H12 RF and Fabrication SOW 6-24-20.doc

C.1

BACKGROUND

The Weapons Control and Integration Department (H 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, mechanical fabrication, and fabric assemblies.

The Asymmetric Systems Department is 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 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 radar, voice and data communications, cryptographic equipment, electronic countermeasures and navigation aids 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 Orders (DOs) 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 DOs, 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.

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 Open Architecture (OA) - The Contractor shall develop and maintain an architecture that incorporates appropriate considerations for re-configurability, portability, maintainability, technology insertion, vendor independence, reusability, scalability, interoperability, upgradeability, and long-term supportability as defined in the OA Contract Guidebook (https://acc.dau.mil/NOAGuidebook). Other applicable standards, practices and procedures related to the design, construction and material selection for deliverable prototypes include the following:

· AFSC DH 1-6 System Safety

· AS50881 SAE Aerospace Standards, Wiring Aerospace Vehicle

· IPC J-STD-001 Soldering Certification

· IPC-A-610E Acceptability of Electronic Assemblies

· IPC/WHMA-A-620A Requirements & Acceptance for Cable & Wire Harness Assemblies

· MIL-STD-416G Electromagnetic Interference Characteristics of Subsystems and Equipment

· MIL-STD-461 Requirements for the Control of Electromagnetic Interference Emissions and Susceptibility

· MIL-STD-462 Test Method Standard for Measurement of Electromagnetic Interference Characteristics

· MIL-STD-464 Electromagnetic Environmental Effects, Requirements for Systems

· MIL-STD-704 Department of Defense Interface Standard, Aircraft Electric Power Characteristics

· MIL-STD-810 Department of Defense (DoD) Test Method Standard for Environmental Engineering Considerations and Laboratory Tests

· MIL-STD-882E System Safety

· MIL-STD-1760 Department of Defense Interface Standards for Aircraft/Store Electrical Interconnection System

· MIL-STD-7179 Finishes, Coatings, and Sealants

C.3.3.2.1 Circuit cards shall be fully populated and built to IPC 610 Class 2 level and inspected to IPC A-600 Class 2.

C.3.3.2.2 For cabling, IPC 620 shall include AS50881, MIL-STD-1310, 461, 464, 704, 901, 1274.

C.3.3.2.3 Specific versions of standards, handbooks, and applicable interface documentation will be articulated in individual Delivery Orders for the respective prototype deliverables.

C.3.3.2.4 Drawings shall be in accordance with ANSI/ASME applicable standards and practices with specific tailoring provided in individual Delivery Orders.

C.3.3.2.5 Technical Data Packages (TDP) shall be of sufficient quality to enable prototype reproduction by qualified vendors. As a minimum, per MIL-STD-31000, TDP quality shall be Level II (Developmental) with Level III (Production) aspects as specified in individual Delivery Orders. (CDRL 0001) C.3.3.2.6 Copies of Government specifications, standards, handbooks and guidance data listed above may be obtained from: http://assist.daps.dla.mil/online/start/ C.3.3.3 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.3.3.4 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 A002, CDRL A003).

C.3.4 Hardware Fabrication

C.3.4.1 The Contractor shall fabricate hardware, rope, and cable assemblies in accordance with specifications identified at the DO 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).

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 A002, CDRL A003).

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 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. DOs may be written against any portion of this SOW.

C.3.7.2 The Contractor shall participate in a kick-off meeting for the contract. The kick-off meeting will be held via teleconference.

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

Each DO 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 or AS9001C certified. The following quality assurance items are required:

· MIL-I-45208A Inspection System

· Testing and Burn-in capabilities

· Electostatic 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 may be required to travel in performance of this contract. Specific travel requirements will be provided within each Delivery Order.

C.5

MANDATORY REQUIREMENTS

The following mandatory requirements shall be maintained throughout the life of this task order.

Requirement 1: Facility location:

The Offeror’s design and manufacturing facility supporting this contract must be located within 100 miles of Dahlgren, VA, 100 miles of Patuxent River, MD, or 100 miles of Jacksonville, FL.

Requirement 2: Quality Assurance Requirements:

The Offeror must meet the Quality Assurance Requirements (QAR) as stated in Section C of the Statement of Work, which includes being ISO9001:2008 or higher or Aerospace Quality Standard AS9100C certified.

C.6

SECURITY

C.6.1 Personnel providing direct support to this effort are not required to have a clearance. All deliverables associated with this contract are unclassified.

C.6.2 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.6.3 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.6.4 Portable Electronic Devices (PEDs) C.6.4.1 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.6.4.2 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. This approval will be granted using the TARIS form and action tracker process.

C.6.4.3 Personally owned hardware or software shall not be connected or introduced to any NSWCDD hardware, network or information system infrastructure.

C.6.5 Operations Security (OPSEC)

C.6.5.1 All Contractors (including Subcontractors) shall supplement their current security practices by requiring any personnel involved in executing this contract to complete Government-sponsored and administered Operations Security (OPSEC) training. In addition, all Contractors should be aware of the Critical Information List (CIL) for the department they are supporting as well as the OPSEC plan for NSWCDD. Upon contract award, all identified Contractors (including Subcontractors) shall sign a Contractor's conformance statement and submit it to the NSWCDD COR named in block 13 of the attached DD-254 thereby acknowledging that they will meet the requirements of this contract. The COR shall contact their Department Training Coordinator to schedule key employees to attend the Government-sponsored OPSEC training. The Contractor must immediately notify the Government upon the discovery of any nonconformance with the OPSEC Plan.

C.6.6 Privacy Program Training

C.6.6.1 Privacy Program Training. Privacy training is mandatory for all NSWCDD personnel (military, civilian, and contractor) and must be completed annually. The Total Workforce Management System (TWMS) is the official database for workforce training and is the preferred tool for taking and recording privacy act training. All NSWCDD personnel are responsible for ensuring individual annual privacy training requirements are met.