ATTACHMENT_1_-_1A_thru_1H_16MAY2019.pdf

ATTACHMENT 1

SUPPLEMENT ATTACHMENTS TO

STATEMENT OF WORK

TABLE OF CONTENTS

MAJOR AREAS COVERED UNDER ATTACHMENT 1

Subsection 1A - Other Requirements

Subsection 1B - Quality Assurance Requirements

Subsection 1C - Configuration Management Requirements

Subsection 1D - Environmental Stress Screening and Semiconductor Testing Program

Subsection 1E - Procurement Requirements for Drawings

Subsection 1F - AEGIS Standardization Program

Subsection 1G - AEGIS Fire Control System Interim Spares (USN) and MAMs (FMS)

Subsection 1H - Contractor Drawing Requirements

SUBSECTION 1A

OTHER REQUIREMENTS

1. Sustaining Engineering

The Contractor shall provide the comprehensive technical skill services required to evaluate and resolve engineering problems related to the MK82/MK200 equipment. This shall consist of, but not be limited to conducting the necessary performance studies, trade-off studies and technical evaluations leading to the preparation of the appropriate documentation necessary to support engineering changes to be promulgated under various support contracts. Task status and accomplishments will be reported monthly to PEO IWS 1AP6. This effort shall provide the necessary engineering and management support to administer the technical aspects of the

MK82/MK200 as part of the MK99 Fire Control System.

The Contractor will continue to provide the necessary skills to operate and maintain the Fleet

Support Center (FSC). This effort will include unscheduled minor maintenance of the

MK82/MK200, performance of the Maintenance Requirement Cards (MRCs) and periodic maintenance activity. The Contractor shall schedule all testing activity and provide the necessary resources to support the tests as well as inventory control of GFE and GFM and the administrative functions necessary to maintain the FSC.

2. Technical Manuals and Provisioning Technical Documentation

The Contractor shall prepare and deliver revisions to update the DDG Class MK82/MK200 Fire

Control System Electronic Technical Manuals. These changes can be as a result of fleet Technical

Manual Deficiency Reports (TMDRs), equipment changes, maintenance corrections and/or improvements or by changes directed during Government reviews. In addition, the Contractor shall update the Provisioning Technical Documentation (PTD) by Design Change Notices (DCNs) and submit to the government via the Interactive Computer Aided Provisioning System (ICAPS).

3. Accelerometers

In the event accelerometers are required for use during shipment of hardware, they shall be supplied by the Contractor. These accelerometers are to be returned to the Contractor for reuse in subsequent shipments.

4. Identification Plates and Nameplates

Nameplates or equipment identification plates shall conform to MIL-P-15024/10 as defined in OD

32187.

5. High Reliability Soldering Specification

The Contractor shall comply with IPCJ-STD-001E (Class 3), Requirements for Soldered Electrical and Electronic Assemblies.

6. Electrostatic Discharge Control Program

The Contractor shall maintain an Electrostatic Discharge Program Plan in accordance with MIL-

STD-1686 (MIL-HDBK-263 is to be used for guidance) with exceptions as noted in the

Government approved MIL-STD-1686 exception matrix. Electrostatic discharge control program compliance shall be subject to review and auditing by the Government. Addition of protective circuits to existing designs shall not be required.

7. Serial Numbers

Serial numbers shall be sequentially assigned, unduplicated, for each of the end items provided under this contract, and to lower tiered units and assemblies, down to the Lowest Line Replaceable

Unit (LRU). The Government shall provide a set of numbers for each end item and will specify the method of serialization for LRUs. A status accounting record shall be prepared and delivered with each end item shipped.

8. Safety

The Contractor shall take appropriate measures to ensure that the equipment safety achieved in the design is not compromised during the production process. MIL-STD-882 shall be used as guidance.

The Contractor shall conduct a safety review of new operating and maintenance procedures and technical manuals, or changes thereto, to ensure that the procedures, warning, cautions and other safety information are adequate, and that inherent safety is not degraded.

The Contractor shall provide a statement of safety impact with each engineering change or waiver request. Existing hazards analyses shall be updated to reflect approved engineering changes.

9. OD 32187

The AEGIS Standards Manual VOLS I & II will be modified by STD Bulletins reflecting the most recently approved Non-Standard Parts. The effective version of OD 32187 as applied to this contract shall include all STD Bulletins issued prior to and during the performance of this instant contract.

All AEGIS approved parts, material and processes, as delineated in the AEGIS Program Standards

Manual OD 32187 and referenced, Electronic Listing of Nonstandard Parts, may be used without further approval by the originally submitting Contractor.

10. MIL-HDBK-2036 “GENERAL REQUIEMENTS FOR ELECTRONIC EQUIPMENT

SPECIFICATION”

Modifications:

Painting requirements contained in MIL-HDBK-2036 are tailored as follows:

(a) Primer: One coat of primer conforming to TT-P-1757or TT-P-645 shall be applied. The primer shall have a dry film thickness of 0.0006 to 0.0008 inch.

(b) Enamel: Enclosures shall be painted with two continuous film coats of grey enamel conforming to MIL-C-22750 or MIL-E-24635.

