CKU-5 SOW Machined.pdf

MANUFACTURING OF HARDWARE USING NSWC IHD DRAWINGS

PERFORMANCE WORK STATEMENT

1.0 Scope of Work

The requirements in this document contain the information necessary to manufacture hardware for assembly in fleet-deliverable Aviation Critical Safety Items (ACSIs) at Naval Surface

Warfare Center Indian Head Division (NSWC IHD).

2.0 Applicable Documents

CKU-5 - CDRL_A001_Inspection

CKU-5 - CDRL_A002_CoC

CKU-5 – CDRL_A003 CoA

CKU-5 – CDRL_A004_Test Plan

512-174-0076 Rev A – Plug

512-174-0076 Rev A Form 16

512-174-0076 Form 43

512-174-0087 Rev B – Pin, Locking

512-174-0087 Rev B Form 16

512-174-0087 Form 43

5184315 Rev F – Plug, Breech

5184315 Rev F Form 16

5184315 Form 43

11735367 Rev H – Wire, Lock

11735367 Rev H Form 16

11735367 Form 43

11740596 Rev F – Cap, Protective

11740596 Rev F Form 16

11740596 Form 43

11744252 Rev E – Pin

11744252 Rev E Form 16

11744252 Form 43

ASTM A108-18

ASTM A29/A29M-23

SAE AMS QQ-P-416F

MIL-A-8625F

SAE AMS2460B

ASTM B853-16(2021)e1

SAE AMS5643/H900A

SAE AMS5646R

ASTM E1417/E1417M-21e1

MIL-DTL-5002E

2.1 General Specifications

American National Standards Institute (ANSI)/American Society for Quality (ASQ)

Standards:

ANSI/ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes

Code of Federal Regulations (CFR):

22 CFR 121 The United States Munitions List

22 CFR 122 Registration of Manufacturers and Exporters

Department of Defense (DoD) Directives:

5230.25 Withholding of Unclassified Technical Data From Public Disclosure

International Organization for Standardization (ISO)/International Electrotechnical

Commission (IEC) Standards:

ISO 9001 Quality Management Systems

ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration

Laboratories

2.2 Technical Drawings

Department of Defense Drawings:

512-174-0076 Rev A – Plug

512-174-0087 Rev B – Pin, Locking

5184315 Rev F – Plug, Breech

11735367 Rev H – Wire, Lock

11740596 Rev F – Cap, Protective

11744252 Rev E – Pin

2.3 Conflicting Document Requirements

If there are any conflicts between specifications, drawings, or requirements listed herein, the contractor shall notify the Contracting Officer (KO) and the Technical Point of Contact (TPOC), in writing for interpretation, clarification, and resolution.

3.0 Requirements

3.1 General Manufacturing

The Contractor shall fabricate, inspect, test, and deliver components in accordance with the applicable drawings and specifications. Components shall be packaged by part number and ready for use. The Contractor shall provide, design, and fabricate all necessary tooling to manufacture and dimensionally inspect the components, and provide data as detailed herein.

The Prime Contractor shall bear the ultimate responsibility for all deliveries and performance of all requirements under this contract. The Prime Contractor shall monitor and maintain all subcontractor relationships. At the Government’s sole discretion, the Government may apply quality and/or on-time delivery issues stemming from the work of a subcontractor to the Prime

Contractor’s quality performance metrics.

3.2 Test and Inspection

The Contractor shall maintain and control processes to inspect and test components as described in this PWS. These processes should cover all phases from the ordering of the material to the

Government acceptance of the finished product.

3.2.1 First Article Testing

The Contractor shall submit First Article Test (FAT) samples to the Government if the

Contractor has not provided contract deliverables for the same drawing numbers within the last 3 years.

