Z17_RF_and_Circuit_Design_PWS_5-17-15.pdf

PERFORMANCE WORK STATEMENT

SECTION C – DESCRIPTION/SPECIFICATION/WORK STATEMENT

C.1 BACKGROUND

The Asymmetric Systems Department (Z Department), Naval Surface Warfare Center, Dahlgren

Division actively supports Naval, Joint, and national needs by providing design and fabrication, rapid prototyping, special acquisition, and technology integration related to circuit board design and Radio Frequency (RF) distribution assemblies, synthetic rope assemblies, mechanical fabrication, and fabric assemblies.

The Asymmetric Systems Department is responsible for the design, development, test, and fielding of maritime vessel disablement systems for the Navy. These systems include synthetic rope assemblies, fabric bags, enclosures and panels, and machined custom hardware. These systems are designed and fabricated using high strength synthetic rope produced by Samson

Rope. One of the key rope materials used in the construction is Amsteel Blue rope. Amsteel

Blue is used in various diameters ranging from 0.5 inches to 1.5 inches. This rope is then custom fabricated into unique geometries per government drawings and industry splicing specifications.

In addition to the rope material, there are numerous custom machined mechanical parts that are required to fully build the rope assembly. Custom fabricated fabric bags, enclosures and panels are required to store and deploy the various synthetic rope assemblies from various maritime platforms. A fabric material called Herculite 80 is used predominately for these items and is custom cut and sewn per government drawings. Each disablement system also requires numerous custom machined parts to complete each system. Due to the harsh maritime environment, a variety of materials including stainless steel, anodized aluminum, titanium, and plastic are used judiciously to provide the appropriate material properties for the application.

The Asymmetric Systems Department is also responsible for the design, development, fabrication, test, and delivery for various Command, Control, Communications, Computers, Intelligence, Surveillance and Reconnaissance (C4ISR) systems. These systems include custom rack-mount installation kits, power/signal/RF cable sets, machined mechanical installation hardware sets, printed circuit board subassemblies, and fully functional/enclosed C4ISR subsystems. Due to the typical airborne environment, all of the products are designed to operate over a wide temperature range under high-vibration loading. The mechanical and electrical installation kits are fabricated to specifications directly from government drawings. All other systems and components are designed and fabricated using government requirements as needs arise from the sponsor’s direction. All cable sets are assembled with labels, heat shrink, and sometimes a strain relief on each termination. Long cables are laser-marked with a wire number as designated in government drawings. Mechanical hardware is generally made of aluminum, stainless steel, and various plastic materials. Due to the electrical bonding requirements and the dynamic operating environment, the aluminum parts are finished with an anodized coating, primer, or paint. Every part, component, and system undergoes Quality Assurance (QA) testing and inspections before completing government supervised acceptance measures.

C.2 SCOPE

This Statement of Work (SOW) defines the requirements for contractor support to be provided to the Naval Surface Warfare Center, Dahlgren Division, in support of full spectrum operations and the Global War on Terrorism. When ordered by the issuance of individual delivery/task orders, the contractor shall provide design, technical documentation, fabrication, system integration, test and evaluation, and rapid prototyping support for the systems defined in this SOW. Types of equipment may include voice and data communications, cryptographic equipment, electronic countermeasures, navigation aids, radar, and sonar, as they pertain to Electronic Warfare (EW) and RF systems. Other types of equipment or systems may include maritime vessel disablement systems, deployment systems, and electrical/mechanical systems.

C.3 REQUIREMENTS

C.3.1 Work to be performed and required deliverables shall be specifically described in delivery/task orders to be placed against the contract by the Contracting Officer or designated

Ordering Officer and shall be within the parameters of one or more of the tasks described below.

As defined in individual delivery/task orders, the contractor shall furnish all labor and facilities, fabricate, assemble, receive, inventory, verify, package, temporarily store and ship material and equipment necessary in the performance of these tasks except for those facilities, material, equipment, and information to be provided by the Government.

C.3.2 Design

C.3.2.1 The contractor shall participate in design reviews in conjunction with NSWCDD personnel and recommend design improvements to NSWCDD personnel. The contractor shall participate in up to 20 design reviews per year.

C.3.2.2 The contractor shall design, review, and comment on proposed engineering changes, waivers, deviations, and alterations for their impact on performance, reliability, maintainability, availability, quality, safety, and life cycle cost. The contractor shall perform these reviews on the following types of items:

a) Printed Circuit Boards (PCB)

b) Electronic devices, to include analog, digital, and RF

c) Cable harnesses and assemblies, to include power, signal, and RF

d) Enclosures for electronic sub-systems

e) Custom machined mechanical hardware

f) Synthetic rope assemblies, subassemblies, and net based systems

g) Plastic and fiberglass parts

h) Custom sewn fabric bags, enclosures, and panels

i) Custom rigging and lifting assemblies to include load rated pendants and tow bridles

C.3.3 Technical Documentation, Specifications, and Standards

C.3.3.1 The contractor shall develop, review the technical adequacy and accuracy, maintain engineering drawings and associated lists, and propose and implement changes to technical documentation, specifications, and standards and drawings (CDRL A001).