Each coat shall have a minimum thickness of 0.001 inch, dry film thickness. Enamel for shipboard portable equipment enclosures shall conform to Class 1 of MIL-C-22750 or Class 1 of MIL-E-24635. Enamel for other protected equipment shall conform to Class 2 of MIL-C-

22750or Class 3 of MIL-E-24635.

SUBSECTION 1B

QUALITY ASSURANCE REQUIREMENTS

I. CONTRACT PROVISIONS

A. The Contractor shall provide and maintain a quality program acceptable to the Government for supplies and services covered by this contract. The Quality Program shall be in accordance with ANSI/ISO/ASQC Q9001 or AS9100C

B. Quality Assurance Contract Requirements implementing, supplementing or contrary to

ANSI/ISO/ASQC Q9001 or AS9100 shall be in accordance with the Quality Provisions included herein.

C. Definitions

Quality System may be referred to as “Quality Program” and/or “Quality Management

System”.

Supplier may be referred to as “Vendor” or “Sub-Contractor”.

Organization may be referred to as “Contractor”.

Customer and Government are the same and refer to the body of the government procuring, administering or providing contract oversight activities.

NOTE: If the Contractor has previously provided a Quality Assurance Program Plan (QAPP) that was found acceptable in accordance with ANSI/ISO/ASQC Q9001 or AS9100 and/or satisfied the requirements of previous contracts for the same supplies or services required herein, it shall be acceptable for this contract except all changes to the original

QAPP shall be approved prior to implementation. When the Contractor proposes changes in the QAPP, IWS 1AP shall be notified in writing of the proposed changes and obtain approval of IWS 1AP in writing prior to implementing the change.

II. QUALITY ASSURANCE REQUIREMENTS

A. The Quality Program shall be in accordance ANSI/ISO/ASQC Q9001 or AS9100 and the requirements stated herein:

1. The Contractor shall comply with all the requirements of ANSI/ISO/ASQC Q9001-- or

AS9100 and these provisions with regard to all supplies and services developed and delivered under this contract. This applies to items manufactured or performed by the

Contractor at his plant or any other outsourced facility.

2. The Contractor shall flow-down in his purchasing documents the appropriate quality requirements to all suppliers, e.g. AS9100C, ANSI/ISO/ASQC Q9001 or ISO 9001

Quality Program, Inspection System, or the AQAP Century Series. The quality requirement imposed on the supplier shall be based on complexity and criticality of the items being procured. The Contractor shall identify in the purchase document any item which is critical to the deliverable product and require the supplier to submit their quality program or inspection system documentation for review and approval prior to production. These plans shall be made available to the designated Government representative upon request.

B. The following Quality Assurance Provisions are incorporated. These provisions interpret or supplement provisions contained in the referenced clauses of ANSI/ISO/ASQC Q9001- or

AS9100.

1. Notwithstanding, the requirements of ANSI/ISO/ASQC Q9001 or AS9100:

“The Quality System shall be judged acceptable by the Contractor and the Government representative before fabrication or procurement of any product for eventual delivery.

Acceptance of the Contractor's Quality Program shall not in any way relieve the

Contractor of his responsibility for compliance with all contract requirements."

2. Notwithstanding, Clauses 4.1 General Requirements:

The authority and responsibility of personnel performing quality functions shall be stipulated in the company organization plan or other appropriate document. Personnel responsible for directing and implementing the quality system shall have direct unimpeded access to a management level sufficient to provide solutions to quality problems and shall report on the status and adequacy of the quality System Quarterly.

The report and documented review thereof shall be made available to the Government representative.

3. Notwithstanding, Clause 4.2.2 Quality Manual:

The Contractor’s quality assurance system shall be documented in the form of a Quality

Assurance Program Plan (QAPP) which shall contain a description of the quality organization (including the responsibility and authority for each functional element), flow charts, work instructions and other documentation prepared to implement the

Quality System. The plan shall identify all policies, existing instructions and procedures which are necessary to comply with the provisions of this standard. The plan shall be made available for review by the Government representative and must be judged acceptable before implementation of the Contractor’s quality assurance program.

Subsequent to acceptance of the QAPP, the Government representative shall be notified within 10 days of instituting any change to the QAPP.

The Government’s right to perform independent assessments is recognized by the

Contractor including the Government’s right to disapprove the Contractor’s quality program whenever procedures do not accomplish their objective.

4. Notwithstanding, Clause 4.2.3 Control of Documents:

All fabrication, assembly, inspection and test instructions shall be placed under the

Contractor's document control system to the extent necessary to maintain control of changes.

5. Notwithstanding, Clause 4.2.4 Quality Records:

The Contractor shall maintain records of all tests and formal inspections performed throughout the entire process, fabrication and assembly cycle. The records shall provide objective evidence that required inspections and tests have been performed and shall include part, component or system identification, inspection or test involved, number or articles inspected or tested, number rejected, and causes for rejection. The records shall cover both conforming and nonconforming items. Where variable data are involved, the actual numerical result obtained shall be indicated, and were data or information are recorded, the film, tape or other recording media shall be identified with the characteristic measured, the date and identification of the article under test. For nonconforming articles, the records shall include the results of analysis, cause and corrective action taken. These records shall be available for review by the Government

Representative and copies of individual records shall be furnished on request.

