRIATION

22. AUTHORITY FOR USING OTHER THAN FULL AND OPEN COMPETITION:

10 U.S.C. 2304(c)( ) 41 U.S.C. 253(c)( ) (4 copies unless otherwise specified)

23. SUBMIT INVOICES TO ADDRESS SHOWN IN ITEM

24. ADMINISTERED BY (If other than Item 7) CODE 25. PAYMENT WILL BE MADE BY CODE

PART IV - REPRESENTATIO NS AND INSTRUCTIO NS

PART III - LIST O F DO CUMENTS, EXHIBITS AND O THER ATTACHMENTS

33 - 48

PART II - CO NTRACT CLAUSES

COMMANDER, MARCORSYSCOM

ATTN: KATY HURD

2200 LESTER STREET

QUANTICO VA 22134 703-432-3087

FAX:

TEL:

FAX:

TEL:

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

SOLICITATION

49 - 50

6. REQUISITION/PURCHASE NO.5. DATE ISSUED

15 Sep 2016

4. TYPE OF SOLICITATION

SEALED BID (IFB)

NEGOTIATED (RFP)

[ X ]

3. SOLICITATION NO.

M67854-16-R-1122

Section B - Supplies or Services and Prices

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

FAT - Unfinished Shells

FFP

First Article Test (FAT) - Unfinished Shells. Articles shall include the raw shell only, drilled with attachment holes (no primer, paint (coating), texturing aggregate, edging, edging adhesive, or hook disks).

There shall be one blended price for all sizes.

FOB: Destination

NET AMT

0001AA 6 Each Small

FFP

0001AB 6 Each Medium

0001AC 6 Each Large

0001AD 6 Each X-Large

FAT - Finished Shells

FFP

First Article Test (FAT) - Finished Shells. Articles shall include the unfinished shell, any primer, paint (coating) and texturing aggregate, all necessary attachment holes, any edging and adhesive to hold the edging, and labels.

0002AA 41 Each Small

0002AB 48 Each Medium

0002AC 43 Each Medium

0002AD 39 Each X-Large

FAT - Finished Helmet with IRS

FFP

First Article Test (FAT) - Finished Helemts with IRS. Articles shall include finished shell, hook disks, a complete pad set (mandatory source), a complete retention system (mandatory source), and attaching hardware.

0003AA 64 Each Small

0003AB 79 Each Medium

0003AC 67 Each Large

0003AD 109 Each X-Large

0004 31 Each FAT NVD Mount & Hardware

FFP

Night Vision Device (NVD) Bracket with attaching hardware.

0005 1 Lot ECH FAT Materials

FFP

List of materials required: 6 samples of each shape pad, 8 specimens (2 in x 6 in of each specimen) of the loop material (inner layer), 8 specimens (1 in x 5 in) of the hook used in the hook disks, 8 specimens (25mm x 130mm) of the Pad Inner

Material in the machine direction and 8 specimens in the cross-machine direction, 2" x 6' piece of hook disk material.

0006 1 Lot IRS FAT Materials

FFP

List of materials required: 4 loose IRS, 1 spool of thread, 60 ft of nylon webbing, 5 samples of laminated foam, and 5 each male and female side release buckles.

ITEM NO SUPPLIES/SERVICES MAX

QUANTITY

UNIT UNIT PRICE MAX AMOUNT

0007 84,376 Each Production Helmets

FFP

Enhanced Combat Helmet (ECH) for Marine Corps requirements in accordance with the Purchase Description (PD) provided as Attachment J.1 to this contract and the Statement of Work (SOW) in Section C. Each ECH under this line item shall include the Improved Retention System (IRS), Suspension System, NVD

Mount and NVD Hardware. ECH ordered under this line item shall be in the 4 sizes listed in section 1.2 of the PD. Estimates for production helmets size quantities are as follows:

Small: 2,921

Medium: 36,037

Large: 41,006

X-Large: 4,412

(Offeror's shall insert proposed step-ladder ranges and unit prices for each ordering period in the spaces below)

Step Ladder Qty: XX-XX XX-XX XX-XX XX-XX XX-XX

Ordering Period 1: $____ $____ $____ $____ $____

Ordering Period 2: $____ $____ $____ $____ $____

Ordering Period 3: $____ $____ $____ $____ $____

Ordering Period 4: $____ $____ $____ $____ $____

Ordering Period 5: $____ $____ $____ $____ $____

MAX

ITEM NO SUPPLIES/SERVICES MAX

QUANTITY

UNIT UNIT PRICE MAX AMOUNT

0008 8,438 Each NVD Bracket Kits (w/ hardware)

FFP

Night Vision Device (NVD) Bracket with attaching hardware IAW Attachment

J.1 paragraph 3.7.

(Offerors shall insert unit prices for each ordering period in the spaces below)

Ordering Period 1: $____

Ordering Period 2: $____

Ordering Period 3: $____

Ordering Period 4: $____

Ordering Period 5: $____

MAX

0009 Lot CDRLs

Not separately priced. Exhibit A.

