N0017418R0031_Amendment_01_Conformed.docx

N0017418R0031

Section B - Supplies or Services and Prices

57mm HE-PD First Article Test Report

FFP

First Article Test Requirements/Report in Accordance with the SOW

CDRL A017

FOB: Destination

PSC CD: 1310

NET AMT

57mm HE-PD Lot Acceptance Testing

Lot Acceptance Test Requirements in Accordance with the SOW

CDRL A019

NET AMT

57mm HE-PD Production Units

Production Units in Accordance with the SOW.

NET AMT

57mm HE-PD Shipping

NET AMT

CDRLs

Exhibit A In Accordance with the SOW, and CDRL List.

Not Separately Priced (NSP)

NET AMT

CLAUSES INCORPORATED BY FULL TEXT

HQ B-2-0004 - EXPEDITING CONTRACT CLOSEOUT (NAVSEA) (DEC 1995)

(a) As part of the negotiated fixed price or total estimated amount of this contract, both the Government and the Contractor have agreed to waive any entitlement that otherwise might accrue to either party in any residual dollar amount of $500 or less at the time of final contract closeout. The term "residual dollar amount" shall include all money that would otherwise be owed to either party at the end of the contract, except that, amounts connected in any way with taxation, allegations of fraud and/or antitrust violations shall be excluded. For purposes of determining residual dollar amounts, offsets of money owed by one party against money that would otherwise be paid by that party may be considered to the extent permitted by law.

(b) This agreement to waive entitlement to residual dollar amounts has been considered by both parties. It is agreed that the administrative costs for either party associated with collecting such small dollar amounts could exceed the amount to be recovered.

HQ B-2-0022 CONTRACT SUMMARY FOR PAYMENT OFFICE (FIXED PRICE) (FEB 1997)

This entire contract is fixed price.

Section C - Descriptions and Specifications

STATEMENT OF WORK

Statement of Work For 57mm High Explosive – Point Detonating (HE-PD) Cartridges

1. SCOPE. This Statement of Work (SOW) defines the effort required for the manufacture, assembly, test, and delivery of 57mm High Explosive –Point Detonating (HE-PD) Cartridges.

1.1. Background. The 57mm HE-PD Cartridge is planned for use with the MK 110 57mm Gun Mount. The HE-PD Cartridge consists of a high explosive filled projectile with the ability to point detonate, a brass cartridge case loaded with propellant and a primer. The United States Navy (USN) procures quantities of the 57mm HE-PD cartridge in order to support the use of the MK 110 Gun Mount on USN and Coast Guard (USCG) platforms.

2. APPLICABLE DOCUMENTS.

2.1. NAVSEA Specifications.

Performance Specification PRF WS35805 Item Specification for Cartridge, 57 mm, High Explosive – Point Detonating (HE-PD)

2.2. Department of Defense Lists.

Automated Data List (ADL) 53711-8745880 Cartridge, 57mm, High Explosive – Point Detonating (HE-PD)

2.3. NAVSEA Drawings.

2.4. NAVSEA Manuals.

SW010-AG-ORD-010 List of Explosives For Navy Munitions

2.5. Availability of Documents. Unless otherwise indicated, copies of the specifications, standards and lists are available upon request from the procuring activity.

3. REQUIREMENTS.

3.1. General. The contractor shall manufacture, assemble, test, package, and deliver 57mm HE-PD cartridges as listed in this contract to meet the performance criteria specified by PRF WS35805, ADL 53711-8745880, their lower-tier documents, and the detail requirements below. The contractor shall also be responsible for providing all necessary equipment and tooling, with the exception of any Government Furnished Equipment (GFE) or Material (GFM).

3.2. Configuration Management.

3.2.1. All items shall be produced in accordance with the submitted contractor baseline design and this Statement of Work and an As Built Configuration List (ABCL) shall be submitted accordingly (DICMAN81516, CDRL A001). These cartridges shall be representative of the contractor’s submitted 57mm HE-PD design (DISESS81000E, CDRL A002), as subsequent changes to the design may require requalification.

3.2.2. Configuration Management Plan. The contractor shall prepare a Configuration Management Plan and submit to the Government for review and approval. (DISESS80858C, CDRL A001A003)

3.2.3. Proposed design changes shall be documented in accordance with the approved Configuration Management Plan and work tasks as described in EIA-649-1. The preferred engineering change forms are available upon request by contacting the G2 Configuration Management group at: usn.pica.peo-ammo.mbx.nswc-ihd-g2-cfg-mgt@mail.mil.

3.2.4. The Requiring Technical Activity (RTA) shall verify/determine the Classification of all change requests.

3.2.5. Engineering Change Proposal (ECP) and Notice of Revision (NOR). A request for a permanent engineering change to the Government controlled product baseline configuration shall be submitted to the Government as an ECP (DISESS80639D, CDRL A004) and NOR (DISESS80642D, CDRL A005) for review and approval.

3.2.5.1. ECPs shall be numbered serially with the number constructed as follows:

3.2.5.1.1. Last 4 digits of contract number

3.2.5.1.2. E

3.2.5.1.3. Sequential serial number starting with “0001”

3.2.5.1.4. If the initial formal contractor initiated ECP must be revised for any reason after submission to the Government, the ECP number constructed above shall have “R#” added to the end (where # is the revision being submitted) beginning with R1.