C.3.3.2 The contractor shall develop, review, revise, maintain, and monitor specifications, standards, technical data, and instructions relating to support of equipment or systems and develop recommendations for specific improvements to the following types of equipment or systems:

a) Printed Circuit Boards (PCB)

b) Electronic devices, to include analog, digital, and RF

c) Cable harnesses and assemblies, to include power, signal, and RF

d) Enclosures for electronic sub-systems

e) Custom machined mechanical hardware

f) Synthetic rope assemblies, subassemblies, and net based systems

g) Plastic and fiberglass parts

h) Custom sewn fabric bags, enclosures, and panels

i) Custom rigging and lifting assemblies to include load rated pendants and tow bridles

C.3.3.3 The contractor shall provide facilities, equipment and personnel to perform testing needed to operate these equipment or systems. This includes Burn In, Functional, and

Environmental testing capabilities. The contractor shall provide test plans and test results

(CDRL A004, CDRL A005).

C.3.4 Fabrication

C.3.4.1 The contractor shall fabricate hardware, rope, and cable assemblies in accordance with specifications identified at the delivery order level. The contractor shall fabricate the following types of systems and equipment:

a) Printed Circuit Boards (PCB)

b) Electronic devices, to include analog, digital, and RF

c) Cable harnesses and assemblies, to include power, signal, and RF

d) Enclosures for electronic sub-systems

e) Custom machined mechanical hardware

f) Synthetic rope assemblies, subassemblies, and net based systems

g) Plastic and fiberglass parts, to include rapid prototyping and injection molding

h) Welding and metal fabrication, including custom machined and sheet metal parts

i) Custom sewn fabric bags, enclosures and panels

j) Custom rigging and lifting assemblies to include load rated pendants and tow bridles

C.3.4.2 The contractor shall provide painting of plastic and coating (in the form of paint, primer, or anodizing) for metal parts.

C.3.4.3 The contractor shall provide drawing packages, Bill of materials, Bracket drawings, cable drawings, wiring diagram, and schematics (CDRL A001). The contractor shall provide up to 20 drawing packages per year.

C.3.4.4 The contractor shall accept and process data files in the Pro/Engineer, Solid Works, Solid Edge, or generic IGES or STL 3-D file types, as well as the 2-D AutoCAD DWG/DXF file type.

C.3.4.5 The contractor shall assign part numbers for all the top assembly items, as well as all fabricated parts and cables schematics in a standard configuration management format.

C.3.5 Systems Integration, Test and Evaluation

C.3.5.1 The contractor shall perform systems integration to permit the developmental testing and analytical test and data analysis for selected technologies, prototyped capabilities, and related systems that require evaluation by the Government. The contractor shall integrate subassembly hardware, develop system and component test plans, develop test data collection and analysis plans, conduct testing, and document test results (CDRL A004, CDRL A005).

C.3.6 Rapid Prototyping

C.3.6.1 The contractor shall conduct rapid prototype development. The contractor shall develop systems, including electrical and mechanical systems across a variety of technical areas including voice and data communications, cryptographic equipment, electronic countermeasures, navigation aids, radar, and sonar, RF systems, maritime vessel disablement systems, deployment systems, and electrical/mechanical systems.

C.3.6.2 The contractor shall refine conceptual designs through a build-test-build cycle to mature prototype systems into fieldable systems. The contractor shall review designs and recommend improvements to NSWCDD based upon prototype testing.

C.3.6.3 The contractor shall conduct hardware and mechanical engineering support in the development and fabrication of electrical and mechanical components to support system development and design. The Contractor shall provide system architecture engineering research and support in the development and implementation of new architecture designs.

C.3.7 Tasking Method and Management

C.3.7.1 Each requirement placed against the Basic Contract will be in the form of a Delivery

Order (DO) containing its own Statement of Work (SOW) and applicable Contract Data

Requirements List (CDRLs). Each DO SOW will describe the specifics of the requirement with respect to performance, end item deliveries, delivery schedules, performance milestones, Government reviews, and travel. Delivery Orders may be written against any portion of this

SOW.

C.3.7.2 The contractor shall provide a status report (CDRL A002) for each Cost-Type

Delivery Order.

C.3.7.3 The contractor shall participate in both formal and informal IPRs of work being performed. IPRs may be conducted at the overall Task Order level or for specific projects/work areas/TIs. Reviews will be scheduled by the Government. At the time the review is scheduled, the Government will communicate the specific purpose of the review. An initial formal IPR is planned within 60 days of the Task Order award date and will follow the agenda agreed to by the

Task Order’s COR. Subsequent formal IPRs shall be held approximately every 90 days thereafter unless waived by the Government (CDRL A003).

C.3.8 Government Furnished Equipment/Information (GFE/GFI)

Each Delivery Order issued by the Government will specify and describe the Government furnished equipment, information, data, documentation, and facilities.