BERRY AMENDMENT COMPLIANCE

B-1 BERRY AMENDMENT COMPLIANCE

The Defense Appropriations and Authorizations Acts and other Statutes (including what is commonly referred to as the “Berry Amendment”) imposes restrictions on the DOD’s acquisition of foreign products and services.

A preference for certain domestic commodities is required by 10 USC 2533a and DFARS 252.225-7012. These references require the Department of Defense to acquire specific end items or components that have been grown, reprocessed, reused, or produced in the United States. Items provided under this solicitation and the resulting contract shall be compliant with the above references. Offerors are required to complete and submit the Berry

Amendment Self-Certification located in Section K of this solicitation.

Offerors shall maintain additional documentation substantiating the claim that all materials, including components and raw materials, submitted under this solicitation and the resultant contract are Berry Amendment Compliant.

Offerors shall be able to provide this documentation to Government personnel upon request.

CONTRACT LIMITATIONS

B-2 CONTRACT LIMITATIONS

CONTRACT MINIMUM AND MAXIMUM LIMITATIONS:

Minimum: CLIN 0001: 24 each Maximum: CLIN 0001: 24 each

CLIN 0002: 171 each CLIN 0002: 171 each

CLIN 0003: 319 each CLIN 0003: 319 each

CLIN 0004: 31 each CLIN 0004: 31 each

CLIN 0005: 1 lot CLIN 0005: 1 lot

CLIN 0006: 1 lot CLIN 0006: 1 lot

CLIN 0007: 15,000 each CLIN 0007: 84,376 each

CLIN 0008: 31 each CLIN 0008: 8,438 each

PERIOD OF PERFORMANCE

The period of performance for this effort is from date of award to 60 months.

ORDERING PERIODS

Ordering Period One (1) is defined as "Year One," Months 1-12 After Date of Contract (ADC); Ordering period

2017 through 2018.

Ordering Period Two (2) is defined as "Year Two," Months 13-24 ADC; Ordering period 2018 through 2019.

Ordering Period Three (3) is defined as "Year Three," Months 25-36 ADC; Ordering period 2019 through 2020.

Ordering Period Four (4) is defined as "Year Four," Months 37-48 ADC; Ordering period 2020 through 2021.

Ordering Period Five (5) is defined as "Year Five," Months 49-60 ADC; Ordering period 2021 through 2022.

MANDATORY SOURCES

B-3 MANDATORY SOURCES

In accordance with FAR 52.208-9, the mandatory source for the ECH Pad Suspension and Retention Systems is:

National Industries for the Blind

1310 Braddock Place

Alexandria, VA 22314

See the Purchase Description for the specific descriptions and part numbers.

Section C - Descriptions and Specifications

STATEMENT OF WORK

SECTION C - DESCRIPTIONS AND SPECIFICATIONS

1 SCOPE. This Statement of Work (SOW) sets forth the work required to fabricate, produce and prepare associated documentation, and deliver the Enhanced Combat Helmet (ECH) in accordance with the ECH Purchase

Description (PD), First Article Test (FAT) Plan, and Lot Acceptance Test (LAT) Plan. The Contractor is responsible for providing all specific material, services and necessary support documentation needed to complete the tasks identified in this SOW. The ECH is a Critical Safety Item (CSI) and has a criticality designation of "A" in accordance with (IAW) FAR 42.1105

2 APPLICABLE DOCUMENTS. The following documents form a part of this SOW to the extent specified herein. All parties shall use the most recent revision of the referenced document at the time of contracting unless specified otherwise. All Government document issue dates are those listed in the Department of Defense Index of

Specifications and Standards (DoDISS). In the event of conflict between the applicable documents and this SOW, the SOW shall take precedence. While the Government has made every effort to ensure the below lists are complete, the SOW may reference documents not included below. Contractors shall meet all specified requirements cited in this SOW regardless whether an applicable document appears below.

2.1 Military Standards and Specifications - Mandatory Compliance.

MIL-STD-129P Military Marking for Shipment and Storage

MIL-STD-130N Standard Practice Identification Marking of U.S. Military Property

MIL-STD-882E Standard Practice for System Safety

MIL-STD-2073-1 DoD Standard Practice for Military Packaging

MIL-STD-31000A Technical Data Packages

2.2 Military Standards and Specifications - Guidance Only.

Not Applicable.

2.3 Federal Standard - Mandatory.

FED-STD-313 w/CN #1 Material Safety Data, Transportation Data and Disposal Data for

Hazardous Materials Furnished to Government Activities

2.4 Drawings.

ECH Drawing Packages

Night Vision Device Mount Drawing Package

Helmet Pad Drawing

2.5 Handbooks - Guidance Only.

MIL-HDBK-61 Configuration Management Guidance

MIL-HDBK-512 Parts Management

2.6 Non-Government Documents.

ASME Y14.34 Associated Lists

ASME Y14.100 Engineering Drawing Practices

ASTM D-3951 Standard Practice for Commercial Packaging

ASTM D4169-01e1 Standard Practice for Performance Testing of Shipping Containers and

Systems

EIA-649 National Consensus Standard for Configuration Management

NAS 411 Hazardous Materials Management Program

3 REQUIREMENTS. The Contractor shall perform all tasks delineated in this statement of work including providing all materials, equipment, hard tooling, personnel, and facilities necessary to manufacture, fabricate, integrate, produce, and deliver First Article Test items, production ECH, Night Vision Device (NVD) brackets and hardware, and data item deliverables as specified by the contract, Section J attachments, and individual delivery orders. The Government will provide helmet covers to the Contractor for packaging with each ECH. The Contractor shall install the NVD bracket on the shell with the hardware before shipment.