3.2.5.2. NORs shall be numbered as follows:

3.2.5.2.1. ECP number as determined above

3.2.5.2.2. Sequential serial number starting with “-001”

3.2.5.2.3. Revision numbering described in 3.2.5.1.4 is applicable to NORs if changes are required.

3.2.6. Request for Variance (RFV). A request for a temporary departure from any requirement of the Government controlled product baseline configuration shall be submitted to the Government as a RFV (DI-SESS-80640D, CDRL A006) for review and approval.

3.2.6.1. RFVs shall be numbered serially with the number constructed as follows:

3.2.6.1.1. Last 4 digits of contract number

3.2.6.1.2. V

3.2.6.1.3. Sequential serial number starting with “0001”

3.2.6.1.4. If the initial formal contractor initiated RFV must be revised for any reason after submission to the Government, the RFV number constructed above shall have “R#” added to the end (where # is the revision being submitted) beginning with R1.

3.2.7. Procuring Activity Number (PAN). Prior to formal submission of any contractor submitted change request (permanent or temporary) against the Government controlled product baseline configuration, the contractor shall contact the G2 Configuration Management group at: usn.pica.peo-ammo.mbx.nswc-ihd-g2-cfg-mgt@mail.mil to request a PAN for Government tracking. The number supplied shall be populated on the change request form when submitted.

3.2.8. In the interest of expedited processing and avoiding revisions, it is recommended that the contractor (through the PCO) submit DRAFT copies of all change requests and supporting documentation for NSWC IHEODTD comment.

3.2.9. After finalization of the contractor’s Technical Data Package, the contractor shall submit all contractor approved change requests (permanent and temporary) to contractor controlled technical data (DI-SESS-81253C, CDRL A007) for potential subsequent incorporation into the contract.

3.3. Quality Assurance.

3.3.1. Quality Management System (QMS). The contractor shall implement and maintain a Quality Management System in accordance with ISO 9001-2008 or equivalent.

3.3.2. Quality Program Plan. The contractor shall implement and maintain a Quality Program Plan in accordance with the contractor’s Quality Management System and include sections covering Inspection/Test Plans, Critical Defect Program, Acceptance Inspection Equipment (AIE), Process Control Documentation, and Rework. The contractor shall maintain this plan throughout the life of this contract (DI-QCIC-81722, CDRL A008).

3.3.3. Quality Audit. The contractor shall maintain the Quality Audit documentation for both the contractor and its subcontracts/vendors.

3.3.4. Government Audit. At any time during this contract effort, the Government reserves the right to independently audit or examine the contractor’s and subcontractors’ Quality Management System and Records for compliance with all contractual quality requirements. The contractor shall ensure the necessary provisions are placed in all sub-contractor/vendor purchase orders/contracts to grant the Government access to perform these audits. The contractor shall provide personnel and facilities to support the above audits.

3.3.5. Quality Deficiency Report. The contractor shall provide a Quality Deficiency Report on any Government Furnished Materials (GFM), if applicable (DIQCIC80736, CDRL A009).

3.3.6. Control of Critical Characteristics. The requirements for the control of Critical Characteristics stated herein shall apply to the prime contractor and extend to any suppliers having processes that may contain critical characteristics or any materials/processes affecting Critical Characteristics. All aspects of the Critical Characteristics provisions contained herein shall be flowed down to the suppliers in the contractor’s purchase orders. The contractor’s processes shall be designed with the objective of preventing the creation or occurrence of non-conforming critical characteristics.

3.3.6.1. The contractor shall establish, document and maintain a product specific, Critical Characteristics Control Plan (CCCP) that shall be submitted to and approved by the Procuring Contracting Officer (PCO). The CCCP shall include or reference all procedures, work and handling instructions and process controls relating to any critical characteristics. Mistake Proofing techniques of the material handling and inspection systems shall be a part of the CCCP. Guidance for developing this plan and submitting Critical Plans of Action (CPOA) can be found at http://www.ardec.army.mil/organizations/QESA/_files/CCCP_&_CPOA_Review_Guide_Rev-A_Amd_1_UNCLASSIFIED.PDF

3.3.6.2. The contractor shall assure its critical processes are robust in design, capable and under control, with the objective of not generating any critical non-conformances. The contractor shall calculate, document, clearly identify, and have a schedule that routinely assess the reliability and effectiveness of its critical processes to prevent generating critical non-conformances as identified in the CCCP (DI-MGMT-80004A, CDRL A010).

3.3.6.3. An inspection and verification system shall be employed that will verify the robustness of all critical processes. The contractor shall calculate, document, clearly identify, and have a schedule that routinely assess the reliability and effectiveness of its inspection and verification system to detect and prevent critical non-conformance escapes as identified in the CCCP. The Government expects that a contractor will allow zero critical escapes. To demonstrate its critical escape risk the contractor will utilize the non-conformance escape risk goal of less than one critical non-conformance escape in one million items delivered.

3.3.6.3.1. Unless otherwise approved by the PCO, the non-conformance escape risk is the sum of the individual characteristic escape rates. The probability of escape for a single characteristic shall be calculated by multiplying the non-conformance rate(s) entering the inspection system(s) by the error rate of the inspection system(s). These escape rates are then summed and shall not exceed the tolerable critical non-conformance escape risk.