6. Notwithstanding, Clause 6.2.2 Competence, Training, and Awareness:

The Contractor shall determine indoctrination and training requirement of this contract and based upon this, establish a training program for manufacturing, quality control and other personnel whose work affects the quality of the product. Personnel responsible for manufacture, inspection and control of special processes and operations that require special skills that could affect product quality shall be certified.

Records indicating course, schedule, detailed content and personnel attending shall be maintained and a method established for identifying certified personnel at the location where they conduct operations for which they are certified.

7. Notwithstanding, Clause 7.2 Customer-Related Processes:

The quality program shall assure that there is complete compliance with contract requirements for proposing, approving and effecting of engineering changes.

The quality program shall provide for monitoring effectively compliance with contractual engineering changes requiring approval by Government design authority.

The quality program shall provide for monitoring effectively the drawing changes of lesser importance not requiring approval by Government design authorities.

Delivery of correct drawings and change information to the Government in connection with data acquisition shall be an integral part of the quality program. This includes full compliance with contract requirements concerning rights and data both proprietary and other.

The quality program’s responsibility for drawings and changes extend to the drawings and changes provided by the subcontractors and vendors for the contract.

8. Notwithstanding, Clause 7.1 Planning for Product Realization:

Flow charts, indices or listings shall be prepared outlining each step in the fabrication, processing, inspection and testing operations for each item of assembly. Identification numbers shall be assigned to specifications, inspections, work instructions and test procedures. The flow charts, indices or listings shall utilize these identification numbers so as to provide a complete fabrication sequence.

Fabrication and assembly instructions shall define the work to be done, the step-by-step method for accomplishment, tooling and test or inspection equipment required the criteria for acceptance, record keeping instructions and disposition. Use of multi-color or multi-shade graphics, diagrams, overlays and visual standards should be made when practicable.

The contractor shall monitor and measure the characteristics of the product/assembly to verify that the product requirements have been met. This shall be carried out at the appropriate stages of the assembly process in accordance with the assembly process plan. Evidence of conformity to the acceptance criteria shall be maintained through the use of the “Assembly & Subassembly Manufacturing Quality Reports” (i.e. DPMO

Charts, Pareto Charts, Histograms, etc.).

All instructions shall be legible, shall contain the date of issue and revision level and shall be subject to audit under Clause 8.2.2 Internal Audit. Handwritten changes may be made because of special or unusual circumstances provided they are accomplished in accordance with the Contractor’s approved change control procedures and are authenticated by responsible personnel. The instructions shall be clearly legible and shall be protected from damage by appropriate means. Faded, defaced, illegible or otherwise damaged instructions shall be replaced promptly.

All instructions shall be accessible to the operator at all times. No operation shall be performed without direct access to the appropriate instructions.

Written inspection and test procedures shall be prepared as appropriate for each inspection and test operation to be performed by the Contractor. These inspection and test procedures shall be maintained current in accordance with the change control system requirements. The inspection and test procedures shall include the following:

(1) Identification of the item to be inspected or tested.

(2) Identification of or reference to measuring and test equipment, listing type, manufacturer, and model number except for Standard Measuring Instruments, such as inside and outside micrometers, plug and ring gauges.

(3) Detailed operations to be performed by the test operator, including operational checks and/or preliminary calibration of test setup.

(4) The characteristics to be inspected, with inspections defined in terms of:

(i) The conditions that shall exist at each inspection or test point;

(ii) The tolerance limits that define conformance.

(iii) On Multi-scale Devices, the particular scale, dial or device to be observed;

and

(iv) The method for performing the inspection or test, including manipulation of controls on the item and on the inspection and test equipment.

(5) Data collection requirements, such as data sheet, time/cycle logs and control charts.

(6) Conditions to be maintained during inspection and test, including environment when required.

(7) Special precautions to be followed for safety of personnel and to prevent damage to the items and to the inspection and test equipment.

(8) Criteria for passing or failing the test and for determining the conformance and nonconformance of the item.

(9) Details of the acceptable condition for visual inspection characteristics by reference to workmanship.

(10) Details of sampling plans to be used.

Inspection and Test Planning. The Contractor’s program shall provide the necessary planning function for tests and inspection conducted during the entire phase of fabrication, processing and assembly. The planning shall be based on a comprehensive study of the supplies, the fabrication and processing operations, the methods of material integration, assembly and checkout and the final test and inspection procedures.

Inspections shall be established at points which will minimize delays resulting from deficiencies, and in all cases shall be at or before the last point at which the acceptability of the operation or quality of the characteristic may be verified.

Process Control Procedures. Process control procedures shall be prepared when necessary to supplement applicable process specifications to provide detailed performance and control methods. These procedures shall document the preparation, fabrication details, conditions to be maintained during each phase of the process, the method of verifying the adequacy of processing materials, solutions, equipment, their associated control parameters, including statistical quality control plans where applicable, and the required records to indicate the results of such inspection and process verification. The Contractor’s quality organization shall review the written procedures for these process controls and conduct audits to determine that the actual operations conform with approved methods and procedures.