NOTE: Note 1 contained in Drawing 2-1-2566 - HELMET PADS incorporated as Attachment J.9 to this contract, is hereby clarified to read as follows: “1. WORKMANSHIP, CONSTRUCTION AND QUALITY ASSURANCE

PROVISIONS SHALL CONFORM TO GL-PD-09-04.” GL-PD-09-04 is the ECH Purchase Description (PD).

3.1 Program and Data Management.

3.1.1 Program Management. The Contractor shall designate a single individual to serve as the primary point of contact (POC) between the Government and Contractor, who shall be responsible for coordinating all Contractor activities related to this contract. This individual shall have the authority to commit the Contractor to specific courses of action and accept direction from the Contracting Officer or the Contracting Officer's authorized representatives. This individual shall coordinate all meetings between the Government and Contractor; shall immediately bring any conflicts in the Contractor's interpretation of the contract requirements to the Contracting

Officer's attention (first by telephone verbal notification, to be followed by written notification); and shall bring to the Contracting Officer's attention any problems that could adversely affect the Contractor's ability to meet the contract quality, cost, production schedule, delivery schedule, or other performance requirements. The Contractor shall submit Progress, Status and Management Reports.

Contractor’s Progress, Status and Management Report – CDRL A001

3.1.2 Subcontractor Management. The Contractor is responsible for performing requirements delineated in this

SOW and shall institute appropriate management actions for subcontractor performance. Contractually specified requirements shall apply to subcontractor performance; however, the Contractor shall be accountable for subcontractor compliance and is ultimately responsible for ensuring all deliverable products comply with the contract requirements.

3.1.3 Data Management. The Contractor shall establish a single, centralized system for management of all data required under this contract. The Government reserves the right to review all data associated with and developed for the ECH and to require delivery of any such data. Security of data generated under this contract shall comply with

ECH Security Classification Guide provided as Attachment J.2 and the DD 254, Contract Security Classification

Specification provided as Attachment J.3 to this contract.

3.1.4 Security Requirements. The contract requires certain Contractor personnel to obtain and maintain classified access eligibility. The Contractor shall have a valid Secret Facility Clearance and a Secret Document Safeguarding

Level prior to receiving classified information for performance at the Contractor’s facility. The prime Contractor and all subcontractors (through the prime Contractor’s oversight) shall adhere to all aspects of DoD Directive

5220.22-M. All personnel performing on this contract shall comply with Department of Defense, Department of the

Navy, and Marine Corps Information and Personnel Security Policies to include subjecting themselves to background investigations (as required) and not accessing classified information until the investigations are complete. This contract includes a DoD Contract Security Classification Specification (DD Form 254) as an attachment.

3.2 Government Furnished Property/Government Furnished Information.

3.2.1 Government Furnished Information. The Government will provide the Government Furnished

Information (GFI) identified below to the Contractor:

ECH Purchase Description with Drawing Package (Attachment J.1)

NVD Bracket Drawing Package (Attachment J.8)

Helmet Pad Drawing (Attachment J.9)

NVD Mount .stp File (Attachment J.13)

ECH Shell Drawing (Attachment J.16)

ECH Assembly Drawing (Attachment J.17)

3.2.2 Government Furnished Property. The Government will provide the Government Furnished Property

(GFP) identified below to the Contractor for packing with each ECH delivered against Marine Corps

CLINs:

Schedule of Government Furnished Property (Attachment J.18)

The Contractor shall secure, store, and account for the GFP and GFI. The Contractor shall inspect and inventory all

GFP and GFI and report any discrepancies and deficiencies as well as any associated costs (e.g., materials, labor, and tests) to repair the GFP and GFI to like-new conditions.

Receipt of Government Materiel Report (GFP/GFI) – CDRL A002

3.3 Meetings, Formal Reviews, Conferences, and Audits.

3.3.1 Post Award Conference. The Contractor shall host a Post Award Conference (PAC) at its facility no later than

30 days after contract award. The PAC is for the Contractor to demonstrate its production, quality control, and management procedures for producing the ECH. The Contractor shall ensure its key operations and management personnel attend the PAC. The Contractor shall provide a meeting agenda and meeting minutes for Government approval.

Conference Agenda – CDRL A003

Conference Minutes – CDRL A004

3.3.2 In-Process Reviews (IPRs). IPRs will occur no more than quarterly at dates and locations mutually agreed upon by the Government and the Contractor. The meetings generally occur only when the Contractor is under production to meet delivery orders under the contract. Topics such as complying with contract requirements, identifying and resolving problems, and assessing manufacturing performance, could be matters that necessitate face-to-face meetings. The Contractor shall deliver meeting agendas and meeting minutes for Government approval.