3.3.6.3.2. Within 45 days after award, the contractor can elect to submit a phased-in approach on how the non-conformance escape risk will be achieved over a period of time not to exceed 180 days from the date of first article approval. Submission will require approval by the Government and is subject to a technical review and analysis. Allowance for a phased-in approach will then become a part of the contract. Disapproval of the contractor’s submission does not relieve the contractor of its obligation to comply with the terms of paragraph 3.3 and its sub-paragraphs.

3.3.6.3.3. Based on the maximum error rate defined for the inspection system, the contractor shall develop a test procedure to demonstrate the error rate. As part of the test plan the contractor shall include sufficient test quantities to assure 90% statistical confidence in the resultant rates unless otherwise approved by the PCO. Once established, the contractor shall have a documented schedule to routinely monitor the non-conformance and inspection system error rates to assure they do not exceed the maximum rates allotted.

3.3.6.4. Contractor Identified Critical Characteristics List (CICCL). In addition to critical characteristics defined in the Government’s technical data (drawings, specifications, etc.), the contractor shall identify and document in its contractor developed technical data all known material, component, subassembly and assembly characteristics whose non-conformances would likely result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the product. All additional critical characteristics identified by the contractor shall comply with the critical characteristic requirements of the technical data package, supplemented herein. The contractor’s additional critical characteristics shall be reviewed and approved by the procuring activity prior to manufacturing. (DI-SAFT-80970A, CDRL A011, A012, A013)

3.3.6.5. Discovery of Critical Non-conformance. In the event that a Critical non-conformance is found anywhere in the production process, the contractor, as part of the quality system, shall have procedures in place to ensure:

3.3.6.5.1. The non-conformance is positively identified and segregated to ensure that nonconforming product does not inadvertently remain in or reenter the production process. This control shall be accomplished without affecting or impairing subsequent non-conformance analysis. Final disposition of non-conforming product shall be documented and audited for traceability.

3.3.6.5.2. The operation that produced the non-conforming component or assembly and any other operations incorporating suspect components or assemblies are immediately stopped.

3.3.6.5.3. The Government is immediately notified of the critical non-conformance (telephonically and electronic mail) (DI-SAFT-80970A, CDRL A011, A012, A013).

3.3.6.5.4. Any suspect material (material in process that may contain the same defect) is identified, segregated and suspended from any further processing and shipment (DI-SAFT-80970A, CDRL A011, A012, A013).

3.3.6.5.5. An investigation is conducted to determine the root cause of the non-conformance and the required corrective actions. An evaluation shall also be conducted with regard to suspect material to ensure that no additional critical non-conformances are present. A report of this investigation shall be submitted to the Government (DI-SAFT-80970A, CDRL A011, A012, A013). The use of the DID report shall not delay notification to the Government.

3.3.6.5.6. A request to restart manufacturing or to use any suspect material associated with the critical non-conformance is submitted to the Government (DI-SAFT-80970A, CDRL A011, A012, A013). Restart of production shall not occur until the investigations are complete and upon authorization from the procuring contracting officer, unless previously addressed in the approved CCCP. All objective evidence of the investigations to date shall be available for review at the time of restart. Suspect materiel found to be nonconforming shall not be used without Government approval.

3.3.6.5.7. The procuring activity reserves the right to refuse acceptance of any suspect material until the root cause or reasonably likely cause of the critical non-conformance has been identified, corrective action has been fully implemented and sufficient evidence has been provided to exclude non-conforming material from the conforming population.

3.3.6.6. The contractor may develop alternative plans and provisions, collectively referred to as a Critical Plan of Action (CPOA), relative to government or contractor identified critical characteristics. All CPOAs are independent and shall be evaluated by the government for this contract. The CPOA and any subsequent revisions require PCO approval prior to implementation. Unless otherwise specified at time of approval, contractor shall review and evaluate CPOAs for currency and process improvements at least on an annual basis and submit results to the PCO. Unless otherwise approved by the PCO, each critical characteristic shall require a separate CPOA. If the CPOA includes other documents by reference they shall be submitted upon request (DI-MGMT-80004A, CDRL A014, A015).

3.3.6.7. The contractor may continue production with an approved CPOA provided that the critical non-conformance is consistent with the failure mode(s) and rates established in the CPOA. Failure to meet all CPOA requirements will require the contractor to revert back to paragraph 3.3.6.5 requirements.

3.3.6.8. If a critical non-conformance is discovered beyond its designated inspection point and prior to Government acceptance the contractor shall take actions specified in paragraph 3.3.6.5 above. If a critical non-conformance is discovered after Government acceptance the Government has the right to invoke the requirements of paragraph 3.3.6.5 with respect to the contractors remaining production under this contract.

3.4. Statistical Process Control Plan.

3.4.1. General Statistical Process Control Requirements.

3.4.1.1. In addition to the quality requirements of the technical data package, the contractor shall implement Statistical Process Control (SPC) in accordance with a Government accepted SPC Program Plan. Control chart techniques shall be in accordance with the American National Standards Institute (ANSI) B1, B2 and B3. Alternate SPC charting methods may be proposed and submitted to the Government for review.

