Draft_SOW_2016_03_28.pdf

Section_C_20160328_final

Section C - Descriptions and Specifications

Statement of Work

JCREW Increment 1 Block 1 (I1B1) System of Systems Full Rate Production

1.0 SCOPE

This Statement of Work (SOW) describes the tasks required to manufacture and deliver the Joint Counter Radio- Controlled Improvised Explosive Device Electronic Warfare (JCREW) I1B1 systems. In performance of the Build-to-Print (BTP) effort, the Contractor shall build the JCREW systems in accordance with (IAW) the Technical Data Package (TDP), provided as Government Furnished Information (GFI) and as referenced in Section J Attachment 6.

The Contractor shall provide systems, support equipment, training, spares and the depot capability necessary to support the production and sustainment of JCREW I1B1 systems. The Contractor shall provide Engineering Support Services to support the integration of Technology Insertion Elements (TIE), as defined by the Government, into the existing JCREW I1B1 baseline. TIE efforts shall include any requirements for material, engineering, test, repair and repair parts, data and services.

1.1 BACKGROUND

The JCREW I1B1 program provides the military services with an electronic warfare capability to counter the threat from Radio-Controlled Improvised Explosive Devices (RCIED). The JCREW System of Systems (SoS) approach includes three (3) distinct systems that utilize common component, software/firmware and hardware solutions for an open, flexible and compatible system design approach that is modular, interoperable and affordable to upgrade.

These systems are: dismounted system (man-portable), mounted system (ground), and fixed site system (semi-permanent geographical area and fixed). The JCREW I1B1 systems will provide RCIED protection to the members of military services operating world-wide.

The Full Rate Production (FRP) systems shall include any hardware, firmware, software, shipping containers, batteries, and all the components necessary to operate the system and any other support equipment necessary to achieve the requirements defined in the JCREW I1B1 TDP, Attachment 6, provided as GFI.

1.2 PROGRAM DESCRIPTION

The JCREW System of Systems (SoS) will operate worldwide, supporting United States (U.S.) Forces’ dominance over the electromagnetic spectrum, and will not require new or unique communication systems, but will operate within the bandwidth and quality of service of current and future systems. JCREW SoS is capable of functioning in a stand-alone mode (as do legacy systems), and will be network capable. JCREW utilizes an open architecture and well defined, common standards to support an incremental development approach which assures the JCREW SoS will pace or remain ahead of future threats. Operating as part of a Family of Systems (e.g., airborne CREW devices or legacy ground-based CREW devices), the JCREW SoS will provide commanders of the Joint Forces, U.S. Marine Corps, U.S. Navy, U.S. Air Force, U.S. Army, Special Operations Command, other Department of Defense (DoD) components, and non-DoD agencies with a capability to counter RCIEDs.

2.0 APPLICABLE DOCUMENTS

In the event of conflict between the documents referenced herein and the contents of this SOW, the order of precedence shall be the JCREW I1B1 SOW and then any applicable reference document(s). When, in the opinion of the Contractor, a deviation from standards or requirements of this SOW is in order, the Contractor shall make a Request for Variance (RFV) in writing to the Procuring Contracting Officer (PCO) with an informational copy to the designated technical representative. The Government will notify the Contractor in writing of approval or disapproval of the deviation, within forty-five (45) days after receipt by the PCO.

Unless otherwise indicated, copies of federal and military specifications, standards, and handbooks are available on the internet at the Department of Defense ASSIST database at https://assist.dla.mil/. Joint Chiefs of Staff, DoD Directives (DoDD), DoD Instructions (DoDI) and Publications documents can be found on the Acquisition, Technology, and Logistics (AT&L) Acquisition Knowledge Sharing System (AKSS) at or at the DoD Issuances website at: http://www.dtic.mil/whs/directives/. Non-Government documents should be obtained from commercial sources.

The following documents of issue in effect as of the execution date of the contract are applicable to this Statement of Work and attached appendices to the extent specified herein or as modified under the contract:

2.1 MILITARY STANDARDS, SPECIFICATIONS, AND HANDBOOKS

MIL-HDBK-61A (SE) DoD Configuration Management Handbook, 7 Feb 2001

MIL-HDBK-2164A DoD Environmental Stress Screening Process for Electronic Equipment, 19 Jun 1996

MIL-HDBK-781A Reliability Test Methods, Plans, and Environments for Engineering, Development, Qualification, and Production, 1 April 1996

MIL-HDBK-1568 Material and Processes for Corrosion Prevention and Control in Aerospace Weapons Systems (Replaced by MIL-STD-1568), 18 Jul 1996

MIL-HDBK 29612-2A Instructional Systems Development/Systems Approach to Training and Education, 20 Jun 2011

MIL-STD-1839D DoD Standard Practice: Calibration and Measurement Requirements, 12 May 2010

MIL-STD-2073-IE Standard Practice for Military Packaging Ch-7, Jan 2011

MIL-STD-129P Military Marking for Shipment and Storage, 29 Oct 2004

MIL-STD-40051-2B DoD Standard Practice: Preparation of Digital Technical Information for Page-Based Technical Manuals (TMs), 30 Nov 2012

MIL-PRF-29612B Performance Specification: Training Data Products, 20 Jun 2011

2.2 DEPARTMENT OF DEFENSE REGULATIONS, DIRECTIVES AND INSTRUCTIONS

DOD-5220.22-M National Industrial Security Program Operating Manual Supplement, 28 Feb 2006

DODI 1322.20 Development and Management of Interactive Courseware (ICW) for Military Training, 16 Nov 1994

DODI 1322.26 Development, Management, and Delivery of Distributed Learning, 16 Jun 2006