Conference Agenda – CDRL A003

Conference Minutes – CDRL A004

3.4 Environment, Safety, and Occupational Health.

3.4.1 System Safety. The Contractor shall evaluate any environmental, safety, and health hazards; and define associated risk levels. The Contractor shall also establish a program that reduces the probability and severity of all hazards associated with development, use, and disposal of the ECH in accordance with MIL-STD-882E. Residual risks will be evaluated by the Government in accordance with MIL-STD-882E and accepted as appropriate prior to exposing people, equipment, or the environment to known system related Environment, Safety, and Occupational

Health (ESOH) risks. The Contractor must identify all explosive safety risks in the system safety documentation to be delivered.

3.4.1.1 Safety Assessment. The Contractor shall perform, document, and deliver a Safety Assessment identifying all safety features of the hardware and system design as well as procedural and hardware related hazards present in the ECH. The Safety Assessment shall include procedural controls and precautions to reduce all hazards.

In addition, the Contractor shall make recommendations to reduce hazards when the ECH interfaces with other foreseeable systems.

Safety Assessment Report – CDRL A005

3.4.1.2 Health Hazard Assessment. The Contractor shall perform, document, and deliver a Health Hazard

Assessment Report (HHAR) to identify health hazards, evaluate hazardous materials, and propose protective measures to reduce the associated risk.

Health Hazard Assessment Report (HHAR) – CDRL A006

3.4.2 Safety Data Sheets. The Contractor shall deliver all Safety Data Sheets (SDSs) to the Government for review. A copy of the SDSs are required in accordance with FED-STD-313E.

SDS, Safety Data Sheets – CDRL A007

3.4.3 Environmental Considerations. The Contractor shall deliver information on the potential for any adverse environmental impacts from manufacturing, operating, maintaining, and disposing the ECH. The Government will use this information for a preliminary National Environmental Policy Act (NEPA) decision and to prepare formal

NEPA documents, which include the Categorical Exclusion (CATEX), Environmental Assessment (EA) and

Environmental Impact Statement (EIS). Environmental impacts include air, soil, wetlands, water, flora, fauna, endangered species, emissions and toxic waste resulting from development, maintenance (coatings and primers), operation, disposal, etc.

Technical Report, Study/Services (Environmental Considerations) – CDRL A008

3.5 Configuration Management Process. The Contractor shall maintain a configuration management (CM) process to control all ECH configuration documentation, media, and parts comprising the ECH. The principles contained in EIA-649 and MIL-HDBK-61 may be used for guidance. The Contractor's CM process shall consist of configuration identification, configuration control, configuration status accounting (CSA), and configuration audits.

The Contractor shall notify the Government of any changes at the Contractor's facility, that affect its CM process.

The Government’s CM plan will be Attachment J.11 to the contract to aid the Contractor in the CM process.

3.5.1 Configuration Identification. At the Post Award Conference, the Contractor shall propose Configuration

Items (CIs) for Government control and those to be managed by the Contractor at a lower level/tier. For the CIs under Government control, the Contractor shall provide form, fit, function, and interface documentation necessary for configuration status accounting. The Contractor shall establish management practices for the lower level/tier

CIs.

3.5.1.1 Configuration Status Accounting. The Contractor shall establish and maintain a CSA database and deliver CSA Information, reflecting the ECH’s configuration. All baselines and changes shall be documented in the

Contractor’s CSA Information. The Contractor's CSA Information shall reconcile any differences between the supplier information and Contractor practices to provide the Government with clear accountability of product information. Additionally, the CSA Information shall be a reliable source for support test activities, including program management, systems engineering, logistics support, and modification/maintenance actions.

Configuration Status Accounting (CSA) Information – CDRL A009

3.5.2 Configuration Management Meetings and Audits.

3.5.2.1 Physical Configuration Audit. The Contractor and the Government shall peform a baseline Physical

Configuration Audit(s) (PCA) to verify the ECH and its CIs (e.g., helmet shell, suspension hook disks, attaching hardware, edging, and pad suspension and retention systems) are accurate, complete, and compatible. The PCA shall also verify that the particular CI has achieved the performance and functional characteristics defined in the functional configuration baseline. The Contractor shall consolidate the results of its audits on subcontractors for configuration management of the ECH and its CIs. The Government and the Contractor shall conduct the system-level PCA jointly, at the Contractor’s place of performance, prior to the construction of first articles and the

Government will chair the audit. The Contractor shall plan, organize, chair, and conduct audits on subcontractors, with the Government serving in a support capacity when necessary before submitting the baselined CIs. The PCA shall verify that the drawings reflect the "as-built" configuration of all newly developed or modified portions of the system; confirm that accurate form, fit, function information is provided on control drawings for all CIs; and confirm the drawings accurately represent the "as-built" production configuration. The Contractor shall provide a proposed schedule for conducting the PCA and identification of the CIs to be audited at first article production. The

Contractor shall participate and assist the Government in developing the PCA, using the guidelines contained in

MIL-HDBK-61A, Section 8. The Contractor shall document the PCA results after each audit and correct all audit discrepancies documented in the configuration audit summary reports, which are data deliverables. In the event the

Government finds that any drawings or documents inadequately represent the equipment, the Government reserves the right to request revisions until the Contractor corrects all discrepancies and the Government approves the configuration audit summary report. The product baseline will be established upon completion of the PCA and the resolution of any audit discrepancies.