9. Notwithstanding, Clause 7.3.7 Control of Design and Development Changes:

The quality program shall assure that there is complete compliance with contract requirements for proposing, approving and effecting of engineering changes.

The quality program shall provide for monitoring effectively compliance with contractual engineering changes requiring approval by Government design authority.

The quality program shall provide for monitoring effectively the drawing changes of lesser importance not requiring approval by Government design authorities.

Delivery of correct drawings and change information to the Government in connection with data acquisition shall be an integral part of the quality program. This includes full compliance with contract requirements concerning rights and data both proprietary and other.

The quality program’s responsibility for drawings and changes extend to the drawings and changes provided by the subcontractors and vendors for the contract.

10. Notwithstanding, Clause 7.4 Purchasing:

A Quality Program Plan conforming to the specified Quality requirement and this document shall also be required of subcontractors producing items defined by Critical

Item Product Specifications. The program shall be approved by the Contractor and shall be made available to the designated Government representative upon request.

The contractor’s responsibility shall include assistance and training to suppliers as necessary to achieve required quality levels.

The Contractor shall have access to objective evidence that the subcontractor complies in detail with applicable requirements in accordance with Clause 4.2.4 Control of

Records. Objective evidence shall include inspection data supplied by the subcontractor, source inspection data and /or receiving inspection data.

The Contractor shall assure that all specified inspections and tests required for acceptance (including qualification, preproduction and quality conformance) have been satisfactorily performed. Evidence of such inspections and tests shall be made available to the Government upon request.

The Contractor’s written procedure shall indicate that procurement documents are reviewed by the Contractor’s quality organization prior to release and shall be available for review by the Government representative. This review shall encompass determination that the applicable provisions of this paragraph are included, that the supplier has been approved in accordance with the source selection requirements of

Clause 7.4.1 Purchasing Process.

11. Notwithstanding, Clause 7.4.3 Verification of Purchased Product:

Qualified Products List (QPL) only signifies that at one time the manufacturer made a product which met specifications requirements. It does not relieve the contractor of his responsibility for furnishing supplies that meet all specification requirements for the performance of specified inspections and tests for such material.

The Government reserves the right to perform quality audits to verify the prime

Contractor and subcontractor’s compliance with their Quality Programs. Such audits will consist of evaluations of records, processes and products.

The Contractor will be notified of deficiencies found during these audits and will be given a specified period of time to correct such deficiencies.

The Contractor shall make available to the Government Representative reports of any nonconformance found on Government source-inspected supplies and shall (when requested) require the supplier to coordinate with his Government Representative on corrective action.

The Quality Program shall provide for planning and performance of inspections and tests on all supplies to assure verification of quality requirements of specifications and drawings. The quality and degree of inspection performed shall be consistent with the complex and critical nature of the article. Supplies shall not be accepted in stores or into production without satisfactory evidence that such inspection was accomplished.

Procured supplies which are subject to age deterioration shall include an indication of the date that the critical life of the article was initiated and the date after which the material shall not be used in the manufacturing process. All such supplies shall be adequately controlled in subsequent stores and handling operations, and the expiration date shall be prominently marked on each of the smallest containers that may be issued for use.

12. Notwithstanding, Clause 7.5.3 Identification and Traceability:

All material and products received at the plant shall be clearly identified and this identity maintained in storerooms and during processing in order that receipts for this contract may be readily identified. Receipts shall be specified at receiving and this identification shall be maintained either on the fabricated article or on records traceable to the fabrication article. The receipts released from the Contractor receiving inspection shall be clearly identified to indicate conformance or rejection.

Inspection and testing records shall, as a minimum, indicate the nature of the observations, number of observations made, date of observations, individual making the observations and the number and type of deficiencies, found. Data included in inspection and test records shall be complete and accurate and shall be used for trend analysis and to assess corrective action effectiveness.

13. Notwithstanding, Clause 7.5.4 Customer Property:

This section articulates clear provisions for handling government property and material.

The term “material” applies to government-furnished equipment to be installed in or furnished with the end item. The term “property” is government equipment that is used in the fabrication or assembly of the end item, and is not delivered as part of the end item.

When material is furnished by the Government, the Contractor’s procedures shall include at least the following:

a. Examination upon receipt, consistent with practicality, to detect damage in transit;

b. Inspection for completeness and proper type;

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

d. Functional testing, either prior to or after installation, or both, as required by contract to determine satisfactory operation;

e. Identification and protection from improper use or disposition; and

f. Verification of quantity.

The Contractor shall report to the Government representative any Government-furnished property found damaged, malfunctioning or otherwise unsuitable for use. In the event of damage or malfunction during or after installation, the Contractor shall determine and record probable cause and necessity for withholding material from use.

The Contractor shall, as required by the terms of the Bailment Agreement, establish procedures for the adequate storage, maintenance and inspection of bailed customer property. Records of all inspections and maintenance performed on bailed property shall be maintained. These procedures and records shall be subject to review by the

Government representative.