OPNAVINST 5513.8C DoN List of Security Classification Guides for Electronic Warfare Programs, 21 Jul

2.3 OTHER REFERENCES

Manufacturing Readiness Level (MRL) Deskbook, Version 2.4, May 2011

DOD Corrosion Prevention and Control Planning Guidebook, Spiral 3, Sep 2007

2.4 INDUSTRY STANDARDS

SAE/EIA-649-B Configuration Management Standard, 17 Jun 2011

SAE/EIA-649-1 Configuration Management Requirements for Defense Contracts, Mar 2015

ASTM D 3951-10 DCMA Commercial Packaging, 2010

ANSI/ISO/ASQ 9001:2008 Quality management Systems – Requirements

SAE AS5553 Counterfeit Electronic Parts: Avoidance, Detection, Mitigation and Disposition, Apr 2009 http://www.dtic.mil/whs/directives/

ITAA/GEIA-STD-0009 Reliability Program Standard for Systems Design, Development, and Manufacturing, 01 Aug 2008

SAE/GEIA-STD-0007-B Logistics Product Data Handbook, 1 May 2013

SAE/GEIA-HB-0007-B Logistics Product Data Handbook, 1 Feb 2014

SAE/TA-HB-0007-1 Logistics Product Data Reports Handbook, 1 May 2013

3.0 REQUIREMENTS

3.1 MANUFACTURE, ASSEMBLY, AND TEST

The Contractor shall build and deliver the JCREW I1B1 systems IAW the relevant TDP and specifications, provided as attachments in Section J.

The Contractor shall procure, manufacture, and assemble materials required to produce JCREW I1B1 systems, including any special test equipment, and conduct component and manufactured item testing necessary to assure the quality of all items.

The Contractor shall use existing production documentation provided as attachments in Section J. Where the Contractor identifies the specifications and associated documentation and drawings provided as GFI are inadequate to ensure system conformance and/or impact the Contractor’s ability to manufacture and assemble a component/item, the Contractor shall notify the Government Contracting Officer’s Representative (COR) and Program Manager via e-mail.

The Contractor shall develop and submit a First Article Qualification Test (FAQT) Plan. The Contractor shall execute the FAQT Plan using the first JCREW I1B1 production article for each variant. The Contractor shall furnish all labor and materials to procure piece parts, fabricate, assemble, test, repair failed items found during FAQT, re-test, clean, package, and ship completed systems to the destination(s) identified in the Contract. The Contractor shall submit an FAQT Report subsequent to successful completion of the FAQT Plan.

IAW the Contractor’s Quality Management System (QMS) and IAW paragraph 3.3, the Contractor shall perform all necessary incoming inspections and acceptance tests of material received from subcontractors, suppliers, and vendors to assure that items meet the requirements of the specification control drawings or source control documentation. All nonconforming material shall be segregated from material acceptable for production line use and disposition of nonconforming material shall be accomplished IAW the Contractors Quality Assurance (QA) Procedures as outlined in the Contractor’s QMS. An Engineering Change Proposal (ECP) shall be the vehicle to request any changes resulting from obsolescence, Diminishing Manufacturing Sources and Material Shortages (DMSMS), or end-of-life issues.

The Government will take acceptance of completed JCREW I1B1 systems. The following criteria must be met for all systems accepted and signed for:

1. Submission of the FAQT Report.

2. Submission of the As-Built Configuration List (ABCL) for each individual system being sold off.

3. Submission of a completed Functional Evaluation/Acceptance Test (FE/AT) System Test Report for each individual system being sold off.

4. Submission of a completed Production Reliability Acceptance Test (PRAT) System Test Report for any system that was run through PRAT being sold off.

CDRL ABCL (A002), FAQT Plan and Procedures (A005), FAQT Report (A006), FE/AT Plan (A007), FE/AT Report (A008), PRAT Plan (A024), PRAT Report (A025)

3.1.1 PRODUCTION READINESS REVIEW (PRR)

The Contractor shall complete a successful PRR IAW the JCREW I1B1 Systems Engineering Plan, provided as GFI, in Section J, Attachment 5, PRR requirements, as well as the Manufacturing Readiness Level Deskbook, Version 2.4, Aug 2015, or latest approved version, no later than 8 months after contract award (see Defense Acquisition Guidebook 4.2.15, Production Readiness Review (PRR) (https://dag.dau.mil). The Contractor shall not proceed to production without successful completion of the PRR. The Contractor shall identify existing and projected manufacturing problems and areas of risk and shall assess the progress in the Contractor's planning to achieve production rates required under the delivery schedule. The Contractor shall develop a Manufacturing Plan CDRL (A001) that addresses the following criteria, at a minimum:

• Industrial Resources o Plant Facilities, Production Equipment, Test Equipment, and Tooling

Plant capacity to meet production rate Available Surge Capacity GFE, special tooling, production equipment has been identified Needed Plant modernization, productivity enhancements has been accomplished o Personnel Available skilled production manpower available Personnel training and certification available and completed

• Production Engineering and Planning o Production Plan developed and in place o Production schedule developed and meets delivery requirements o Manufacturing methods and processes in place o Alternative production approaches available to contingency needs o Drawings and work instructions are in place and available o Configuration Management is defined, implemented, and maintained for production o Provisions have been made for determining producibility and cost impacts of engineering changes o Production Manager in place with authority and responsibility for manufacture and delivery o Management information system in place to provide production status

• Materials and Purchased Parts o Complete an accurate Bill of Material in-place o Make or Buy decisions have been made o Long lead items identified o Sole source items identified o GFE/GFM identified o Material control/inventory system is adequate o Material procurement plan provides