Configuration Audit Summary Report (Physical Configuration Audit) – CDRL A010

3.5.3 Baseline Management. The Contractor shall maintain the established baseline’s currency and accuracy to ensure form, fit, function and interface of the ECH. The Contractor shall establish definitive processes that identify how it will manage and maintain the baseline. The Contractor shall define and deliver these processes in the Contractor's configuration management plan.

Contractor’s Configuration Management Plan – CDRL A011

3.5.3.1 Product Baseline. The Contractor shall establish the product baseline by the successful completion and

Government acceptance of the Configuration Audit Summary Report (Physical Configuration Audit). The product baseline shall describe all the necessary physical characteristics of the ECH and its associated CIs (e.g., helmet shell, suspension hook disks, attaching hardware, edging, pad suspension and retention systems) to include all verifications required to demonstrate the ECH and its CIs meet all required performance parameters. The Contractor shall change the product baseline only through the Engineering Change Proposal (ECP) process.

3.5.3.2 Functional Baseline. The ECH PD and associated government-furnished drawings establish the functional baseline.

3.5.4 Configuration Control. The Contractor shall implement configuration control methods and procedures to maintain the integrity and traceability of an established baseline. The Contractor may only change established baselines upon Government approval of ECPs and Requests for Variation (RFV) within the Multi-User Engineering

Change Proposal Automated Review System (MEARS) (http://mears.army.mil/Home.aspx). The Contractor shall include sufficient supporting data to evaluate the proposed change, such as drawings, supplemental drawings, sketches, specifications, or manufacturer's data sheets, with the ECPs and RFVs. Changes shall identify the affected assembly serial number, or if the item is not part of an assembly, the affected equipment serial number.

3.5.4.1 Engineering Change Proposals. The Contractor shall submit ECPs as data deliverables. MIL-HDBK-61 provides guidance concerning the classification of ECPs. After the product baseline is established, all ECPs shall be submitted and processed in accordance with the ECH CM Plan incorporated as Attachment J.11 to this contract.

The Government will review each ECP upon receipt and notify the Contractor in writing of approval/disapproval.

For Class I ECPs, approval of the ECP grants the Contractor the authority to proceed to testing only. Based on the test results obtained, the Government will decide whether or not to proceed with permanent implementation of the change. The Contractor will be notified of this decision via separate formal correspondence.

Engineering Change Proposal (ECP) – CDRL A012

3.5.4.1.1 ECP Required Data. If there are no costs to the Government associated with the change, the Contractor shall fill out DD Form 1692/1, Aug 96 Blocks 1-36 for Government review. If there are costs to the Government associated with the change, the Contractor shall fill out Block 51 columns a-e identifying the funding required for the engineering change. Block 51 column f will be reserved for the Government to estimate costs outside the contract (i.e. government lab testing, additional GFP, etc.). The Contractor shall submit ECPs, to include supporting documentation, to the Government PCO as a Portable Document Format (PDF) until such time as the Contractor can input the ECP data into MEARS (http://mears.army.mil/Home.aspx) for the approval process. Until Contractor access to MEARS can be established, the Government will return the approved ECPs as a PDF for the Contractor’s status accounting. After MEARS implementation, the Contractor will be notified via the software system of the approved ECPs. The Government will provide MEARS training to the Contractor.

Engineering Change Proposal (ECP) – CDRL A012

3.5.4.1.2 ECP Cost Responsibility. The Contractor shall fund all ECP implementation up to its contractual responsibilities established in the Functional Baseline, Product Baselines, and this SOW. It is the Contractor’s responsibility to resource the manufacturing of test items and testing required for ECP approval at commercial testing facilities. Commercial testing facilities must meet the minimum criteria outlined in the LAT Plan, provided as Attachment J.6 to this contract. If the Government requires testing at a Government test facility, specifically

Aberdeen Test Center (ATC), the Government will assume the cost of the testing via separate agreement with ATC.

3.5.4.2 Requests for Variance. The Contractor shall process any RFVs from approved configuration documentation. Authorized variances are a necessary temporary departure from the specified baseline requirements and do not constitute a change in the approved baseline. The Contractor shall minimize recurring variations. For permanent changes, the Contractor shall process an ECP. EIA-649 Configuration Management for DoD provides guidance concerning the classification and processing of RFVs.

3.5.4.2.1 RFV Required Data. The Contractor shall populate a DD Form 1694, Mar 2016 (EG), filling out Blocks

1-25 for Government review. If there are costs to the Government associated with the variance, the Contractor shall specify the cost information as an attachment to the DD Form 1694. Block 19 will be reserved for the Government to estimate costs outside the contract (e.g., government lab testing, additional GFP, etc.). The Contractor shall deliver RFVs, to include supporting documentation, to the Government PCO as a PDF until the Contractor can input the RFV data into MEARS (http://mears.army.mil/Home.aspx) for the approval process. Until Contractor access to

MEARS can be established, the Government will return the approved RFVs as a PDF for the Contractor’s status accounting. After MEARS implementation, the Contractor will be notified via the software system of the approved

ECPs. The Government will provide MEARS training to the Contractor.