3.4.1.2. The SPC Program Plan developed by the contractor shall consist of a general plan and a detailed plan (DI-MGMT-80004A, CDRL A014, A015). Once a general plan for a facility has been approved by the Government, the approval remains in effect for subsequent contracts as long as the contractual requirements remain substantially unchanged from contract to contract. Therefore, resubmission of a previously accepted general SPC plan is not required if current SPC contract clause requirements are fulfilled. If the Government has previously accepted the general SPC plan under essentially the same SPC contractual requirements, indicate by providing the Contracting Officer with the following information:

Date of Acceptance ______________ Contract Number(s) ______________

3.4.1.3. The contractor is responsible for updating the general plan to current SPC contractual requirements. If errors or omissions are encountered in a previously accepted SPC general plan, opportunities for improvement will be identified by the Government, and corrective action shall be accomplished by the contractor.

3.4.1.4. Statistical evidence in the form of control charts shall be prepared and maintained for each process or operation parameter identified in the detailed plan. These charts shall identify all corrective actions taken on statistical signal. During production runs, control charts shall be maintained in such a manner to assure product is traceable to the control charts. At the conclusion of the production run, a collection of charts traceable to the product shall be maintained for a minimum of three years. The control charts shall be provided to the Government for review at any time upon request.

3.4.1.5. When the process or operation parameter under control has demonstrated both stability and capability, the contractor may request, in writing, through Administrative Contracting Officer (ACO) and Procuring Contracting Officer (CO) channels to the Product Assurance and Test Directorate, that acceptance inspection or testing performed in accordance with contract requirements be reduced or eliminated. Upon approval by the CO, acceptance shall then be based upon the accepted SPC plan, procedures, practices and the control charts.

3.4.1.6. The Government will not consider requests for reduction or elimination of 100% acceptance inspection and testing of parameters or characteristics identified as critical in the technical data package, specifications or drawings of this contract if any one of the following conditions exists:

3.4.1.6.1. The existing process currently utilizes a fully automated, cost effective, sufficiently reliable method of 100% acceptance inspection or testing for an attribute type critical parameter or characteristic.

3.4.1.6.2. The contractor utilizes attribute SPC control chart methods for the critical parameter or characteristic.

3.4.1.6.3. The critical parameter or characteristic is a first order, single point safety failure mode (nonconformance of the critical parameter or characteristic in and of itself would cause a catastrophic failure).

3.4.1.7. The Government will only consider reduction or elimination of the 100% acceptance inspection or test requirement for other critical parameters or characteristics if either of the following conditions is met:

3.4.1.7.1. The process is in a state of statistical control utilizing variable control chart methods for the critical parameter or characteristic under control and the process performance index (Cpk) is at least 2.0. The contractor shall maintain objective quality evidence through periodic audits that the process performance index is being maintained for each production delivery.

3.4.1.7.2. The critical parameter or characteristic is conclusively shown to be completely controlled by one or more process or operation parameters earlier in the process, and those parameters are in a state of statistical control utilizing variable data, and the product of the probability of the conformance for each earlier parameter associated to the critical characteristic is better than or equal to a value equivalent to that provided by a Cpk of at least 2.0. The contractor shall maintain objective quality evidence through periodic audits that the process performance indexes are being maintained for each production delivery.

3.4.1.8. For characteristics other than critical, requests for reduction or elimination of acceptance inspection and testing shall be considered when the process performance index is greater than or equal to a Cpk of 1.33 for variables data. Requests shall be considered for attributes data when the percent beyond the specification limits is less than or equal to .003 (Cpk=1.33).

3.4.1.9. Process or operation parameters under reduced or eliminated inspection or testing that undergo a break in production less than 6 months in length, may continue to operate under reduced or eliminated inspection or testing provided there has been no degradation below a Cpk of 1.33 (2.0 for criticals). Any break in production greater than 6 months shall require resubmission of the request for reduction or elimination of inspection or testing through the same channels cited in paragraph 3.4.1.6 above.

3.4.1.10. Immediately following a change to a process or operation parameter under reduced or eliminated inspection, the process capability (Cp) or Cpk shall be recalculated and documented for variable data; the grand average fraction defective shall be recalculated for attribute data. If any of these values have deteriorated, immediate notification shall be made to the Government along with the associated documentation. Return to original inspection and test requirements may be imposed as stipulated in paragraph 3.4.1.11 below.

3.4.1.11. The Government reserves the right to withdraw authorization to reduce or eliminate final acceptance inspection or testing and direct the contractor to return to original contract inspection or test procedures at any indication of loss of process control or deterioration of quality.

3.4.2. Detailed Requirements Pertaining to Plan Submittal. In accordance with DI-MGMT-80004A and this requirement, the following supplemental information shall be considered and used when designing the general and detailed SPC plans.

3.4.3. SPC General Management Plan. This section shall define management's SPC responsibilities and involvement and shall include management's commitment to continuous process improvement. The plan shall embrace a total commitment to quality and shall be capable of standing on its own merit.

3.4.3.1. Policy/Scope. Describe the contractor's policy for applying SPC, including goals and management commitment to SPC.

