MSR_Blended_Yarn_SOW_RFI.pdf

Draft Statement of Work

Carbon/Phenolic Blended Yarn Fiber Procurement for Mars Sample Return

Preparation Date: October 2019

Ames Research Center Moffett Field, California

National Aeronautics and Space Administration ii

Table of Contents

1 SCOPE

2 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

2.2 NON-GOVERNMENT STANDARDS/DOCUMENTS

3 REQUIREMENTS AND PROCESS SPECIFICATIONS

3.1 Requirement

3.2 Identification

4 MANAGEMENT AND REPORTING

4.1 Reviews and Meetings

4.2 Kick-Off Meeting

4.3 Technical Interchange Meetings (TIM)

4.4 Pre-Ship Review (PSR)

4.5 Contract Management

5 QUALITY ASSURANCE PLAN

5.1 Manufacturing Controls

5.2 Responsibility of Test and Inspection

5.3 Test Records and End Item Data Package (EIDP)

6 CONFORMITY VERIFICATION

6.1 Contractor Source Inspection

6.2 Nonconformance

6.2.1 Disposition of Nonconformance’s

7 FIRST ARTICLE INSPECTION REPORT

8 PREPARATION OF MATERIAL FOR DELIVERY

9 DELIVERABLES

1 Scope NASA’s Science Mission Directorate is pursing highly reliable sample return missions that require an Earth Entry Vehicle (EEV). Mars Sample Return (MSR) is one such proposed mission. To return samples from the surface of Mars to Earth, the mission would use robotic systems to collect and send samples of Martian rocks, soils and atmosphere to Earth for detailed chemical and physical analysis. The EEV will launch in the mid-2020’s and will bring solar system samples back to Earth several years later. To ensure the success of this mission, the EEV will use the Heatshield for Extreme Entry Environment Technology (HEEET) Thermal Protection System (TPS) material in order to preserve the integrity of the returned samples.

This Statement of Work (SOW) defines the requirements for purchase of 10,000 kg of blended carbon/kynol yarn and the acceptance testing of that blended yarn which will be used in weaving of the insulating layer in the dual-layer HEEET TPS construct.

2 Applicable Documents

2.1 Government Documents

• MSR EEV TPS-5001-Draft. Blended Yarn Material Specification

• FAR 52, Subpart 52.209-4, “First Article Approval”

2.2 Non-Government Standards/Documents

• AS9100 / ISO9001 Standards

3 Requirements and Process Specifications

3.1 Requirement

• NASA requires the fabrication of 10,000 kg of blended carbon/phenolic yarn that meets NASA specification MSR EEV TPS-5001.

• NASA requires a vendor with AS9100 / ISO9001 certification

3.2 Identification

Each blended yarn lot shall have a unique identification number traceable to the manufacturing date and raw material lot for the constituent yarns.

4 Management and Reporting The contractor shall establish and maintain management operations that shall include the following areas:

• Reviews and Meetings

• Schedule and Financial Management

• Data Management

• Quality Control and Testing

4.1 Reviews and Meetings

The required meetings are outlined below. The NASA/ARC COR shall have the authority to remove or modify the requirement for meetings. The elimination of reviews and/or meetings shall be captured by written NASA/ARC COR approval.

Summary Reports shall be submitted for all meetings and reviews and, at a minimum, shall include meeting notice, agenda, attendance, review meeting minutes, action items, action item accomplishment responsibility and agreements. The reports shall be distributed to all meeting attendees at not greater than 5 work days after the meeting, review, or Technical Interchange Meetings (TIM). Electronic PDF format sent by email shall be considered acceptable.

4.2 Kick-Off Meeting

The contractor shall organize and present a Kick-Off meeting to a NASA Review Team at the contractor’s facility, unless otherwise agreed to by the contractor and NASA/ARC COR, no later than 10 business days after the initial contract award. In that meeting the contractor shall present a comprehensive presentation which lays out Key manufacturing requirements which shall be met as defined in the SOW/task order.

• Key manufacturing and/or management processes which shall be met during the subject period.