Request for Variance (RFV) – CDRL A013

3.5.4.2.2 RFV Cost Responsibility. The Contractor shall fund all RFV implementation up to its contractual responsibilities established in the Functional Baseline, Product Baselines, and this statement of work. The

Contractor shall resource the manufacturing of test items and qualification testing (if required) at commercial testing facilities. Commercial testing facilities must meet the minimum criteria outlined in the LAT Plan in Attachment J.6 to this contract. If the Government requires testing at a Government test facility, specifically ATC, the Government will assume the testing cost.

3.5.4.3 Notices of Revision. The Contractor shall generate and deliver Notices of Revisions (NORs) as well as any supporting documentation (e.g., drawings) when technical documentation controlled by another Contractor or

Government agency requires changes following approval of an ECP.

Notice of Revision (NOR) – CDRL A014

3.6 Engineering Data Package.

3.6.1 Engineering Data Package (EDP). The Contractor shall develop and maintain a complete EDP of the current FAT design and deliver it to the Government for use in the Configuration Management Process. The EDP deliverables are identified in 3.6.1.1 through 3.6.1.4. This process may require revising and updating existing documentation and developing new documentation to meet the EDP requirements. The Contractor shall develop a revised EDP to document any design change and shall reflect all changes resulting from Government approved

ECPs. The Government will approve and baseline the EDP at the end of the PCA. After the Contractor submits the final EDP to the Government, all subsequent EDP changes shall follow the Configuration Management Process.

The Contractor shall produce all products in accordance with an approved FAT and EDP.

Drawings, lists, and indices for configuration control shall document the design, construction, and manufacturing.

The EDP shall detail the necessary design, manufacturing, assembly, test/inspection, and configuration details of the

ECH’s materials, parts, subassemblies, and assemblies. The Items required for delivery are as follows:

3.6.1.1 Interface Control Drawings/Models. The Contractor shall develop and deliver interface control drawings/models for the following items: helmet shell and edging subassembly. These drawings/models shall include dimensioning to define the items fully. The helmet shell and edging drawings/models shall include the edging, finish, labels and dimensioning for the inside and outside surfaces. Each helmet shell drawing/model shall correspond with each distinct helmet shell size. The drawings/models shall define the helmet interfaces with other ancillary helmet components such as NVD mounts, sensors, etc.

Product Drawings/Models and Associated Lists – CDRL A015

3.6.1.2 Bill of Materials. For each ECH size, the Contractor shall deliver to the Government a Bill of Materials

(BOM) and drawings documenting all materials and components that comprise the ECH to identify Configuration

Items for CM. Each item in the BOM shall reference an internal or external drawing, specification, data sheet, supplier part number, or similar item, that describes the properties, characteristics, etc. of the material or component.

The Contractor shall version-control all documents and drawings. The BOM shall contain the material’s or component’s supplier. The BOM shall also include control drawings for all commercial-off-the-shelf (COTS) items not conforming to Government or industry specifications. All materials or components with a shelf life shall note their respective shelf life accordingly. There shall be a BOM for each size helmet. The drawings shall include the lay-up or orientation of materials to include ballistic materials. Drawings shall conform to ASME Y14.100 and

ASME Y14.34.

Bill of Materials – CDRL A016

3.6.1.3 Process Flow Chart. The Contractor shall submit a Process Flow Chart documenting the manufacturing process. The Flow Chart shall include all steps, critical inspection points, and sequence of the manufacturing process.

Process Flow Chart – CDRL A017

3.6.1.4 Control Plan. The Contractor shall provide a Control Plan (CP) documenting all processes it used to construct the ECH as well as the critical processing parameters, as determined by the Government, for each manufacturing step. The Control Plan shall also include tolerances for each parameter. The Government will determine which processes are critical based on discussions with the Contractor. The final list of critical processes are subject to Government approval. The documentation of critical processes shall include, but is not limited to:

Process/operation number and description

Machinery/equipment/tooling

Product/process characteristic to be controlled

Specification/tolerances

Reference drawing/criteria

Evaluation/measurement method

Sample size and frequency

Control method

Reaction plan

For example, critical processes such as the molding process, clamping tonnage, dwell time, and mold temperature are items to document in the CP.

Control Plan – CDRL A018

3.7 Item Unique Identification. The Contractor shall implement specific Item Unique Identification (IUID) marking, as defined in MIL-STD-130N and DFARS clause 252.211-7003. The Contractor shall use Construct #2 which includes an enterprise identifier; an original Part/Identification Number (PIN), lot or batch number; a serial number unique within the product identified, and a National Stock Number. When using Construct #2, the

Contractor shall ensure its serialization protocols provide globally unique combinations of serial number with original part, lot, or batch number assignments. The ECH data plate shall incorporate the IUID marking. Bar coding and the two-dimensional (2D) IUID data matrix shall be machine-readable with common optical scanning devices and accompanied by the corresponding human readable markings when practical. All 2D data matrices shall be permanently affixed and able to withstand the same environmental conditions as the ECH.