Effective procedures to determine material needs, lead times, & delivery schedule Criteria for selection of subcontractors and suppliers in place Multi-sourcing of critical items Economic lot size orders Visibility and control of vendors and subcontractors

• Quality Assurance Plans and Procedures o A Quality Assurance function in place o Quality Program IAW contract o Necessary quality control procedures and quality acceptance criteria established o Quality Assurance Organization is a participant in product planning

• Logistics o Capacity exists to manufacture initial and replenishment spares

CDRL Manufacturing Plan (A001)

3.1.1.1 COUNTERFEIT PARTS AND MATERIALS

The Contractor shall document procedures to minimize the risk of procuring and/or using counterfeit parts and materials. Counterfeit parts may typically be used parts which have been refurbished and represented as new. These parts may or may not contain authentic dye, and will often pass most if not all of the system performance requirements and data sheet parameters. However, part reliability may have been compromised during removal, handling, or re-marking, and a reduced life can be expected. Commonly counterfeited electronic parts include https://dag.dau.mil/ expensive parts such as microcontrollers or specially-screened devices, or common parts which have several pin-compatible versions from multiple Original Component Manufacturers (OCM), such as memory devices and operational amplifiers.

Counterfeit mechanical parts are typically improperly made, marked, or treated products. Examples are improper anodizations or heat treatments (or falsified data), mismarked parts sold as a higher grade steel, or used/bogus parts such as valves or circuit breakers. As with electronic parts, counterfeit mechanical parts are significantly more likely to fail prior to the part’s expected life.

3.1.1.2 PREVENTING COUNTERFEIT PARTS AND MATERIALS

The vendor shall take steps as defined below to minimize the risk of receiving counterfeit parts and materials. The Contractor shall:

a. Maximize availability of authentic, originally designed and/or qualified parts throughout the product’s life cycle, including management of parts obsolescence;

b. Assess potential sources of supply to minimize the risk of receiving counterfeit parts or materials;

c. Maintain a listing of approved suppliers with documented criteria for approval and removal of suppliers from the list;

d. Have purchasing procedures which require the selection of parts and materials from OCM or authorized suppliers whenever possible;

e. Require a certificate of compliance and supply chain traceability for all electronic part purchases, and provide to the Government upon request;

f. Use Government or industry services such as Government - Industry Data Exchange Program (GIDEP) and other commercially available services to identify part or supplier quality or authenticity problems;

g. Define minimum inspection and test requirements for parts being procured from unauthorized sources, and shall ensure that in-house, third-party, and/or distributor inspection and test procedures and facilities comply with these requirements;

h. Incorporate procurement clauses which plainly identify quality requirements and liability to all approved suppliers; and

i. Flow the requirements above to affected subcontractors.

Parts and materials shall not be purchased from unauthorized sources (e.g. independent distributor or broker) unless there is no other means for procurement. In isolated cases when an unauthorized source is the only possible choice for procurement, an unauthorized source purchase report shall be provided to the Configuration Control Board. The report shall contain the following information:

a. Reason why an authorized supplier or OCM could not provide the part or material;

b. Product certificate of conformance with traceability to the OCM, if available; and,

c. Verification and authenticity data results (e.g., visual inspection, marking/surface finish permanency, Destructive Physical Analysis (DPA), Scanning Acoustic Microscopy, Energy Dispersive X-Ray Spectroscopy, Fourier Transform Infrared (FTIR) Spectroscopy, Rockwell Hardness Test, etc.).

SAE AS5553 contains information regarding the detection, avoidance, and mitigation of counterfeit electronic components, and may be used as a reference document for meeting the above steps.

3.1.1.3 CORROSION PREVENTION AND CONTROL (CPC)

The Contractor shall implement an effective CPC program IAW DOD Corrosion Prevention and Control Planning Guidebook, Spiral 3, September 2007. MIL-HDBK-1568 may also be used for guidance. The Contractor shall submit a Finish Specification Report which identifies the specific organic and inorganic surface pretreatments and coatings used for corrosion protection in the design and manufacture of JCREW systems.

CDRL Finish Specification Report A027

3.1.2 PHYSICAL CONFIGURATION AUDIT (PCA)

The Contractor shall support and participate in a Government-led PCA conducted on the first production units. The PCA shall be held after the first production unit has completed First Article Qualification Testing. The Contractor shall provide the Government with two (2) units of each system variant (Dismounted, Mounted, and Fixed) for PCA.

The Contractor shall propose a PCA date at least 60 days in advance of meeting PCA Entrance Criteria. PCA Entrance Criteria shall include, at a minimum, availability of: Production schedules, Production test plans, Production acceptance plans, Configuration Management plans and documentation, quality control documentation and reports, ECP/RFV that may affect system baseline, and production hardware (to include any fabricated or manufactured testing fixtures and testing equipment). The Contractor shall execute the Government’s PCA Plan, provided as GFI, in Attachment 5 on the first FRP unit produced of each system variant. The Contractor shall respond to audit findings, recommend corrective actions, and resolve all findings and deficiencies identified. The Contractor shall support a delta PCA if required by the Government to address all audit findings, corrective actions, and resolved deficiencies. The PCA will cover all products to include any manufacturing, production, and assembly documentation and hardware, as well as all mission enabling products.

3.1.3 CONTRACTOR PRODUCTION QUALIFICATION

Contractor qualification, as well as all subcontractors and all facilities, for this BTP procurement shall be established upon successful completion of PRR and the Government PCA. Successful qualification is predicated on the Government’s determination that the systems meet final production configuration, and that production capability and capacity demonstrates a satisfactory basis for proceeding into Full Rate Production. The Government will provide a letter indicating successful completion of Contractor Production Qualification.