3.4.3.2. Applicable Documents: List documents that are the basis for the contractor's SPC program (i.e., ANSI standard, textbooks, Government documents).

3.4.3.3. SPC Management Structure. Define the SPC management structure within the organization. Identify and include interrelationships of all departments involved in SPC (i.e., Production, Quality, Engineering, Purchasing, etc.) Identify by job title or position all key personnel within departments involved in the application of SPC. Describe which functions are performed by key personnel and when these functions are performed (i.e., include personnel responsible for performing inspections/audits, charting and interpreting data; personnel responsible for determining, initiating and implementing corrective action upon detecting assignable causes, etc.)

3.4.3.4. SPC Training. Identify by job title or position the primary individual responsible for overseeing that SPC training is accomplished. Describe the qualification program required and in use for all personnel utilizing SPC techniques, including the qualification of trainers. Identify who is to be trained and the type, extent and length of such training (i.e., on-the-job, classroom, etc.). Identify when refresher training is required and how personnel using SPC techniques are monitored.

3.4.3.5. Manufacturing Controls. Identify the criteria for performing SPC gage capability studies and describe how and when these studies are applied. Repeatability and accuracy of gages should be addressed.

3.4.3.6. Determination of SPC Use. Describe how the process/operation parameters are determined appropriate for SPC application and explain what actions are taken if SPC is not deemed appropriate for critical, special and major process/operation parameters (i.e., Pareto analysis; analysis of characteristics with tight tolerances, etc.)

3.4.3.7. Process Stability and Capability: Identify the criteria for performing process capability studies and describe how and when these studies are applied. Describe how the process capability index is calculated and include the frequency of these calculations. Describe what actions are taken as a result of each process capability study. Describe the contractor's methodologies when process capability is for variable and attribute data. To determine a capable process, the process/operation parameters shall meet the following requirements:

3.4.3.7.1. Variable Data. Process capability (Cp) shall be determined. Process performance index shall be greater than or equal to 1.33 (Cpk). For critical parameters/characteristics, the process performance index shall be greater than or equal to 2.0 (Cpk).

3.4.3.7.2. Attribute Data. Process capability/performance shall be the percent beyond the upper/lower specification limit less than or equal to .003 percent (Cpk=1.33).

3.4.3.7.3. Describe what actions will be taken if process/operation is sub-marginal or marginal. (Cpk less than 1.33 or 2.0 for criticals) or grand average fraction defective is greater than .003 percent).

3.4.3.7.4. Include analysis of statistical distributions and define all formulas and symbology utilized.

3.4.3.7.5. Process Stability and Capability data from vendor/subcontractor activities shall be provided on a best effort basis.

3.4.3.8. Control Chart Policy

3.4.3.8.1. Type of charts to be used (i.e., x bar/R x bar/S, etc.) and rationale for use; the criteria for selection of sample size, frequency of sampling and rational subgroups.

3.4.3.8.2. Procedures for establishing and updating control limits, including frequency of adjustments.

3.4.3.8.3. Criteria for determining out-of-control conditions (i.e., trends, points beyond control limits, etc.) and the corrective action taken; to include failure analysis when the process is unstable or when nonconforming product has resulted from unstable processes. Illustrate out-of-control tests.

3.4.3.8.4. Describe the method of recording pertinent facts on control charts such as changes in raw material, machines, manufacturing methods and environment, and corrective actions taken and describe how control charts are traceable to the product.

3.4.3.8.5. Control Chart information from vendors/subcontractors shall be provided on a best effort basis.

3.4.3.9. Vendor/Subcontractor Purchase Controls. Identify whether suppliers are required to utilize SPC and describe the extent the vendor's policies and procedures are consistent with in-house procedures of the prime contractor. Describe the following: methods utilized to determine that suppliers have adequate controls to assure defective product is not produced and delivered; the system utilized to audit suppliers, what will be audited and how often; what action will be taken when out-of-control conditions exist at subcontractor/vendor facilities.

3.4.3.10. SPC Audit System. At a minimum, the contractor's SPC Audit System shall consist of auditing compliance with the planned arrangements specified in the general and detailed SPC plans followed by a review and analysis of the outcome to include implementation of necessary corrective action.

3.4.3.11. SPC Records. Identify various records to be used in support of SPC and describe their use. Identify retention periods.

3.4.4. Detailed Plan. This section shall detail specific manufacturing process/operation parameters under control.

3.4.4.1. Control of Process/Operation Parameters or Characteristics. Identify the following for each process/operation by name or characteristic under control:

3.4.4.1.1. Identify process/operation by name or characteristic and provide rationale for selection; justification for non-selection if the parameter or characteristic is identified as critical, special and/or major.

3.4.4.1.2. Describe how the characteristic is produced; the chain of events, type and number of machines involved, location of manufacturing facility, tolerances maintained, etc.

3.4.4.1.3. Production and inspection machinery used. Include the production rate, number of shifts and length of shifts plus whether inspection is fully or semi-automatic or manual. If manual, identify the type of gages in use.

3.4.4.1.4. Identify the type of charts to be maintained and whether the process/operation is performed in-house or subcontracted out; identify facility/vendor where process/operation parameters are targeted for SPC.