Data Elements for Physical and Virtual Marking Report – CDRL A019

3.8 Testing/Verification. The Government plans to conduct several stages of testing to ensure the ECH is able to meet the PD’s requirements, as follows:

3.8.1 First Article Test. The Government will conduct FAT in accordance with FAR 52.209-4, First Article

Approval-Government Testing to verify the ECH meets all Government requirements in the PD. The contractor shall ensure that FAT manufacturing is distributed as uniformly as possible over the machinery and tooling it intends on using for lot production. The Contractor shall be responsible for costs associated with additional helmets that may be required for FAT beyond those shown in the FAT Event Design Plan. Additional helmet requirements will be determined in accordance with the FAT Event Design Plan, Attachment J.5, and the Director, Operational Test &

Evaluation (DOT&E) Protocol provided as Attachment J.12 to this contract. The Contracting Officer will notify the

Contractor, in writing, of the conditional approval, approval, or disapproval of the first article. If FAT is approved, the Contractor will be authorized to proceed into production. The notice of conditional approval or disapproval shall not relieve the Contractor from complying with all requirements of the specifications and all other terms and conditions of this contract.

All production quantities submitted after approval of the First Article Test shall be produced using the same raw material suppliers, materials, processes, procedures, equipment and facilities that resulted in the manufacture of the acceptable First Article Test items. This includes all raw materials and/or sub-components. Contractors desiring to make changes to approved First Article Test items, to include raw material supplier and production processes, must request in writing and receive written approval from the Contracting Officer prior to use. The Contracting Officer, along with the Government Project Officer, will determine if the request is approved or disapproved and if a new

First Article Test is required.

3.8.1.1 Conditional FAT Approval. If the Contracting Officer authorizes a Conditional FAT Approval, requirements that have been met with exceptions during FAT and any failures noted during FAT not relating to mandatory source items (e.g., workmanship issues on the ECH, labeling issues) shall be corrected prior to the start of production. For failures noted relating specifically to mandatory source item quality issues, the Contractor shall submit waivers addressing those items and must receive approval of those waivers prior to beginning production.

After receipt of a Conditional FAT approval letter detailing FAT findings, the Contractor shall deliver a Failure

Analysis and Corrective Action Report (FACAR) which must be approved by the Government prior to the

Contractor beginning production. All costs related to any additional FAT testing that may be required shall be borne by the Contractor. After correction of all issues, the Contracting Officer will issue a final FAT approval letter authorizing the Contractor to proceed into production.

Failure Analysis Corrective Action Report (FACAR) – CDRL A020

3.8.1.2 FAT Disapproval. If the FAT is disapproved, the Contracting Officer will detail the findings in the FAT

Disapproval Letter. After receipt of a FAT Disapproval Letter, the Contractor shall deliver a FACAR addressing the findings which must be approved by the Government prior to the Contractor beginning production. All costs related to any additional FAT testing that may be required shall be borne by the Contractor.

3.8.1.3 First Article Test Methods. The Government will conduct FAT in accordance with FAR 52.209-4 First

Article Approval – Government Testing (clause is included in full text in Section I of this contract), the ECH PD, and the FAT Plan (Attachment J.5). The Contractor shall submit in-process manufacturing certifications of compliance.

Certificate of Compliance – CDRL A021

3.8.2 Confirmation Testing. After approval of FAT, any changes below the product baseline may require a

Government approved confirmation test. Additionally, any proposed changes in equipment/tooling (hardware or software) replacement or modifications, equipment additions, and changes in equipment location will require

Government approved confirmation testing. The Government will determine if additional testing is required and what that additional testing will encompass based on the scope of the change. Contractors shall notify the

Government in writing in advance of any planned changes.

3.8.3 Lot Acceptance Test. The Contractor shall implement the Government’s LAT procedures to demonstrate that its production processes and procedures suitably achieve the performance inherent in the design. The ECH shall demonstrate the system meets all requirements identified in the PD through LAT testing. LAT shall be conducted

IAW the LAT Plan provided as Attachment J.6 to this contract. The Contractor shall be responsible for costs associated with additional helmets and testing that may be required for LAT. Additional helmet requirements will be determined in accordance with the LAT Plan and DOT&E Protocol provided as Attachments J.6 and J.12 to this contract. The Contractor, with Defense Contract Management Agency (DCMA) surveillance, shall conduct any non-destructive tests the Contractor elects to retain internally at its own facility. The Contractor shall be responsible for conducting the destructive portions of LAT at ATC or any of the National Institute of Justice (NIJ) certified independent commercial laboratories in accordance with the LAT Plan. ATC or the Marine Corps Operational Test and Evaluation Activity (MCOTEA) is required to witness testing at any independent commercial laboratory;

however, the Contractor will not bear any of the additional costs of having an ATC or MCOTEA witness present at commercial test facilities. During LAT, non-destructive testing on each lot shall be complete before submitting the lot for destructive testing. If a lot has met the required performance parameters for non-destructive testing as described in the ECH PD and LAT Plan, it will then be submitted for destructive testing. If the DCMA representative concurs with the Government’s technical recommendation for lot approval, he or she will then provide the Contractor with notification of acceptance of the lot and authorize release of shipment via the Wide Area

Workflow (WAWF) documentation process. Formal technical recommendation for approval and DCMA concurrence is required prior to shipment. The Contractor may be present during LAT. The finished helmet shall conform to the quality of product established by the PD. The Contractor shall immediately report to the

Government any deviations in acceptable manufacturing procedures or material quality. Except as otherwise specified herein, repairs are not allowed to be made to the helmet.