3.1.4 CONFIGURATION STATUS ACCOUNTING (CSA)

The Contractor shall establish, implement, and maintain a Configuration Status Accounting (CSA) database to record and track status of JCREW I1B1 hardware and software. This database shall be established and functional prior to PRR. The Contractor shall provide the Government electronic access to this database throughout the term of the contract. The Contractor shall record the CSA data for each JCREW I1B1 system in this database when each system is delivered. The CSA data shall be identified to the Lowest Reportable Unit (LRU) level as defined in the TDP, Attachment 6.

The Contractor shall include a report of CSA database activities in the Contractor’s Progress, Status, and Management Report.

CDRL Configuration Status Accounting Information (A003): Contractor’s Progress, Status and Management Report (A004)

3.1.5 AS-BUILT CONFIGURATION

The Contractor shall develop and deliver an As-Built Configuration List (ABCL): Indentured Bill of Materials for each delivered item. The ABCL shall extend down to the LRU level and be recorded in a CSA database. The list of LRUs is provided as GFI in Section J, Attachment 5.

CDRL ABCL (A002)

3.1.6 PRODUCTION ASSURANCE TEST SUPPORT

The Production Program Manager shall ensure the associated Test Personnel, Equipment, and Facilities are used for all the required Production Tests.

3.1.6.1 FIRST ARTICLE QUALIFICATION TEST (FAQT)

First Article Qualification Test (FAQT), as referenced in paragraph 3.1, shall be conducted on first FRP system of each variant. The Contractor shall perform FAQT IAW the approved FAQT Plan and Procedures, provided as GFI in Section J, Attachment 5. The Contractor shall own or have access to equipment and facilities capable of performing FAQT. The Contractor shall use the FAQT Plan and Procedures provided as a baseline, updating only as required for successful First Article Test completion. The Contractor shall submit a First Article Qualification Test Plan and Procedures. The Contractor shall document the results in the FAQT Report.

CDRL FAQT Plan and Procedures (A005), FAQT Report (A006)

3.1.6.2 FUNCTIONAL EVALUATION/ACCEPTANCE TEST (FE/AT) REQUIREMENTS

All systems shall be subjected to a Functional Evaluation/Acceptance Test (FE/AT). FE/AT shall be conducted after each produced system has successfully completed the required testing. The purpose of functional evaluation is to verify that key performance attributes are met. Functional evaluation will include tests to verify:

a. System Timing

b. System Zeroization

c. Power output (test frequencies across full spectrum)

d. Received sensitivity (test frequencies across full spectrum)

e. Functionality of Control and display Unit (CDU) controls

f. CDU display is fully functional

g. Voltage Standing Wave Ratio (VSWR)

h. Global Positioning System (GPS) operational

i. Loading of loadset

j. Operation of all Built In Test (BIT) modes (e.g. P-BIT and S-BIT)

k. Acceptable noise levels

The Contractor shall provide the Government with a FE/AT Test Report with functional results.

CDRL FE/AT Test Report (A008)

3.1.6.2.1 ENVIRONMENTAL STRESS SCREENING

All produced systems shall be subjected to environment stress screening. The purpose of environment stress screening is to detect and correct latent manufacturing defects (marginal and defective parts, workmanship defects, and other non-conforming anomalies). MIL-HDBK- 2164A paragraphs 5.1.1 and 5.1.2 shall be used to conduct environmental stress screening. During thermal testing of operational environment stress screening, the item shall be cycled through operational modes while simultaneously being subjected to environmental thermal and vibrational stresses. Environment stress screening shall be tailored to meet program requirements and conducted to include, at a minimum, five (5) cycles with the last three (3) failure free. The Contractor shall conduct a vibration response survey in preparation of the environment stress screening procedure to ensure that environmental stress screening does not exceed design limits. The Contractor shall conduct a thermal survey to determine appropriate dwell time for temperature stabilization. At the completion of environment stress screening, FE/AT shall be completed and delivered to the Government as required by Paragraph 3.1.6.2 of this SOW.

CDRL Environment Stress Screening Plan and Procedures (A015), Environment Stress Screening Report (A016)

3.1.6.2.1.1 ENVIRONMENTAL STRESS SCREENING TEMPERATURE STRESS

The thermal stress profile shall be conducted as effectively as possible to maximize the number of temperature reversals. The environment stress screening profile illustrated in MIL-HDBK-2164A, Figure 4a shall be used to accomplish this goal. A minimum of 10OC/minute rate of change is required to expose thermally sensitive manufacturing defects. The ambient operating temperatures are specified in the Performance Specification.

3.1.6.2.1.2 ENVIRONMENTAL STRESS SCREENING VIBRATION STRESS

MIL-HDBK-2164A, Figure 3 depicts a typical random vibration spectrum that shall be applied, as an input, to the equipment to be screened, with the equipment hard mounted to the screening fixture and shaker system. Vibration test levels and profiles shall be tailored to the specified intended application of the equipment and shall consider the mounting location and the classification category for field use.

3.1.6.2.2 PRODUCTION RELIABILITY ACCEPTANCE TEST (PRAT)

Each system produced shall be subject to a Production Reliability Acceptance Test (PRAT). PRAT shall be conducted after each produced system has successfully completed Environmental Stress Screening. The purpose of PRAT is to identify deficiencies in design, components, materials & workmanship introduced over the course of the production program. PRAT shall allow verification of key operational performance characteristics of each system under environmental stresses. Environmental stresses shall be combined whenever possible. The Contractor shall test each system in accordance with paragraph 5.11, MIL HDBK-781A, Test Plan XVIII-D, and Figure 35. Test duration shall be the completion of three (3) mission profiles (defined in the Performance Specification). Cumulative equipment operating time and equipment failures shall be recorded and plotted on the chart of the approved test plan. The Contractor shall provide the Government with a PRAT Test Plan and PRAT Test Reports. PRAT closeout for each system under test shall be the completion of FE/AT in accordance with Paragraph 3.1.6.2 of this SOW.

