Attach_J-4_SOW.FINAL_11082016.pdf

STATEMENT OF WORK

FOR

MARITIME SECURITY HELMET (MSH)

19 August 2016

1.0 SCOPE

NAVSEA PMS 408 has a requirement to outfit U.S. Naval personnel aboard Navy ships with the Maritime

Security Helmet (MSH). This Statement of Work (SOW) defines the efforts required for the production and delivery of the MSH, to outfit U.S. Naval personnel aboard Navy ships, and at Naval Activities, US Navy Military Sealift

Command and other DoD activities. MSH will provide protection against multiple ballistic and fragmentation hazards while performing security and Anti-Terrorism /Force Protection (AT/FP) duties. The MSH is a critical safety item. Qualification and eligibility for any production task orders under this contract is contingent upon the contractor’s successful completion of First Article Test (FAT) in accordance with NQ/PD 16-02 Maritime Security

Helmet Purchase Description and the NQ/CID 16-01Adjustable Retention System Commercial Item Description, Attachments J-1 and J-2 respectively.

1.1 Acronyms

AT/FP Anti-Terrorism /Force Protection

CAR Corrective Actions Report

CATEX Categorical Exclusion

CI Configuration Item

CID Commercial Item Description

CM Configuration Management

CoC Certificate of Conformance

COTS Commercial Off-The-Shelf

CSA Configuration Status Accounting

DCMA Defense Contract Management Agency

DoD Department of Defense

EA Environmental Assessment

ECP Engineering Change Proposal

EIS Environmental Impact Statement

EPA Environmental Protection Agency

ESOH Environment, Safety, and Occupational Health

FAT First Article Testing

HHA Health Hazard Assessment

HMMP Hazardous Materials Management Program

IPR In-Process Review

LAT Lot Acceptance Testing

MSDS Material Safety Data Sheet

MSH Maritime Security Helmet

NAS National Aerospace Standard

NDI Non-Developmental Item

NEPA National Environmental Policy Act

NOR Notice of Revision

NCTRF Navy Clothing and Textile Research Facility

ODC Ozone Depleting Chemical

ODS Ozone Depleting Substance

PCA Physical Configuration Audit

PCO Procuring Contracting Officer

PD Product Description

QA Quality Assurance

QALI Quality Assurance Letter of Instruction

QAR Quality Assurance Representative

QASP Quality Assurance Surveillance Plan

RFV Request for Variance

SOW Statement of Work

2.0 APPLICABLE DOCUMENTS

The following documents, of the exact issue shown, form a part of this statement of work (SOW) to the extent specified herein. In the event of conflict between the documents referenced and the contents of this SOW, the

SOW shall supersede. Second tier and lower references, (i.e., those referenced in the primary references) shall be used for guidance only.

2.1 Military Standards

None

2.2 Military Specifications

None

2.3 Other Documents

a) ANSI/ASQ Z1.4-2008 Sampling Procedures and Tables for Inspection by Attributes

b) MIL-HDBK-61 Configuration Management Guidance

c) NAS 411 National Aerospace Standard

d) MIL STND 882 Department of Defense Standard Practice System Safety

e) FED-STD-313D Material Safety Data, Transportation Data and Disposal Data for Hazardous Materials Furnished to Government Activities

f) ASME Y14.100 Engineering Drawing Practices

g) ASME Y14.34 Associated Lists

h) NQ/PD 16-02 Product Description, Helmet, Maritime Security

(Attachment J-1), 76 pages,

i) NQ/CID 16-01 Commercial Item Description, Adjustable Retention System, (Attachment J-2), 8 pages

j) MSH Quality Assurance Letter of Instruction, 4 pages (Attachment J-3)

3.0 REQUIREMENTS

3.1 Fabrication Support

3.1.1 Maritime Security Helmet (MSH)

The Contractor shall provide all facilities, materials and labor to fabricate and deliver the Maritime

Security Helmet (MSH). The MSH shall be manufactured in two sizes: Medium (M) and Extra-Large (XL). The

MSH Pad Set shall be manufactured in a single size. The Adjustable retention system shall be manufactured in one

(preferred) or two sizes. The Contractor shall provide MSHs in accordance with the form, fit, and functional requirements as described in this Statement of Work, Purchase Description NQ/PD 16-02 (Attachment J-1), and Navy

NQ/CID 16-01 (Attachment J-2). The contractor shall produce and deliver a minimum of 1,000 MSH per month, commencing 60 days after any potential production contract award.