C.3.9 Quality Assurance Requirements

C.3.9.1 The contractor shall, at a minimum, be ISO9001-2008 certified. The following quality assurance items are required:

MIL-I-45208A Inspection System

Testing and Burn-in capabilities

Electrostatic Discharge (ESD) Program in accordance with MIL-STD-1686C

Calibration System in accordance with MIL-STD-45662

Receiving Inspection Control

First Article Inspection, In-Process Inspection, & Final Inspection

Test Monitoring

Inspection of Packaging and Shipping

C.3.9.2 Workmanship shall be performed in conformance with IPC A-610C criteria, classes

1, 2, and 3. Visual Inspection and Electrical Testing failure data shall be acquired from all operations and logged by Assembly Serial Number. Summary reports should indicate Yield

Rates by assembly Type and Operation, and chart defect Types should be in order of magnitude by Assembly Type and Component Location. Systems shall be in place to ensure full

Component and Product traceability and in-house history.

C.4 TRAVEL

The contractor shall be required to travel in performance of this contract. The numbers of trips and types of personnel traveling shall be limited to the minimum required to accomplish work requirements and shall be coordinated with the COR. All travel shall be conducted in accordance with FAR 31.205-46 Travel Costs and the Joint Travel Regulations (JTR) and shall be pre-approved by the COR. The travel to the following locations is anticipated:

Dahlgren, VA (up to 3 times per year)

Patuxent River, MD

C.7 SECURITY

C.7.1 Personnel providing direct support to this effort are not required to have a clearance. All deliverables associated with this contract are unclassified.

C.7.2 Electronic Spillages (ES) are unacceptable and pose a risk to national security. An electronic spillage is defined as classified data placed on an information system (IS), media or hardcopy document possessing insufficient security controls to protect the data at the required classification level, thus posing a risk to national security (e.g., sensitive compartmented information (SCI) onto collateral, Secret onto Unclassified, etc). The contractor's performance as it relates to ES will be evaluated by the Government. ES reflects on the overall security posture of NSWCDD and a lack of attention to detail with regard to the handling of classified information of IS security discipline and will be reflected in the contractor's performance rating.

In the event that a contractor is determined to be responsible for an ES, all direct and indirect costs incurred by the Government for ES remediation will be charged to the contractor.

C.7.3 NSWCDD Security will continue to be responsible for the corrective action plan in accordance with the security guidance reflected on the DOD Contract Security Classification

Specification - DD254. NSWCDD Security will identify the contractor facility and contract number associated with all electronic spillages during the investigation that involve contractor support. NSWCDD Security will notify the Contracts Division with the contractor facility name and contract number, incident specifics and associated costs for clean up. The Contracting

Officer will be responsible to work with the Contractor Facility to capture the costs incurred during the spillage clean up. The Contractor is also responsible for taking Information Security

Awareness training annually, via their Facility Security Officer (FSO), as part of the mandatory training requirements. If a spillage occurs additional training will be required to prevent recurrence.

C.7.4 Portable Electronic Devices (PEDs)

C.7.4.1 Non-government and/or personally owned portable electronic devices (PEDs) are prohibited in all NSWCDD buildings with the exception of personally owned cell phones which are authorized for use in spaces up to and including Controlled Access Areas. The Contractor shall ensure the onsite personnel remain compliant with this PED policy. NSWCDD instruction defines PEDS as the following: any electronic device designed to be easily transported, with the capability to store, record, receive or transmit text, images, video, or audio data in any format via any transmission medium. PEDS include, but are not limited to, pagers, laptops, radios, compact discs and cassette players/recorders. In addition, this includes removable storage media such as flash memory, memory sticks, multimedia cards and secure digital cards, micro-drive modules, ZIP drives, ZIP disks, recordable CDs, DVDs, MP3 players, iPADs, digital picture frames, electronic book readers, kindle, nook, cameras, external hard disk drives, and floppy diskettes.

C.7.4.2 PEDs belonging to an external organization shall not be connected to NSWCDD networks or infrastructure without prior approval from the NSWCDD Information Assurance and Compliance Branch, Code 1043. This approval will be granted using the TARIS form and action tracker process.

C.7.4.3 Personally owned hardware or software shall not be connected or introduced to any

NSWCDD hardware, network or information system infrastructure.

C.8 Labor Tripwire Justifications

C.8.1 The Contractor shall advise the COR and the Contract Specialist, by email, if the pending addition of any individual (Key or non-Key) will be at a fully loaded (through target fee) labor rate that exceeds the labor tripwire amount in a contract labor category with no previous tripwire approval. If the contract labor category has not been approved, the contractor may not proceed with the addition until he is advised by the Contract Specialist that the request has been approved.

C.8.2 The Contractor’s request shall include: the proposed individual’s resume, labor hourly rate build-up, labor hours per work year, detailed justification for the addition of the particular individual based on his/her technical expertise and projected technical impact on the Task

Order/Technical Instruction. If the individual is a subcontractor or consultant, the rate build-up shall include the prime contractor’s pass through rate.

C.8.3 Currently, the labor tripwire is $156 per hour, regardless of the number of labor hours the proposed individual will work. The Contractor will be advised of any changes to this tripwire level that occur during performance.