Upon successful completion of at least 2 production lots with diminishing reject events, the Contractor shall submit a request for conversion to a lot sample PRAT. Sample sizes for mounted, fixed site and dismounted shall be in accordance with MIL-HDBK-781A, Paragraph 5.4.2.2(b).

CDRL PRAT Test Plan (A024), PRAT Test Report (A025)

3.1.6.2.2.1 PRAT THERMAL STRESS

The thermal stress profile shall be a realistic simulation of the actual thermal environment that the equipment experiences in the service application and shall cover the entire operational temperature range. Factors to be considered in the definition of thermal stress include: a) starting temperature (hot soak, cold soak) and turn on (warmup) time; b) operating temperature (range, rate of change, and frequency of change; c) number of temperature cycles per mission profile; and d) cooling airflow (rate and fluctuation). The ambient operating temperatures are specified in the Performance Specification.

3.1.6.2.2.2 PRAT VIBRATION STRESS

Vibration test levels and profiles shall be tailored to the specified intended application of the equipment and shall consider the mounting location and the classification category for field use. The vibration stress shall follow the general guidance as specified below:

a. Tracked vehicle equipment: 5 Hz to 500 Hz to 5 Hz for a maximum time of 3 hours, using a cycle of 15 minutes on each of the three axes. Maximum g-level is 4.2 g. Maximum displacement is 1-inch displacement amplitude (DA).

b. Man-pack equipment: 5 Hz to 500 Hz to 5 Hz for a maximum of 3 hours, using a cycle of 15 minutes on each of the three axes. Maximum g-level is 4.2g. Maximum displacement is 1-inch displacement amplitude (DA).

3.1.6.2.2.3 PRAT REJECT CRITERIA

All failures shall be subjected to the Failure Reporting, Analysis and Corrective Action System (FRACAS), requirements defined in Paragraph 3.2.2 of this SOW. All failures shall be analyzed to determine root cause(s).

Occurrence of a pattern failure (defined as two (2) or more occurrences of failures having the same assignable root cause) or when the plot of equipment operating time verses failures crosses the reject line of the approved test plan shall be cause for "Reject" in PRAT. Any time a reject situation is reached, the Contractor shall notify the COR within three (3) days by phone, followed immediately with written notification via e-mail. A Reject decision in PRAT shall require development and implementation of a corrective action plan. Continued acceptance of systems shall be based on the Government approval of the corrective action plan. The Government reserves the right to stop acceptance of systems until implementation and verification of appropriate corrective action occurs IAW an approved corrective action plan. Repairs shall require a complete repetition of PRAT. The Contractor shall provide the Government with PRAT Test Plan and PRAT Test Reports with functional results. PRAT requirements shall be executed IAW MIL-HDBK-781A, Figure 35.

CDRL PRAT Test Plan (A024), PRAT Test Report (A025)

3.2 RELIABILITY AND MAINTAINABILITY (R&M) PROGRAM

The Contractor shall develop and maintain a Reliability and Maintainability (R&M) Program using guidance from GEIA-STD-0009, The Contractor shall plan, implement, and manage the R&M effort that assures the satisfaction of system requirements. Details on R&M management processes, analyses, and tests shall be explained, documented, and addressed, as applicable. The Contractor shall track actual Lowest Replaceable Unit/Lowest Replaceable Module (LRU/LRM) failure rates using information obtained from production testing and during any subsequent repair process. The Contractor shall conduct R&M Failure Analysis as follows:

a. LRUs/LRMs whose actual reliability is less than 90% of that initially predicted/allocated shall be identified and assessed for impact;

b. LRUs/LRMs whose actual reliability is less than 80% of that initially predicted/allocated shall be identified, assessed and options recommended to resolve these reliability issues.

CDRL R&M Program Plan (A030)

3.2.1 FAILURE MODES, EFFECTS, AND CRITICALITY ANALYSES (FMECA)

The Contractor shall adhere to the existing Failure Modes, Effects, and Criticality Analyses (FMECA), provided as GFI in Section J, Attachment 5, to address any approved design changes introduced during manufacture of the JCREW systems.

3.2.2 FAILURE REPORTING, ANALYSIS AND CORRECTIVE ACTION SYSTEM (FRACAS)

The Contractor shall adhere to the closed loop failure reporting system provided as GFI in Section J, Attachment 5.

The Contractor shall employ procedures for analysis of failures to determine cause, and documentation for recording corrective actions taken. The FRACAS shall include uniform failure reporting, failure analysis reports and corrective actions. All hardware/software failures from system level down to the component level shall be subject to these requirements throughout the production period. The Contractor shall provide for visibility and traceability of all reported failures and BIT anomalies from discovery to close-out. All failure and BIT anomalies analysis reports shall be closed out within sixty (60) days of occurrence, or rationale provided for any extensions. The Contractor shall notify the Government, in writing, within twenty four (24) hours of any critical failure which impacts cost, schedule, producibility, interface, performance, or safety. The Contractor shall report the FRACAS failures that are not defined as critical to the Government, in writing, ten (10) working days from occurrence. All failures shall be reported in the monthly Failure Review Board (FRB) meetings and in the Contractor Program Status and Monthly Report (CPSMR). The Contractor shall record FRACAS failures, Analysis, and Corrective Actions Failures, BIT anomalies (e.g., BIT failure to detect, BIT failure to isolate properly, and BIT false alarms), or non-conformances experienced from the end item level LRU/LRM or lower through the system level during manufacture and test through completion of the Contract. The Contractor shall perform failure analyses on all reported failures and BIT anomalies to the level required to determine the cause of failure, define the failure mechanism, and develop corrective actions to eliminate or limit their recurrence. In general, these analyses shall include a physical and failure analysis on electrical and electronic parts.