14. Notwithstanding, Clause 7.6 Control of Monitoring and Measuring Equipment:

Calibration. The Contractor shall maintain a system for calibration of all measuring devices against standards of proven traceable accuracy, in accordance with AS9100

“Control of Monitoring and Measuring Equipment”.

Tool and Gauge Control. The Contractor shall maintain a system for the selection and control of inspection and production tools, measuring instruments, test equipment and controlling or recording instruments. All such devices must perform to the degree necessary within the envelope of engineering parameters relative to accuracy range, resolution, tolerance, sensitivity, regulation and other applicable requirements.

Special Purpose Test Equipment. All special purpose test equipment shall be validated as appropriate by the Contractor prior to use under this contract. This requirement includes all final acceptance equipment and major subassembly test equipment with provisions for including lower level equipment if problems or circumstances indicated such a requirement. The requirement applies to both prime and major subcontractors.

Contractor procedures shall provide for special purpose test equipment to assure that the test system accuracy, stability, operability, calibration procedures and techniques, operation procedures, servicing requirements, environmental requirements, drawings, fault detection, correlation with similar equipment, supporting equipment, calibration marking and records, and control of unauthorized access are acceptable.

Production Tools and Inspection Media. When production gauges, jigs, fixtures, test equipment or other manufacturing devices are used as inspection or test media, they shall be initially inspected or calibrated for accuracy and shall be proof tested prior to release for production and at established intervals thereafter. The Contractor shall determine the extent and frequency of such inspections as part of its inspection procedures and shall maintain records of inspection or other conclusive evidence that control is being maintained.

Use of Contractor’s Inspection Equipment. The Contractor’s gauges, and measuring and testing devices shall be made available for use by the Government when required to determine conformance with contract requirements. If conditions warrant, the

Contractor’s personnel shall be made available for operations of such devices and for verification of their accuracy and condition.

Test Software (i.e. non-deliverable software). Reference DOD-STD-2168, “Defense

System Software Quality Program:

Only paragraphs 4.7, 4.8 and 5.6 shall apply as follows:

Implementation of paragraphs 4.7 (software quality records) and 4.8 (software corrective action) shall be limited to the evaluation of non-deliverable software per paragraph 5.6 and previously identified non-deliverable software that has been requested for delivery by the Navy. All records provided will be in contractor format.

15. Notwithstanding, Clause 8.2.2. Internal Audits:

The Contractor’s quality system shall include an on-going process of audits to ensure that the documented quality system is implemented and working as planned and that effective corrective action is taken when it is not.

The procedures for performing Internal Quality Audits shall be documented and maintained. Audits shall be planned and scheduled on the basis of status and importance of the activity to be audited. Auditors shall be independent of any responsibility for the activity being audited. As a minimum, the requirements of this standard shall be audited annually.

The results of audits shall be recorded and reported to management and personnel having responsibility for the action being audited who, in turn will take timely corrective action in response to any nonconformities found during an audit.

Follow-up audit activities shall verify and record implementation and effectiveness of corrective actions taken.

16. Notwithstanding, Clause 8.3 Control of Non-Conforming Product:

The Contractor’s system for controlling nonconforming material shall comply with the requirements of MIL-STD-1520 as tailored in Attachment A1. Repair and rework of nonconforming material shall be in accordance with documented procedures acceptable to the Government.

17. Notwithstanding, Clause 8.4 Analysis of Data:

Quality Reporting shall be used to define the quality level of the assembly & subassembly process in conjunction with the Defect Reduction Program.

The contractor shall monitor and measure the characteristics of the product/assembly to verify that the product requirements have been met. This shall be carried out at the appropriate stages of the assembly process in accordance with the “Assembly and

Subassembly Manufacturing Quality Report” and the “Manufacturing Defect Reduction

Report”.

18. DEFECT REDUCTION PROGRAM

As part of the requirements of the AEGIS Weapon System quality requirements, the

Contractor shall have a defect reduction program that includes an organized data collection and corrective action system. The Contractor will implement a Defect

Reduction Program as described herein. The Defect Reduction Program shall include maintenance of a corrective action and disposition system for non-conforming material in accordance with the requirements of MIL-STD-1520, except as “tailored” in attachment A1. This system will incorporate statistical process control techniques designed to continuously improve quality and reduce the number of defects in all procurement, processing, assembly, and test areas involved in the manufacture of items to be delivered under the contract. The Contractor’s defect reduction program shall be fully documented and made part of the Quality Assurance Program Plan to include an

End Item Manufacturing Defect Reduction Report. Defect data shall be organized, formatted and presented as required in this attachment. Defect history data shall be reported to the Government on any item that falls into one or more of the following categories:

(1) Weapon Replaceable Assembly (WRA)

(2) Lowest Order Replacement (LOR) items as identified in Logistics Support

Analysis (LSA)

(3) Lowest assembly level identified with S/N

(4) Controlled configuration item

(5) Any assembly level higher than 1, 2, 3, or 4 above

Defect history data shall identify the defect rates between adjacent production units and shall be plotted with the units in chronological order of production against the corresponding defect rates. The Contractor will determine the appropriate defect rate computation for the level of assembly being reported. Commonly used defect rates for plotting defect history follow:

a. Defect per Unit (DPU);

b. Defects per Million Opportunity (DPMO).