The Contractor shall submit an Inspection Test Plan in accordance with DI-QCIC-81110 per

CDRL A004 to the Government for review and approval prior to first article manufacture and delivery. The Contractor shall submit a first article sample of 5 EA complete units prior to the first delivery of any production hardware. The first article units shall be fully representative of those proposed for production, and demonstrate the adequacy and suitability of the Contractor's processes and procedures in complying with the requirements set forth by the drawings and specifications.

Any production by the Contractor before formal acceptance of the first article sample shall be at the Contractor’s cost risk.

3.2.2 Dimensional Inspection

The Contractor is responsible for performing in-house inspections to ensure each first article or production component and dimension conforms 100% to the contract, PWS, and product dimensional requirements. The Contractor shall provide copies of in-process dimensional data and/or proof of inspections, such as floor shop travelers or final QA inspections, as requested by the Government.

The Contractor shall submit a Final Dimensional Inspection Report in accordance with DI-NDTI-

80809 per CDRL A001 for each deliverable line item. The final dimensional inspection report shall include either a list of all drawing dimensions and tolerances, and their actual measured values, or a marked-up copy of the drawing with actual measured values written in red next to the corresponding dimension.

3.2.3 Product Certification

The Contractor shall submit a certificate of compliance in accordance with DI-QCIC-81356 per

CDRL A002 to accompany the shipment of each first article and/or production lot, as required by

Table 3. The certificate shall state compliance of the material with its respective drawing or specification, and contract/order requirements. The certificate shall as a minimum state the company name, contract/order number, drawing or specification number, and date.

The Contractor shall submit a certificate of analysis/test in accordance with DI-QCIC-82386, showing the first article and/or production material has been sampled and/or tested and found to be within the minimum requirements of the specification/drawing/contract, as required by Table

1. The certificate shall be forwarded to the Government; one (1) copy to accompany the shipment (in the packing list envelope), and one (1) copy mailed to arrive at time of receipt of the shipment (mark the certificate to the attention of the designated POC above). Each certificate must be traceable to the material covered by the certificate. The certificate shall state, above the signature of a legally authorized representative of the company the following:

Both Certificates of Analysis and Compliance shall state, above the signature of a legally authorized representative of the company, the following:

“This certification concerns a matter within the jurisdiction of an agency of the United States and making a false, fictitious, or fraudulent certification may render the maker subject to prosecution under Title 18, United States Code 1001.”

Test Requirement

Certificate Dwg Location

Material 512-174-0076 Rev A DWG Note #2 (M101) Analysis

Plating 512-174-0076 Rev A DWG Note #5 (M102) Compliance

Material 512-174-0087 Rev B DWG Note #2 Analysis

Material 5184315 Rev F DWG Note #2 Analysis

Dye Penetrant 5184315 Rev F DWG Note @5 Analysis

Plating 5184315 Rev F DWG Note #6 Compliance

Visual 5184315 Rev F DWG Note #3 Compliance

Material 11735367 Rev H DWG Note #2 (M104) & #6 (M107) Analysis

Hardness 11735367 Rev H DWG Note #2 (M104) Analysis

Heat Treat 11735367 Rev H DWG Note #2 (M104) Compliance

Plating 11735367 Rev H DWG Note #4 (M105) Compliance

Visual 11735367 Rev H DWG Note #5 Compliance

Material 11740596 Rev F DWG Material Block Analysis

Plating 11740596 Rev F DWG Note #3 Compliance

Material 11744252 Rev E DWG Note #2 (M101) Analysis

Plating 11744252 Rev E DWG Note #4 (M102) Compliance

Table 1: Certification Requirements

3.3 Quality Control

3.3.1 Quality System and Quality Control Processes

The Contractor shall maintain a quality system which adheres, at minimum, to the requirements of ISO 9001:2015 standards.

The Contractor quality management system shall ensure products are in compliance with the applicable drawings, specifications, and contract. The quality management system shall outline processes to identify, record, and disposition nonconforming material or other characteristic discrepancies for the entire duration of this contract. Procedures, planning, and all other relevant documentation and data which comprise the quality management system, if requested, shall be made available to the Government for review.