CDRL Failure Summary and Analysis Report (A009)

3.2.2.1 FAILURE REVIEW BOARD (FRB)

The Contractor shall conduct a Failure Review Board (FRB) IAW the Contractor’s approved Corrective Action Plan / FRACAS. The Government shall be an active member of the FRB and shall have the final authority for classification and disposition of all failures reviewed by the FRB. The Government shall be notified of the FRB meeting dates at least ten (10) working days in advance. The FRB shall meet as often as necessary. However, the FRB shall not meet less frequently than monthly during any period when open failure reports exist.

CDRL Corrective Action Plan A028

3.2.2.2 FAILURE REPORTING

The Contractor shall record failures, BIT anomalies (i.e. BIT failure to detect, BIT failure to isolate properly and BIT false alarms) or non-conformance experienced from the end item level (LRU or lower when spares are procured) through the system level during manufacture. MIL-HDBK-781A, paragraph 4.6.1, shall be used to report the minimum data for each failure occurrence.

CDRL Failure Summary and Analysis Report (A009)

3.2.2.3 FAILURE CLASSIFICATION

All failures shall be classified as relevant or non-relevant. Relevant failures shall be further classified as chargeable or non-chargeable. Classification of failures shall be proposed by the Contractor and forwarded to the procuring agency for approval. Failure categories are described in the Failure Definition and Scoring Criteria (FD/SC) documentation, provided as GFI in Section J, Attachment 5.

CDRL Failure and Summary Analysis Report (A009)

3.2.2.4 FAILURE ANALYSIS

The Contractor shall perform failure analyses on all reported failures and BIT anomalies to the level required to determine the cause of failure, define the failure mechanism and develop corrective actions to eliminate or limit their recurrence. In general, these analyses shall include a physical and failure analysis on electrical and electronic parts.

The analyses of parts shall, as necessary, include electrical failure verification, dissection, microphotography, and adequate chemical and metallurgical analysis to define the failure mechanism (e.g. most fundamental cause).

Records of failure analyses, including causes and effects, shall be maintained by the Contractor with data feedback to R&M and BIT-related design analysis functions.

CDRL Failure Analysis and Corrective Action Report (FACAR) (A010)

3.2.2.5 CORRECTIVE ACTIONS

The Contractor shall develop and implement effective corrective actions to eliminate or minimize recurrence of all failures, faults and BIT anomalies. Corrective actions must meet the following criteria:

a. Be established (analytically or by test) as an effective corrective action to the satisfaction of the Government.

b. Be scheduled for incorporation into all subsequent production equipment via official change controls (i.e. ECPs) as approved by the Government.

c. Must address impact and correction to retrofit of previously delivered equipment.

CDRL Corrective Action Plan (A028)

3.3 QUALITY MANAGEMENT PLANNING

The Contractor’s quality management program shall be in compliance with applicable ANSI/ISO/ASQ 9001:2008 standards or higher. Registration is preferred, however not required. All manufacturing processes and quality systems procedures shall also be IAW applicable ANSI/ISO Standards. The Contractor shall flow all quality system requirements down to sub-tier suppliers.

3.4 INTEGRATED LOGISTICS SUPPORT (ILS)

The Contractor shall establish a Logistics Product Data (LPD) program that complies with and updates ILS documentation provided as GFI in Section J, Attachment 5, as part of the change management process. The GFI provided includes: Technical Manuals, Training Materials, and Logistics Product Data (LPD). Impacts to the ILS product support elements shall be considered and documented during the change management process.

Technical Manual updates shall be IAW MIL-STD-40051-2B. Training Material updates shall be IAW Instructional Systems Development (ISD)/Systems Approach to Training (SAT); a systematic approach which supports DODI 1322.20, DODI 1322.26, MIL-PRF-29612B, and MIL-HDBK 29612-2A. LPD updates shall be IAW SAE GEIA-

STD-0007-B, SEA GEIA-HB-0007-B, and SAE TA-HB-0007-1. The Contractor shall use the PowerLOG-J tool (https://www.logsa.army.mil/lec/powerlog), or equivalent, when updating the LPD Database, provided as GFI in Section J, Attachment 5.

3.4.1 CONTRACTOR OPERATED REPAIR DEPOT

The Contractor shall establish, operate, and maintain a Continental U.S. (CONUS)-based Original Equipment Manufacturer (OEM) repair depot facility to support deployed JCREW I1B1 systems. The OEM Repair Depot facility shall provide depot repair services, full system restore processes and services for hardware, software, firmware and key management, repair parts and troubleshooting that shall remedy any system failures within the time period required to effectively support meeting the Operational Availability (Ao) specified in the Performance Specification. The Contractor shall provide required spares based on the list provided as GFI in Section J, Attachment 15. The Contractor shall establish a list, grouping the Depot Repairable items into the three (3) major categories, as defined in Sections 3.4.1.1, 3.4.1.2, 3.4.1.3 of this SOW. The Contractor shall include the detail of depot actions with each Repair Parts Report.

Contractor shall implement a process to ensure that all applicable electronic test equipment used in the depot repair of JCREW I1B1 systems, LRUs, and shop replaceable units (SRUs) are properly calibrated using MIL-STD-1839D as guidance.