DPMO equates to Parts per Million (PPM).

The corrective action threshold shall be plotted as an Upper Control Limit (UCL) using

Poisson distribution theory at the 97.5% confidence level or 3 sigma limits on the

Poisson approximation to the normal distribution. The process averages shall be computed at least once quarterly for the reporting period. There shall be immediate aggressive corrective action taken whenever the defect rate is greater than the corrective action threshold.

Defect distribution data shall be analyzed at the same hardware levels as in paragraph b., above. Defect distribution should be subjected to “Pareto” analysis and plotted in bar graph showing the defect classifications that contribute most to the overall defects.

The defect classifications shall be charted in descending order of cumulative frequency occurrence. The charts shall be drawn quarterly, and if production rates are low, may be cumulative.

Defect reduction charts shall be kept in "learning curve" format on log-log paper beginning with the first production unit. These charts shall be kept at assembly level 3 of the AEGIS Weapon System Work Breakdown Structure. Defects per unit at his level shall be plotted on the vertical axis with the cumulative number of corresponding units on the horizontal axis. The chart should be approximately linear with a negative slope to show learning progress. This chart is a top management tool and management use of the learning curve shall be discussed at the program review.

20. Software Quality Assurance Program – See clause 7.6.

21. COST RELATED TO QUALITY

The Contractor shall maintain and use quality cost data as a management element of the quality program. Specific cost data to be maintained and used will be determined by the Contractor. This data shall, on request, be identified and made available for “on-site” review by the Government Representative.

SUBSECTION 1C

CONFIGURATION MANAGEMENT REQUIREMENTS

I. CONFIGURATION MANAGEMENT PROGRAM

The Contractor shall provide the administrative systems and disciplines necessary to perform configuration identification, change control, status accounting and reporting, and auditing of the material and data required herein in accordance with the defined production baseline and with the

Contractor's approved AEGIS Configuration Management Plan implemented by Contractor

Program Directives. The configuration management effort shall encompass a framework of management policies, procedures, instructions and practices to accomplish effective coordination and control of the production baseline.

The Contractor shall prepare for approval and maintain an AEGIS Configuration Management Plan

(CMP) to meet the requirements of MIL-STD-480 and this attachment.

II. PRODUCTION CONFIGURATION BASELINE(S)

The production configuration baseline for the configuration items specified in Section B of the RFP as defined in the TDP.

III. CONFIGURATION IDENTIFICATION

The Contractor shall maintain a disciplined process to document the physical and functional characteristics of each configuration item required under the contract as defined in his approved

AEGIS Configuration Management Plan. The Contractor shall maintain and ensure accuracy of drawings, specifications, engineering lists and other data as required to fully define each configuration item.

The Contractor shall provide information to the AEGIS Combat System (ACS) Design Agent for establishing and maintaining the required configuration item identification data.

IV. CONFIGURATION AUDITS

A. The Contractor shall maintain an effective Configuration audit process in accordance with the approved AEGIS Configuration Management Plan to provide a configuration audit process for the configuration items required under the instant contract. The Contractor's process shall verify that each Configuration Item (CI) and its configuration identification are accurate, complete and meet the CI's functional and physical characteristics and contract requirements. This shall be accomplished as a continuing process of surveillance of methods, controls, tests and accuracy of the status accounting records. Government representatives may review of participate in this process at their discretion.

B. The Contractor shall verify that the technical data package to be released to the production facility is in compliance with the production configuration baseline specified in the instant contract and applicable drawing lists.

C. Functional Configuration Audits (FCAs) or Physical Configuration Audits (PCAs) may be required and directed by the Government as a result of deficiencies in the

Contractor's audit process, as a result of authorized changes, or breaks in production.

In the case of authorized changes an FCA and/or PCA, as directed, shall be conducted for the first of each item produced/delivered under this contract which is modified by an authorized change to the configuration baseline of the item. These audits will be conducted in conjunction with the Administrative Contracting Officer

(ACO)/AEGIS Program representatives at their discretion. "Item" in this context is defined as the lowest order unit(s) assembly(ies) or subassembly(ies) to which the configuration modification applies. Contractor shall be responsible for the accuracy of Label Plates and Modification Plates for each physical configuration item.

V. CONFIGURATION STATUS ACCOUNTING

The Contractor shall update and maintain the Configuration Status Accounting Report in accordance with SAE ANSI / EIA-649.

The Contractor shall provide information to the AEGIS Combat System Design Agent for updating and maintaining the AEGIS Status Accounting System.

VI. CONFIGURATION CONTROL

The Contractor shall maintain all documentation defining AEGIS configuration items

(specifications and drawings) under a configuration control process in accordance with MIL-STD-

480. Control of changes to the Production Configuration Baseline (and delivered configuration items) shall be as prescribed herein.