The Contractor shall provide the cognizant Government Quality Assurance Representative (QAR) with written notice of the time and place for each periodic LAT. This notice shall be provided at least four working days before each conformance inspection if the QAR is in residence at the Contractor’s facility or ten working days before each conformance inspection if the QAR is not in residence at the Contractor’s facility. Destructive and non-destructive testing requires 100% witness by Government representative.

Test/Inspection Report – CDRL A022

3.8.3.1 Lot Acceptance Testing Methods. The Contractor shall conduct LAT in accordance with the ECH PD and the LAT Plan.

3.8.3.2 Nonconformance of First Article and Lot Acceptance Test. At the Contractor’s expense, the Government will return any FAT or LAT article failing to meet requirements as described in the PD, FAT Plan or LAT Plan, to the Contractor, who shall submit plans for the corrective action or disposition to the Government for approval.

Disposition will depend on the nature of the failure and the discussion in the FACAR. For Padding Layer Material

(suspension pad water absorbency) failures only, the Government may authorize the Contractor to conduct one retest of the failed suspension pad at the Contractor’s cost. The Contractor shall document results of the test and the retest in the test report and submit to the Government for review and approval. If the retest results in a failure, the

Contractor shall notify the Government immediately and prepare a FACAR for submission to the Government.

A sample form including the elements referenced above is included as Attachment J.10 to this contract. Contractor format for the FACAR is acceptable; however, the Contractor shall also include a discussion of the following elements in the form to assure that all actions are completed and verified appropriately:

a. Problem Description – A detailed, specific description of the problem including how many items contain the problem as well as when, where, and how the the problem discovered.

b. Containment Actions – Detailed explanation of the quantity of suspect products in the failed lot at the

Contractor’s facility including the method of quarantine, quarantine identification, method of certification against the problem and certification identification (e.g., if product is screened and bad product is removed, good product is re-packaged and the package has a green “certified” label adhered to it). Specify the quantity of products in transit, including method of notification to the recipient, a proposed method of certification against the problem (e.g., return authorization, Contractor to go on-site and rework or screen product), and a method of certification identification. Detail the quantity of suspect products in the

Customer’s possession, including the return authorization, details of quarantine, and certification upon receipt into the Contractor’s facility, or details of any arrangements made for quarantine and certification at the Customer’s facility.

c. Root Cause Analysis – An explanation of why the failure happened (the root cause) and an explanation of why the failure escaped detection prior to FAT or LAT.

d. Root Cause Verification – An explanation of what actions were taken to assure the true root cause of the failure was found (i.e. could not be something else). Explain in detail what actions were taken to assure the true root cause was found.

e. Corrective Actions / Verification of the Actions – Discuss each corrective action individually as it relates to the root cause. Also discuss how each corrective action relates to non-detection of the problem. For each problem identified by the Contractor, the Contractor shall list each individual action taken, the date of action implementaion, and proof that the action taken eliminates the problem. Additionally, the Contractor shall describe what quality assurance procedures would have detected the problem, the date the Contractor will implement those actions in the future, and proof the action taken eliminates non-detection of the problem. Lastly, list if any mechanisms that will help an equipment operator to avoid mistakes (Poke

Yokes) were implemented for this problem and provide details. If none implemented, explain why not.

f. Standardization and Control – An explanation regarding document updates such as Process Control

Plans, Process Flow Diagrams, Visual Aids, Work Instructions, Operating Procedures, Training

Methods/Records, and Preventive Maintenance Plans.

g. Verification of Corrective Actions – An explanation of the methods to verify the corrective actions are effective and will remain effective in the long term. Provide the number of trials with corrections in place, measurements, inspections, etc., including data on the number inspected vs. number of subject defects found.

Failure Analysis Corrective Action Report (FACAR) – CDRL A020

In the event of a conformance inspection failure, the Contractor shall submit a FACAR for each. The Government will not consider accepting failed lots until the Contractor resolves the failure to the Government’s satisfaction.

Government acceptance of a FACAR does not imply acceptance of a failed lot. Acceptance of failed lots is at the discretion of the Government. After lot failure, the Contractor’s production is at its own risk unless the PCO directs the Contractor in writing to discontinue production.

The Government has a right to revoke acceptance of any and all items potentially containing the root cause failure mode and to require the Contractor to replace the failed units or correct the failure mode at its expense. If the PCO approves the FACAR, the Contractor may perform any such action at destination or otherwise return the affected items to another location subject to the PCO’s approval. Transportation costs to and from the Contractor’s in this instance will be at the Contractor’s expense.

When the Contractor has shipped products from a failed lot, the Contractor shall notify the PCO in writing, with copy to the Administrative Contracting Officer (ACO) and Program Manager (PM) representative. The notification shall indicate the nature of the failure and shipments, to include consignees, date of shipments, carriers, waybill numbers, and quantity.