3.4.4.2. Reduction or Elimination of Inspection/Test. The Procuring Contracting Officer (PCO) will accept submissions of requests for reduction or elimination of final acceptance inspection/testing when the requirements of the SPC requirement and this SOW are met. Each request shall contain and/or address the following: control charts documenting twenty (20) consecutive production shifts or more for the same process/operation parameter under control; type of control chart utilized; control chart limits and process average or grand average fraction defective (as applicable); definition of out-of-control condition and corrective actions taken during out-of-control conditions; specification and part number.

3.5. First Article

3.5.1. The contractor shall produce First Article lots of cartridges sufficient in quantity to meet the First Article requirements specified in PRF WS35805 and this Statement of Work. All items shall be produced in accordance with ADL 53711-8745880 and this Statement of Work.

3.5.2. First Article Test Procedures. The contractor shall prepare test procedures for the HE-PD Cartridge First Article Test (FAT) (DI-NDTI-80603A, CDRL A016).

3.5.3. Government Participation in First Article Tests. The Government may send one or more representatives to witness the FAT. The contractor shall notify the Government of the test dates at least 14 days prior to the original or revised date of domestic tests, whichever is earlier. The contractor shall notify the Government of changes to test dates at least 45 days prior to the original or revised date of tests outside of the United States, whichever is earlier.

3.5.4. Cartridge First Article Test. The contractor shall perform FAT on the HE-PD Cartridge in accordance with the ADL 53711-8745880, PRF WS35805, and all drawings listed in the contractor’s Technical Data Package, unless otherwise stated in this SOW or in the Contract. Inspections and tests, excluding Function and Casualty, shall be arranged by the contractor to be performed at the contractor’s, subcontractor’s, and/or Government’s facilities. Once the Government has been notified by the contractor that the cartridge FAT has commenced, PCO approval is required for stoppage of the FAT.

3.5.5. Function and Casualty Test. Function and Casualty tests of the HE-PD Cartridges, as required by PRF WS35805, shall be conducted by the Government at Government facilities. Written notice of conditional acceptance or rejection shall be provided to the contractor by the PCO within 60 calendar days after receipt of the test cartridges at the Government facility.

3.5.6. First Article Test Report. The contractor shall prepare a First Article Test report, including Government executed Function and Casualty test results, following the First Article Test event (DI-NDTI-80809B, CDRL A017). The reports shall fully document the results of the tests required by Paragraph 3.5.2. The reports shall also include material certification for any components that have material requirements.

3.5.7. Material Certification. Material Certifications shall be provided for all components, both energetic and non-energetic, utilized to manufacture the cartridge as part of the First Article Test Report (DI-NDTI-80809B, CDRL A017). Certificates of Compliance will not be accepted in place of material certifications. Material Certifications shall provide objective evidence that the material meets the requirement of the associated material specification or standard.

3.6. Lot Acceptance (Quality Conformance)

3.6.1. Lot Acceptance Test and Inspection (LAT) Procedures. The contractor shall prepare test procedures for the HE-PD Cartridge Lot Acceptance Tests and Inspections (DINDTI80603A, CDRL A018).

3.6.2. Government Participation in Lot Acceptance Tests. The Government may send one or more representatives to witness the LAT. The contractor shall notify the Government of the test dates at least 14 days prior to the original or revised date of domestic tests, whichever is earlier. The contractor shall notify the Government of changes to test dates at least 45 days prior to the original or revised date of tests outside of the United States, whichever is earlier.

3.6.3. Cartridge Lot Acceptance Test and Inspection. The contractor shall perform LAT on the HE-PD Cartridge in accordance with the ADL 53711-8745880, specification PRF WS35805, and all drawings listed in the contractor’s Technical Data Package, unless otherwise stated in this SOW or in the Contract. All inspections and tests, excluding Function and Casualty, shall be arranged by the contractor to be performed at the contractor’s, subcontractor’s, and/or Government’s facilities. Once the Government has been notified by the contractor that the cartridge LAT has commenced, PCO approval is required for stoppage of the LAT. One LAT shall be conducted per production lot delivered.

3.6.4. Function and Casualty Test. Function and Casualty tests of the HE-PD Cartridges, as required by specification PRF WS35805, shall be conducted by the Government at Government facilities. Written notice of conditional acceptance or rejection shall be provided to the contractor by the PCO within 60 calendar days after receipt of the test cartridges at the Government facility.

3.6.5. Lot Acceptance Test and Inspection Report. The contractor shall prepare a Lot Acceptance Test and Inspection report, including Government executed Function and Casualty test results, following each LAT event (DI-NDTI-80809B, CDRL A019). The reports shall fully document the results of the tests required by Paragraph 3.6.3 and 3.6.4. The reports shall also include material certification for the components which have material requirements.

3.7. Destructive Testing.

3.7.1. All costs of destructive testing by the contractor and items destroyed by the Government are considered as being included in the contract unit price.

3.7.2. Where destructive testing of items or components thereof is required by contract or specification, the number of items or components required to be destructively tested, whether destructively tested or not, shall be in addition to the quantity to be delivered to the Government as set forth in the Contract Schedule.

3.7.3. All pieces of the complete First Article shall be considered as destructively tested items unless specifically exempted by other provisions of this contract.