CDRL Repair Parts Report (A026)

3.4.1.1 CATEGORY A DEPOT REPAIR ITEMS

Category A items are those for which the cost of repair is equal to or greater than the new item cost. These items shall be classified as "Throw-Away" and the Contractor shall be authorized to replace them with new items, without further approval from the COR or the Contracting Officer. The Contractor shall ship a Depot spare replacement within the time period required to effectively support meeting the Ao specified in the Performance Specification.

Contractor shall include the details of depot actions with each Repair Parts Report (RPR).

CDRL RPR (A026)

3.4.1.2 CATEGORY B DEPOT REPAIR ITEMS

Category B items are those for which the cost of repair is less than 50% of the new unit cost. For Category B items, the Contractor shall be authorized to perform immediate repair, without pre-approval from the COR or the Contracting Officer. The Contractor shall either complete the repair or ship a Depot spare replacement within the time period required to effectively support meeting the Ao specified in the Performance Specification. Contractor shall include the details of depot actions with each RPR.

CDRL RPR (A026)

3.4.1.3 CATEGORY C DEPOT REPAIR ITEMS

Category C items are those for which the cost of repair is greater than 50% of the new unit cost and less than the new unit cost, approval to repair must be obtained from the Contracting Officer. Within seventy-two (72) hours of receipt at the OEM Depot, the Contractor shall perform an analysis of the failure and recommend material and labor hours required to effect repairs. The Contractor shall notify the Government if the analysis cannot be completed within seventy-two (72) hours. The Contractor shall provide to the Government the following minimum information: unit Serial Number (S/N), failed part description and Part Number (P/N), hour meter reading (at the sub-system level), time to repair and price to repair. Upon the Government's approval to proceed, the Contractor shall either complete the repair or ship a Depot spare replacement within the time period required to effectively support meeting the Ao specified in the Performance Specification.

CDRL Man-Hour Estimate, Technical Cost Proposal A029

Once repaired and accepted by the on-site Government representative (Defense Contract Management Agency (DCMA) QA Representative), the system/assembly shall be shipped back to the Government CONUS/Outside of the https://www.logsa.army.mil/lec/powerlog

Continental U.S. (OCONUS) point of debarkation and placed back into the spares pool. The preferred method of shipment shall be commercial next day air. The Contractor shall submit a monthly status report of all Depot activities with the RPR.

CDRL RPR (A026)

3.4.2 SPARES

3.4.2.1 INITIAL ORGANIZATIONAL-LEVEL (O-LEVEL) SUPPORT, SPARES AND

CONSUMABLES

The Contractor shall provide the initial spares and consumables necessary to support deployed operation, training, and maintenance of the systems. The initial O-level spares and consumables shall be based upon the USG provided O-Level Spares and Consumables List as identified in Section J, Attachment 14.

CDRL Parts List Initial O-Level and Initial Depot Spares Consumables Lists (A011)

3.4.2.2 INITIAL DEPOT-LEVEL (D-LEVEL) SUPPORT, SPARES AND CONSUMABLES

The Contractor shall provide all initial spare parts and consumables to support Depot Repair of the systems for twelve (12) months after final system delivery. The initial depot-level spares and consumables shall be based upon the USG provided D-Level Spares and Consumables List as identified in Section J, Attachment 15.

CDRL Parts List Initial O-Level and Initial Depot Spares Consumables Lists (A011)

3.4.3 DEPOT MAINTENANCE WORK REQUEST (DMWR) MANUALS

The Contractor shall develop and deliver a Depot Maintenance Work Requirement (DMWR) with Repair Parts and Special Tools List (RPSTL) for each system (fixed, mounted, and dismounted) IAW MIL-STD-40051-2B as promulgated by Technical Manual Contract Requirement (TMCR).

CDRL DMWR Manuals (A012)

3.4.4 ITEM UNIQUE IDENTIFICATION (IUID)

The Contractor shall include Item Unique Identification (IUID) markings on JCREW Systems and Line Replaceable Units (LRU) IAW DFARS 252.211-7003 and the TDP, Attachment 6. The Contractor shall maintain marking and verification records for all IUID qualifying items manufactured on this contract. These records shall be available for inspection by the Government at all times.

CDRL IUID Marking Activity and Verification Report (A013)

3.4.5 PACKAGING, HANDLING, STORAGE, AND TRANSPORTATION (PHS&T)

The Contractor shall establish and maintain a Packaging, Handling, Storage, and Transportation (PHS&T) program IAW MIL-STD-2073-1E, DoD Standard Practice for Military Packaging and ASTM D 3951-10 (2010), Standard Practice for Commercial Packaging guidance, and the JCREW I1B1 PHS&T Plan to be provided as GFI. The Contractor shall implement radio-frequency identification (RFID) on all shipments IAW DFARS Clause 252.211- 7006 and MIL-STD-129P.

3.4.6 MAINTAINER TOOL KIT

The Contractor shall provide a maintainer tool kit which shall contain all tools necessary for maintainers to perform the maintenance tasks outlined in the Field Maintenance Manuals, provided as GFI in Section J, Attachment 5. The maintainer tool kit shall be based on a tool kit list provided to the Contractor as GFI in Section J, Attachment 5.

3.5 CONFIGURATION MANAGEMENT

The Contractor shall develop and implement a Configuration Management (CM) Program, guided by MIL-HDBK- 61A and EIA-649-1, which adheres to the processes defined in the JCREW I1B1 CM Plan, provided as GFI in Section J, Attachment 5. The Contractor shall develop a CM Plan. The Contractor’s change management process shall be capable of processing required configuration changes in a time frame that enables identification, evaluation, and implementation of proposed changes without impact to production schedules.