A. Configuration Control Board. The Contractor shall operate the Configuration Control

Board (CCB) as described in the Contractor's approved Configuration Management

Plan to review all proposed changes originated from any source. The Government reserves the right to participate in the operation of the Contractor's Configuration

Control Board at the Contractor's facility.

B. Ship Change Documents. The Contractor shall submit Ship Change Documents

(SCDs) in accordance with PEO IWS 1AP Combat System Change Control Procedures

Manual. The SCD describes the concept of a change and must be approved by the PEO

IWS 1AP Local Configuration Control Board (LCCB). An approved Phase 1 SCD is required prior to beginning development of Engineering Change Proposals.

C. Engineering Changes Proposals. The Contractor shall submit any Engineering

Changes Proposals in accordance with MIL-STD-480. All Class I changes, except those defined as Class I (compatibility) in MIL-STD-480, shall be clearly marked as such and approved or disapproved and, if approved, issued by the Naval Sea Systems

Command Principal Contracting Officer. Those defined as Class I (compatibility) shall be clearly marked as such and shall be approved or disapproved and, if approved, issued by the ACO.

Once the ECP has been approved, a Configuration Control Board Directive (CCBD) will be issued by PEO IWS 1CM.

Any corrections or comments included in the CCBD shall be addressed/corrected in the next update of the ECP, if and when an update is required. No updated ECP is required simply to agree with the CCBD.

All proposed Class II changes shall be handled as follows:

1. The Contractor proposing the change shall submit a copy to the ACO for review.

2. Concurrent with the submittal to the ACO, a copy will be provided to the

ACS Design Agent for review. If no response is received within thirty (30) working days, the Contractor proposing the change will assume that there is no impact on the ACS.

3. Concurrence as to the classification of Class II changes shall be made by the

ACO.

D. Engineering Deviations/Waivers

Each request for deviation or waiver shall be prepared and submitted by the Contractor in accordance with the requirements of 5.3 and 5.4 of MIL-STD-480 and MIL-HDBK-61A shall use the forms referred to therein. Minor deviations will be approved or disapproved by the ACO. Minor waivers will be approved or disapproved by the local Material

Review Board which shall include at least one member from the cognizant DCMA office whose vote for approval shall be necessary for approval of the minor waiver. Approval or disapproval of major or critical deviations and waivers shall be made by the PCO.

E. Change implementation. The Contractor shall implement those SCDs approved by the

Government's Configuration Control Board (CCB) and as authorized by the Principle

Contracting Officer and those Class II changes approved by the Contractor's CCB. The

Contractor shall update all approved configuration changes throughout the applicable configuration identification documentation and verify that the documentation accurately defines the production baseline as modified, and the as-built configuration.

F. Coordination of Configuration Control. The Contractor shall coordinate with and assist the ACS Design Agent to ensure that all aspects of configuration control are fully performed and configuration documentation is maintained current.

SUBSECTION 1D

ENVIRONMENTAL STRESS SCREENING

AND SEMICONDUCTOR TESTING PROGRAM

I. Environmental Stress Screening Program Requirements

The Contractor shall conduct an Environmental Stress Screening (ESS) Program which shall be considered as part of the manufacturing process under the control of the Contractor subject to

Government surveillance. The objective of the ESS Program shall be to transform latent part and workmanship defects into detectable failures for their elimination prior to delivery of the equipment to the ultimate users and to adjust manufacturing processes as necessary to eliminate or reduce the frequency of latent defects. The ESS Program Plan shall be a part of the Contractor's Reliability and Maintainability Program Plan. The plan shall be approved by the AEGIS Program Office prior to implementation of the ESS Program. The Contractor shall analyze and report on the effectiveness of its ESS Program in the Tri-annual R&M Corrective Action Summary Report.

Environmental Stress Screening levels used by the Contractor for each equipment type subjected to screening shall be based on the use of TE000-AB-GTP-020 as a guideline. However, at no time shall equipment be stressed at or beyond their design limits.

The ESS Program shall be dynamic in nature and structured so that high screening effectiveness is obtained without causing equipment degradation due to overstress or incurring prohibitive cost or schedule impacts on the manufacturing process. The program shall be designed so that the manufacturing process can readily be adjusted to minimize recurrence of defects found during stress screening. Records shall be kept on failure, rework and yield data and reviewed and analyzed on a regular basis to monitor the overall effectiveness of the program. All such records and analysis results shall be made available to the Government. Changes to the ESS Program to make it more cost-effective are encouraged. The Contractor is expected to make recommendations based on its assessment of screening effectiveness and the Navy shall request changes as appropriate. The

Contractor may flow down environmental stress screening requirements where applicable to subcontractors. Responsibility for the ESS Program remains with the Contractor and subcontractor

ESS programs shall be documented in the Contractor's R&M Program Plan.