3.3.2 Calibration of Measuring and Testing Equipment

Measuring and testing equipment used by the contractor shall, at a minimum, adhere to the requirements of ISO/IEC 17025:2017.

3.3.3 Acceptance of Product

Final acceptance of first article samples and production deliverables will be determined by

Government dimensional inspection and certification verification at Government destination for each deliverable line item. The Government shall complete sample testing within 60 days of receipt of all documentation and deliverables relevant to the relevant line item. Unless otherwise stated, the Government sampling plan shall be in accordance with Table 2. The Government reserves the right to perform additional inspection and testing of hardware to verify acceptability.

This may include testing at other facilities.

ASQ Z1.4 [ANSI/ASQ Z1.4-2003 (R2013) – October 2013]:

Critical: 100%

Major: Level II

Minor: Level I

Table 2: ACSI Sampling Plan

3.3.4 Government-Identified Nonconformity Reporting Procedures

The Government shall alert the Contractor to any nonconforming deliverables within one (1) working day of identifying the nonconformity. The Contractor shall respond with their recommended disposition on the deliverables within one (1) working day.

3.4 Export Control

The Contractor shall comply with either one, or both, of the export control options below.

3.4.1 International Trafficking in Arms Regulations (ITAR) Compliance

The Contractor shall maintain ITAR compliance through registration in accordance with 22 CFR

122 to export Category III and IV munitions components, as defined by 22 CFR 121.

3.4.2 Joint Certification Program (JCP) Registration

The Contractor shall maintain JCP registration and a DD Form 2345 to comply with DoD

Directive 5230.25.

3.5 Preservation

The Contractor shall be responsible for packing and packaging of deliverables to prevent any potential damage during transport. The Contractor shall label completed parts packaging to include component name, quantity, contract number, drawing number, revision, and manufacturer name and date. Packaging quantities and methods shall be in accordance with applicable Form 43.

4.0 Deliverables

The Technical Point of Contact and Contracting Officer (KO) for this contract will approve all deliverables as specified. The following Certificates shall include the signature of the Contractor’s representative authorized to make such certification.

CDRL Spec Section Title

A001 DI-NDTI-80809 3.2.2 Final Dimensional Inspection Report

A002 DI-QCIC-81356 3.2.3 Certificate of Compliance

A003 DI-QCIC-82386 3.2.3 Certificate of Analysis

A004 DI-QCIC-81110 3.2.1 Inspection Test Plan

Table 3: CDRL Specifications

4.1 Hardware Delivery

The Contractor shall notify the Contracting Officer 30 days in advance if the Contractor cannot meet the contract delivery schedule.

The Contractor shall be responsible for coordinating and shipping all the units below to the required destination.

Table 4: Procurement Quantities Item Year Drawing Rev Nomenclature Qty UOI

1 Base 512-174-0076 A Plug (FAT) 5 EA

2 Base 512-174-0076 A Plug 600 EA

3 Base 512-174-0087 B Pin, Locking (FAT) 5 EA

4 Base 512-174-0087 B Pin, Locking 600 EA

5 Base 5184315 F Plug, Breech (FAT) 5 EA

6 Base 5184315 F Plug, Breech 2,400 EA

7 Base 11735367 H Wire, Lock (FAT) 5 EA

8 Base 11735367 H Wire, Lock 1,200 EA

9 Base 11740596 F Cap, Protective (FAT) 5 EA

10 Base 11740596 F Cap, Protective 600 EA

11 Base 11744252 E Pin (FAT) 5 EA

12 Base 11744252 E Pin 600 EA

Delivery address provided below:

Naval Surface Warfare Center Indian Head Division

ATTN: David Dias/Navdeep Sharma

4522 McMahon Road

Bldg. 116, Suite 100

Indian Head, MD 20640