CDRL Configuration Management Plan (A014)

3.5.1 CHANGE MANAGEMENT PROCESS FOR DESIGN CHANGES

In the event that the design of the system has to be permanently changed, a Preliminary Engineering Change Proposal (PECP) must be submitted and approved prior to submission of an Engineering Change Proposal (ECP) for Class I/II ECPs. All PECPs and ECPs shall be submitted IAW the approved JCREW I1B1 CM Plan.

CDRL ECP (A020)

3.5.2 NOTICE OF REVISION (NOR)

The Contractor shall provide a NOR, which as required, is an ancillary document to the ECP. This form is used to document the drawing changes associated with the ECPs.

CDRL NOR (A017)

3.5.3 REQUEST FOR VARIANCE (RFV)

The Contractor shall submit a RFV only as required. These requests are called non-permanent design changes because they are only approved for a specific set of serial numbered Configuration Items and Systems. RFVs are used to document specific Configuration Items and Systems that do not meet the documented drawing or specification requirements. RFVs require approval by the Contracting Officer and will require contract consideration from the Contractor. The Contractor shall submit proposed consideration with each RFV.

CDRL RFV (A018)

3.5.4 OBSOLESCENCE MANAGEMENT

The Contractor shall identify obsolete components during procurement of material and document the results in Source Data for Forecasting DMSMS. The Contractor shall install nomenclature and identification plates IAW the Government provided TDP, Attachment 6.

CDRL DMSMS (A019)

3.6 ENGINEERING SUPPORT SERVICES

The Contractor shall provide technical and engineering support services as directed by Government issued Technical Instructions (TI). IAW TIs, the contractor may be required to provide the necessary personnel, equipment and facilities to execute: insertion of new technologies (TIE); configuration changes; refurbishment of hardware;

procurement of materials; inventory control; generation of test, status, financial and logistics documentation;

verification of system operational specifications; sustainment engineering; vehicle installation and integration; travel and field support. The contractor shall provide a status of the following Engineering Support Services in the Contractor’s Progress, Status and Management Report:

• Total cost expended by authorized TI

• Total hours expended by authorized TI

• Summary of any TI issues encountered

• Estimate of percent complete by authorized TI

• Summary of work accomplished by authorized TI

Engineering support services tasking may include a requirement for a technical report at the conclusion of the effort.

Reporting shall be provided in the Contractor’s Progress, Status and Management Report.

CDRL Contractor’s Progress, Status and Management Report (A004)

3.7 MANAGEMENT

The Contractor shall assign a qualified Program Manager (PM) who shall have complete responsibility for the planning, execution, control and reporting of all aspects of the program, and for directing in-house and subcontractors’ efforts. The PM shall ensure all requirements are applicable to the components/parts as specified herein for all items procured. The PM shall ensure that subcontractors’, suppliers’, and vendors’ procedures are compliant with all contract requirements.

The Contractor shall maintain the Integrated Master Schedule (IMS) as a management document from each CLIN award/exercise through its period of performance. The Contractor shall provide status updates to the IMS that describes the status of the planned IMS events and milestones, accomplishments, activities, and current and potential issues, if any. The IMS shall provide most likely start dates and durations for each IMS activity and event, but shall also identify significant risk factors and their potential schedule impacts, when applicable.

CDRL Integrated Program Management Report (IPMR) (A021)

3.7.1 GOVERNMENT FURNISHED INFORMATION (GFI)/GOVERNMENT FURNISHED

PROPERTY (GFP)/GOVERNMENT FURNISHED MATERIAL

The Government will provide GFI, Government Furnished Material (GFM) and Government Furnished Property (GFP) as identified in Section J, Attachment 5. Contractor compliance with GFP requirements (see FAR 52.245-1) shall be reviewed periodically by Defense Contracts Management Agency (DCMA), which is the designated Government Property Administration Office. The Contractor shall inspect GFI/GFP/GFM within thirty (30) working days of receipt and maintain a status of and report deficiencies within any GFI/GFM/GFP discrepancies. Upon contract completion, all GFP shall be accounted for by the Contractor via letter to the COR and transferred back into Government custody.

CDRL GFI Deficiency Report (A022)

3.7.2 INTEGRATED DATA ENVIRONMENT (IDE)

The Contractor shall use the Government furnished Integrated Data (Digital) Environment (IDE) (to include Non-classified Internet Protocol Router (NIPR), Secret Internet Protocol Router (SIPR), or both) to document all aspects of the program, including the production drawings, integration and test engineering efforts, the Contractor's Systems Engineering (SE) efforts, integrated logistics support efforts, and the Contractor's PM effort. Information concerning IDE use, file structure, and access will be provided as Section J, Attachment 4. Access to the IDE will require the issuance of DoD approved Public Key Infrastructure (PKI) certificates. A maximum of three PKI certificates will be allowed for each Contractor. The Government reserves the right to review all data associated with the JCREW I1B1 FRP systems.

3.7.3 MEETINGS

3.7.3.1 POST AWARD CONFERENCE

The Contractor shall conduct a Post Award Kickoff Meeting within thirty (30) calendar days after contract award.

During the Post Award Kickoff Meeting, the Contractor shall provide a detailed briefing on its management and contract execution strategy. The contract briefing shall include: any updates following the proposal; an organizational overview; key people; schedules, specific material purchasing schedules; a description of the Contractor’s quality process, including the quality manager; and, a discussion of risk and risk mitigation strategies.

The Contractor shall plan for a three (3) day Post Award Kickoff Meeting. The Contractor shall provide read-ahead presentation materials to the Government at least four (4) working days prior to all meetings and reviews. Meeting minutes that include a detailed list of actions and responsible parties shall be generated after the conclusion of all meetings and submitted to the Government within seven (7) working days.

CDRL Presentation Material (A023)

3.7.3.2 MONTHLY…