II. Environmental Stress Screening Plan

The ESS Plan shall provide a detailed description of the ESS Program at all levels of ESS testing

(e.g., Parts/Components, Circuit Card Assemblies). The plan shall identify the ESS test parameters, provide the rationale for test parameter selection and verify that the parameters do not induce harmful effects that would shorten the life, or reduce the reliability of the equipment. The ESS plan shall describe the Contractor's process of ESS data analysis and effectiveness evaluation and its process for feeding back the results to adjust the manufacturing program to minimize recurrence of defects found during ESS.

The requirements of this SOW are general requirements for ESS in AEGIS Weapon System (AWS) production programs. It is expected that any previously approved AWS contractor ESS program will satisfy these requirements. When submitting revisions for Government approval, the

Contractor shall identify the differences from the most recently approved ESS plan and provide rationale for these differences.

III. Environmental Stress Screening Requirements

A. Parts

The ESS approach for semiconductors, microcircuits and other parts shall be function of whether military parts are used or not. Rescreening of parts shall consist of: electrical

(Go/No-Go), Hermetic seal, PIND (Particle Impact Noise Detection) (as appropriate), and Destructive Physical Analysis (DPA) as required.

Non-military Parts shall be tested on a 100% basis if there is no previous defect rate data. If the defect rate for the last 12 months of screening is below 0.5%, the Contractor may develop a sampling program provided it has substantiating data. The Contractor shall return to a 100% testing basis if the sample screening defect rate exceeds 1.0%.

B. Printed Wiring Assemblies (PWAs)/Circuit Card Assemblies (CCAs)

PWAs/CCAs shall be subjected to thermal cycling stress screening. Temperature shock may be substituted for temperature cycling. Power on/off cycling or operating is not required during screening. During thermal cycling, the temperature shall be measured on the unit under test (UUT) and the temperature range shall be such that the difference in the low and high temperature range shall be 120C. The temperature range shall be within the design limits of the unit.

The Contractor may elect to subject selected PWAs/CCAs to non-operating random vibration screening. The actual response to the vibration stimuli shall dictate the vibration levels and the PWAs/CCAs shall be subjected to at least two axes of vibration.

The ESS Plan shall fully describe the Contractor's screening levels (e.g., temperature range, number of axes, acceleration spectrum and duration of vibration). See Note (1).

C. Subassemblies (Power Supplies, Modules, Chassis)

Each power supply, module, chassis and other electrically testable subassembly shall be subjected to random vibration and temperature cycling non-operating. Low voltage power supplies, RF modules and other Contractor selected items may be subjected to

ESS while operating. Vibration profiles for the UUT shall be based on actual response to vibration stimulus and shall not overstress the UUT. Temperature shall be measured on the UUT. (See Note (1).

Note (1): The Contractor can reduce sample screening if the historical defect rate of an item with 2000 or more units screened is 0.2% or less.

SUBSECTION 1E

PROCUREMENT REQUIREMENTS FOR DRAWINGS

I. PROCUREMENT REQUIREMENTS FOR DRAWINGS

A. All applicable drawings and associated lists will identify ”Dimensioning & Tolerancing,” under ASME-Y14.5-2009 (Data specified under subsection 1A in this attachment).

B. All drawings and associated lists except Interface Control Drawings (ICD) and Tools, Jigs and fixture drawings shall satisfy Level 3 drawing requirements. ICD and Tools, Jigs and fixture drawings shall be Level 2.

C. The Government Design Activity name and Commercial and Government Entity (CAGE) number will be placed in the Title Block of the engineering drawings and associated lists.

D. Drawings prepared with Naval Sea Systems Command as Design Activity shall use CAGE

Code 53711. NAVSEA drawing numbers shall be obtained from the Naval Sea Systems

Command, Code 04L2 (Mr. Richard Skillman), 1333 Isaac Hull Ave. SE, Washington Navy

Yard, DC 20376, (202) 781-3413, richard.skillman@navy.mil.

The new production units may contain non-approved mil parts and non-mil parts identified by

Raytheon Corporate part numbers and on Raytheon format. Non-Mil IC's are limited to commercial ceramic devices (not plastic). None of the above "grandfathered" parts require submittal of individual NSPARS. Any parts/components changed or added during the performance of work under this contract will have individual NSPARS.

E. Not applicable.

F. The applicable Data Item Descriptions are DI-CMAN-80776 (Technical Data Package), DI-E-

7031 (Engineering Drawing and Associated Lists), DI-3130 for Process Specifications; and

DI-E-3131 for Material Specifications.

G. Metric System will not be used.

H. Use of Electrical and Electronic Reference Designations will be in accordance with ANSI

Y32.16-1975 in lieu of ANSI Y32.16-68. For existing drawings use ASMEY14.5M-82 in lieu of ANSI Y14.5-73.

I. The practice of converting Lockheed Martin MS2 or Raytheon standards to "WS" identification will continue to be acceptable for process and material specifications. The applicable Data Item

Descriptions (DIDs) are DI-E-3130 and DI-E-3031, respectively.

J. Technical Data Package Index (TDPI) in accordance with the CDRL requirements and Parts Lists in contractor format shall be used.

mailto:richard.skillman@navy.mil

K. A Parts List shall be prepared for each assembly. A TDPI shall be prepared in accordance with

CDRL requirements. It shall include all AEGIS systems…