3.7.4. The contractor shall not reuse any components from items used in a destructive test during First Article, lot acceptance or in process testing, unless specifically authorized by the Contracting Officer.

3.7.5. The Government reserves the right to take title to all or any items or components described above. The Government may take title to all or any items or components upon notice to the contractor. The items or components of items to which the Government takes title shall be shipped in accordance with the Contracting Officer's instructions. Those items and components to which the Government does not obtain title shall be rendered inoperable and disposed of as scrap by the contractor.

3.8. Failure Notification, Analysis, Corrective Action, and Report. The contractor shall notify the government when there is a failure during First Article, Lot Acceptance, other testing, or when there is a major production incident that includes, but is not limited to Critical characteristics, issues that will result in significant production stoppage, or issues that result in the failure of the all-up-round or components to meet the applicable performance or safety requirements. The contractor shall document the failure, perform an investigation and analysis to determine the root cause of the failure, determine and implement the appropriate corrective actions to prevent the recurrence of the failure, and provide a Failure Analysis and Corrective Action Report (DI-SESS-81927, CDRL A020).

3.9. Measurement System Evaluation. (DI-QCIC-81960, CDRL A021)

3.9.1. Definitions. This paragraph defines specific terms utilized throughout the rest of the sub-paragraphs to 3.9 and in the accompanying Contract Data Requirements List (CDRL) and Data Item Description (DID). This aids in clarifying the MSE requirements to Government and contractor personnel.

3.9.1.1. Acceptance Inspection Equipment (AIE). All equipment (includes AAIE defined below), special and standard, including dimensional gages, measuring equipment, test fixtures, electronic and physical test equipment, and other test equipment used for examination and test of a product to determine conformance to the Technical Data Package (TDP) which may include drawings and specifications (e.g., Detail, Performance, Weapon specifications, and QAPs).

3.9.1.2. Automated Acceptance Inspection Equipment (AAIE). AIE in which the inspection and acceptance determination of the product is performed, in whole or in part, in an automatic manner.

3.9.1.3. Contractor Inspection Equipment. Government-approved equipment utilized by the contractor to perform examination and tests to assure conformance to contract requirements.

3.9.1.4. Commercial Inspection Equipment. Industry-developed inspection equipment of universal application, without limitations to a specific part or item, which is advertised or cataloged as available to the trade or to the public on an unrestricted basis at an established price. Examples follow:

3.9.1.4.1. Standard Test Equipment. Multi-usage equipment that is specific to a function rather than to an item. It includes such items as hardness testers, tensile strength testers, meters, weighing devices, standard gear testers, ohmmeters, voltmeters, and oscilloscopes.

3.9.1.4.2. Standard Measuring Equipment (SME). Multipurpose equipment and standards used for performing measurements. It includes such items as micrometers, rulers, tapes, height gages, and protractors, etc. Standards include visual inspection equipment such as scratch and dig standards, surface finish comparator, color standards (FED-STD-595), etc.

3.9.1.5. Nondestructive Testing. The development and application of technical methods to examine materials or components in ways that do not impair future usefulness and serviceability in order to detect, locate, measure and evaluate flaws; to assess integrity, properties and composition; and to measure geometrical characteristics. NDT includes Radiography/Radioscopic, Ultrasonic, Eddy Current, Magnetic Particle, and Liquid Penetrant.

3.9.1.6. Measurement System Analysis (MSA). Per ASTM E2782 (Standard Guide for MSA), paragraph 3.1.7, MSA is any of a number of specialized methods useful for studying a measurement system and its properties.

3.9.2. Scope. This section establishes requirements for design, supply, performance, and maintenance of AIE used for product inspection and acceptance. In addition, this clause establishes requirements for the preparation, submission, and approval of AIE documentation.

3.9.3. AIE. The contractor shall provide all AIE necessary to ensure conformance of components and end-items to contract requirements. AIE shall include inspection, measuring, and test equipment whether Government furnished or contractor furnished (including commercially acquired) along with the necessary specifications and procedures for their use (see ISO 10012, paragraph 6.2.1). The AIE shall not create or conceal defects on the product being inspected. All AIE documentation shall contain sufficient information to permit evaluation of the AIE’s ability to test, verify, and/or measure the applicable characteristics or parameters (see DI-QCIC-81960).

3.9.4. AIE Designs & Government Furnished Gages. AIE designs are of two types – Government designs (see 3.9.4.1) and contractor designs (see 3.9.4.2). When applicable, Government designs or Government furnished gages are designated in the TDP/contract; responsibility for all other AIE is assigned to the contractor. The designs, associated inspection procedures, and theory of operation shall have the level of detail to demonstrate capability of the proposed AIE to perform the required inspection.

3.9.4.1. Government AIE Designs. Government AIE designs may consist of detailed drawings necessary for the fabrication and use of the AIE. Unless otherwise specified, the contractor may submit alternate or modified contractor designs of Government AIE designs.

3.9.4.2. Contractor AIE Designs. Contractor AIE design drawings shall meet the requirements of ASME Y14.100, ASME Y14.5 and ASME Y14.43 and may include commercial inspection equipment. [“Commercial inspection equipment” is defined as shown in paragraph 3.9.1.4 above. It shall be fully described by catalog listings or other means which provide sufficient information to permit identification and evaluation by the Government and may include illustrations and engineering data.] Designs shall be submitted for any special fixture(s) to be used. Unless otherwise specified, Gage Tolerancing Policy shall be in accordance with ASME Y14.43, “Absolute Tolerancing (Pessimistic Tolerancing).”