• A Schedule covering all elements of the blended yarn fabrication,

• Status on material purchasing: lead time of materials, dates of anticipated purchases, prospective vendors, anticipated shipping methods, etc.

• The contractor’s planned Quality Assurance Processes for the subject task period.

4.3 Technical Interchange Meetings (TIM)

For the purposes of design transition and communication the contractor is permitted to plan informal, face-to-face TIM at the contractor facilities. The contractor shall support review and coordination of technical issues including, but not limited to manufacturing approaches, Engineering Change Notices/requests (ECN), and reviews of contractor proposed alternative work efforts. TIM’s are intended to work out technical details prior to Manufacturing Readiness Reviews. TIM’s may be proposed by either party as required.

NASA/ARC or the contractor may initiate a TIM. The initiator shall provide notice a minimum of 7 working days prior to the proposed meeting date. The contractor shall support a minimum of 2 TIMs per calendar year throughout the period of performance, as requested by NASA.

4.4 Pre-Ship Review (PSR)

The contractor shall hold a Pre-Ship Review at the contractor's plant at the completion of verification tests and prior to shipment of the Contract Line Item (CLIN) deliverables to ARC. A PSR shall be held prior to the delivery of each item. The PSR shall include presentation of the End Item Data Package (EIDP).

The contractor shall deliver objective evidence with the hardware, showing product assurance acceptance of in-process workmanship processes, and final inspection. The contractor must implement all corrective actions necessary to remedy, before final acceptance, any nonconformance with respect to this SOW. A Government source inspection shall be required prior to shipment. ARC or its representative shall have final approval authority over all tests, verification, and documentation. All discrepancy report documentation shall be discussed and included as part of the EIDP.

At the time of the PSR, documents and analysis to support fulfillment of the requirements of this SOW for the hardware being delivered shall be complete and all actions from previous reviews shall be closed.

A representative from NASA will be on site to view first material off the line for each new batch manufactured. On site acceptance will allow early identification of blended yarn manufacturing issues and ensure that the yarn meets the project needs.

4.5 Contract Management

The contractor shall designate personnel who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract and ensure that all objectives are accomplished within schedule and cost constraints.

The contractor shall designate and identify by name a single employee who shall serve as the point of contact with the NASA/ARC Contracting Officer’s Representative (NASA/ARC COR) for all technical aspects of the Composite Structures contract.

5 Quality Assurance Plan A quality assurance program shall be implemented by the supplier to ensure and verify that the blended yarns manufactured meet the requirements.

5.1 Manufacturing Controls

The supplier shall prepare detailed instructions covering all phases of fabrication and processing either as applicable manufacturing processes and procedures or shop travelers. These process controls shall be documented to give visibility to the procedures and specifications by which all processes, operations, inspections, and tests are to be accomplished by the supplier. The documentation shall indicate required manufacturing checkpoints; the quality assurance verification points; facilities and test equipment utilized; and the verification procedures corresponding to each applicable process or material listed.

5.2 Responsibility of Test and Inspection

Unless otherwise specified, the supplier is responsible for performance of all inspection requirements as specified herein. Except as otherwise specified, the supplier shall utilize its own facilities or commercial laboratories acceptable to the procuring agency. NASA or its representative shall reserve the right to perform any or all of the inspections set forth in this specification where such inspections are deemed necessary to ensure that the product conforms to the prescribed requirements. Inspection records and acceptance test results shall be complete and available to NASA upon request.

5.3 Test Records and End Item Data Package (EIDP)

The supplier shall maintain records of raw material procurements, processing, inspections, and tests performed in the compliance with this specification. Each blended yarn lot shall have inspection and test records maintained by identification number to provide evidence that the required inspections and tests specified herein have been performed. A complete set of records for each yarn lot shall be submitted to NASA Ames and the procuring agency as part of the end item data package, according to an electronic file format agreed-to by the contractor and NASA.