3.9.4.3. Visual Inspection. Visual inspection standards used for the acceptance/rejection of product shall be submitted for approval.

3.9.5. AIE Package Submittals. The contractor shall prepare the AIE package submittal in accordance with DI-QCIC-81960 in the applicable Contract Data Requirements List. In addition, the contractor shall adhere to the following requirements:

3.9.5.1. Designs for Approval. Contractor designs and/or the submission for the use of Government designs shall be approved by the Government. Partial submission of AIE designs is permissible in order to expedite the approval process; however, the response date for design review will be based on the date of the final complete submission of designs.

3.9.5.2. Units of Measurement. The units of measurement within the AIE package submittal shall be consistent with the requirements of the Technical Data Package (TDP).

3.9.5.3. AIE Flow Down. The contractor shall flow down AIE requirements to sub-contractors at any tier who are performing acceptance inspections.

3.9.6. Characteristics for Inspection. AIE documentation for Critical, Special, Major and Minor characteristic inspections shall be submitted to the Government for approval and as required below:

3.9.6.1. Listed Minor (characteristics displayed on specifications and/or drawings)

3.9.7. Automated Acceptance Inspection Equipment. The AAIE shall accept only conforming material. All characteristics requiring AAIE per the TDP shall utilize inspection equipment with a minimum demonstrated reliability of 99.8% at a 90% confidence level to detect non-conforming material unless otherwise specified below.

3.9.7.1. Reliability of _99.5_% at a _90_% Confidence Level for Critical/Special Characteristics.

3.9.7.2. Reliability of _99_% at a _90_% Confidence Level for Major Characteristics.

3.9.7.3. For inspection of major and minor characteristics where contractor utilizes AAIE when it is not required by the TDP, the AAIE package shall be submitted to the Government for approval.

3.9.7.4. All AAIE packages submitted to the Government for approval shall be in accordance with MIL-A-70625 (Automated Acceptance Inspection Equipment Design, Testing and Approval of). Furthermore, the contractor shall be responsible for producing the acceptance and rejection verification standards/masters representative of the characteristics the AAIE is designed to inspect. The verification standards and frequency of use require Government approval prior to use. When verification standards are used for the VL-VII “sampling plan” per MIL-STD-1916 paragraph 4.4, verification standards and frequency of use shall require Government approval prior to use.

3.9.7.5. If the AAIE accepts a critical characteristic “reject” standard the contractor shall notify the Government and act in accordance with paragraph f of the Critical Characteristic Control Clause. In addition, if the AAIE accepts a major and/or minor characteristic “reject” standard the contractor shall act in accordance with paragraph 8.3 of ISO 10012 or paragraph 5.2.3 of ANSI/NCSL Z540.3.

3.9.7.6. All AAIE shall be required to pass a Government-approved Acceptance (Prove-Out) Test. The contractor shall conduct this test per the approved test plan and shall submit a test analysis report for approval. This test shall be performed at the contractor’s facilities whose manufacturing system has had the AAIE fully integrated and calibrated as per paragraph 3.9.10 of this SOW. The contractor shall allow Government personnel access to this facility and unobstructed monitoring of this test.

3.9.7.7. The contractor shall notify the Government prior to a modification and/or relocation of the Government-approved AAIE. The modified AAIE designs shall be submitted for approval. The modified and/or relocated AAIE shall require submission of the acceptance test plan (prove-out) and results for review and approval prior to use. The modified and/or relocated AAIE shall be in accordance with paragraphs 3.9.7.1 – 3.9.7.6.

3.9.8. Measurement System Analysis (MSA). The contractor is responsible to ensure all AIE is, at a minimum, stable, repeatable, and reproducible for all characteristics. Refer to ASTM E2782 and/or AIAG MSA for guidance. The contractor shall provide objective evidence, including the MSA assessment plan, associated data, and analysis, which demonstrates the AIE is, at a minimum, stable, repeatable, and reproducible for the following characteristics:

NOT APPLICABLE

Approval of submitted MSA(s) must be granted before the corresponding AIE can be used or continue to be used for acceptance of product. If at any time following approval of the AIE and MSA the AIE is disapproved, then the MSA shall be disapproved. After the resubmitted AIE is approved, the MSA shall be conducted on the approved AIE and resubmitted for approval.

3.9.9. Robust AIE System. The contractor shall ensure the AIE and its use is not negatively affected by any manufacturing/inspection environmental stimuli including, but not limited to production rate, noise, temperature, humidity, and vibration.

3.9.10. AIE Calibration and Verification. The calibration system shall be in accordance with ISO 10012 or ANSI/NCSL Z540.3. All AIE shall be subjected to scheduled calibration intervals to ensure that the equipment will accept only conforming product and reject all non-conforming product for the duration of the approved calibration period. AIE shall be subjected to periodic verification to ensure that the equipment will continue to accept and reject product with the same consistency as it did at the time of its previous calibration.

3.9.11. Non-Destructive Testing (NDT).