An example of the type of date in the EIDP is a spreadsheet that lists:

• The lot # of blended yarn

• the lot #’s of the constituents fibers used

• All the lot acceptance data

6 Conformity Verification NASA may conduct audits of fiber lots received to ensure compliance to the requirements listed in this document: The audit would include, but is not limited to, the following areas:

• Supply Chain Management Systems

• Part-Level Compliance Documentation

• Product Production Controls

• Traceability of Supplied Materials

In addition, NASA reserves the right to conduct an independent audit of the supply chain.

6.1 Contractor Source Inspection

The contractor shall ensure that its procurement documents impose the applicable requirements outlined in the contract’s Quality Assurance Plan on subcontractors and other suppliers. The subcontractor and other suppliers shall in turn impose the requirements on their procurement sources.

6.2 Nonconformance

The contractor shall implement a nonconformance control system that documents, segregates, and dispositions any material or product that does not conform to the requirements of the applicable drawing, specification, or contract.

Any nonconformance (discrepancy), regardless of nature or where discovered, shall be documented. The NASA COR has authority to initiate a Material Review Board (MRB). The material shall be positively identified. The contractor should perform a preliminary review of such item(s) and make a disposition as follows:

(a) Scrap — If the item(s) are determined unfit for use, they should be scrapped.

(b) Return to subcontractor — If procured item(s) are unacceptable, they should be returned to the subcontractor.

(c) Complete or rework to specification — If the item(s) can be completed or reworked to drawing and/or specification requirements.

(d) Use as is – If the item(s) can be used in their non-conformant state

All finalized nonconformance reports shall be included in the EIDP, and shall be available for review by ARC at the contractor’s facility. The contractor shall not ship any nonconforming articles unless authorized by

ARC.

6.2.1 Disposition of Nonconformance’s

Nonconformances shall be dispositioned as follows:

a) The contractor shall submit all dispositioned non-conformance reports

(repair, use-as-is, and acceptance and qualification test dispositions) to ARC for approval. Nonconformance reports may be in the contractor’s format.

b) Each interim disposition of a nonconformance shall be separately approved by ARC.

c) ARC shall be notified and a formal nonconformance report shall be submitted within two (2) calendar days of a non-conformance. ARC will respond within five (5) work days of receiving the request.

d) In urgent situations, where time does not permit mailing the nonconformance report, the contractor shall notify the appropriate ARC COR by telephone, followed within 24 hours by a confirming e-mail. The contract administrator shall receive the non-conformance from the contractor and submit it to the ARC MRB for immediate action. The appropriate ARC COR will notify the contractor by email message, or telephone of MRB action and will email formal disposition instructions for the nonconformance to the contractor.

e) The contractor’s nonconforming materials report shall cross-reference the applicable nonconformance report.

7 First Article Inspection Report FAR 52, Subpart 52.209-4, “First Article Approval” – Government contractor to provide ARC a First Article Inspection package to include the following:

1. Yarn sample from the same production lot prior to full production

2. Sample End Item Data Package to include acceptance test data and results, Manufacturers Inspection records, Certificate of Conformance with Lot traceability, Materials Test Records indicating materials used.

8 Preparation of Material for Delivery Each delivered fiber roll will contain the following information:

• Location and name of fiber manufacturer

• Manufacturing date

• Lot/batch number

• Copy of the Certificate of Conformance (CoC)

The carbon phenolic blended yarn manufacturer will establish control factors which will yield a consistent product meeting the technical requirements of this specification. These factors are to be documented in the Process Control Document (PCD) that will be held in place at the vendor. The factors which are used in the production of the HEEET carbon phenolic blended yarn and documented in the HEEET PDC shall be followed. Any deviation or change from the HEEET PDC needs to first be approved by the purchaser/project. The change shall not be incorporated into the process prior to the receipt of approval from the project. Control factors are Controlled Process Equipment and Controlled Process Parameters in the PCD for producing the product.

9 Deliverables

Description Date Required Task 1: First Article Inspection Report and Sample TBD Task 2: Fabrication of 10,000 kg of blended carbon/phenolic yarn TBD Task 3: Acceptance Testing of Blended Yarn TBD Task 3: Delivery of End Item Data Package TBD