3.1.2 Commercial Products/Standard Parts

In accordance with FAR 52.244-6 Subcontracts for Commercial Items, the Contractor shall use commercial products, processes, and practices when possible to reduce production and operation support costs unless a material or part is specified in NQ/PD 16-02 and NQ/CID 16-01. In any case where not specified in the

PD, and it is technically and economically feasible, a standard part will be used rather than a non-standard part. A standard part is one that is routinely available in the Government inventory, or commercial supply channels and is not sole source or proprietary in nature. Any non-standard part shall be identified to the Government for written approval to use that part.

3.1.3 Product Improvements

Future improvements in system design which provide improved fit, durability and impact performance or reduce cost are encouraged during the contract term through the use of Engineering Change

Proposals (ECP), Manufacturing Technology, and Operation Support Cost Reduction. Product improvements may be proposed by either the Contractor or the Government to eliminate operational shortcomings, improve operational effectiveness, accommodate fielding requirements, or provide savings to the Government. Product improvements will not be considered prior to contract award.

3.2 Test and Evaluation

3.2.1 First Article Test (FAT)/Performance Based Qualifications

3.2.1.1 The Government will conduct First Article Tests in accordance with FAR

52.209-4 First Article Approval- Government Testing. The Government will evaluate the First Articles in accordance with NQ/PD 16-02 and NQ/CID 16-01.

3.2.1.2 MSH shell and pad sets shall be fabricated in accordance with NQ/PD 16-02.

3.2.1.3 The Contractor shall deliver production MSH systems for non-ballistic and ballistic requirements and verifications within sixty (60) days of contract award in accordance with NQ/PD 16-

02and NQ/CID 16-01 (Delivery address is provided in Section F). The contractor shall provide all certification/compliance documentation with the MSH systems.

3.2.1.4 The government will pay for FAT test articles and conduct of the initial FAT.

Should the contractor fail the initial FAT, the contractor shall pay for subsequent FAT test articles and the conduct of FAT prior to exercising any contract options.

3.2.1.5 The Government’s FAT may include verification of any or all of the requirements specified in Attachments NQ/PD 16-02 and NQ/CID 16-01.

3.2.1.6 Any additional FAT required to validate revised or new designs shall be approved by the Procuring Contracting Officer (PCO).

3.2.1.7 The Contractor shall produce both the first article and the production quantity at the same facility.

3.3 Configuration Management

3.3.1 Raw Materials

All production quantities submitted after approval of the FAT shall be produced using the same raw materials, suppliers, materials, processes, procedures, equipment and facilities that resulted in the manufacture of the acceptable FAT items in accordance with section 3.8.3. This includes all raw materials or sub-components.

Prior to any change in the production of the approved FAT test items, listed above, the contractor must notify the

Contracting Officer in writing. The Contracting Officer will determine if a new FAT is required prior to that change. Should the contractor fail to provide written notification, the contractor will pay for a new FAT, per

Attachments NQ/PD 16-02 and NQ/CID 16-01.

3.3.2 Standard Samples

Upon approval of FAT, three (3) helmets from each size evaluated for end item inspection will then have a 100% inspection for dimensional and quality defects; any and all defects shall be corrected by the contractor. After correction by the contractor, the helmets will be signed as standard samples and will be retained by the NAVSEA, DCMA, and Navy Clothing and Textile Research Facility (NCTRF) to be used as a guide for all future quality inspections. These items are to be fabricated where the items are going to be produced in production and all future lots. If prime contractor uses multiple subcontractors for production of the end item, each subcontractor shall submit a set of standard samples as well.

3.3.3 Configuration Process And Control

The Contractor shall maintain a configuration management (CM) process for the control of raw material utilized in the helmet shell designs that are approved by the Government in accordance with FAT requirements. The Contractor shall furnish with each lot submitted to the Government, the associated helmet shell raw material traceability matrix, to include raw material supplier Certificates of Conformance (CoC) and lots of raw material used in each lot presented to the Government. MIL-HDBK-61 may be used for guidance. The Contractor’s

CM process shall consist of configuration identification and configuration control of all raw materials utilized in the production of the helmet shell. The CM process shall interface with other acquisition requirements such as design review, quality assurance, and other program related disciplines shall be addressed.

3.4 Lot Acceptance Test and Evaluation

3.4.1 Procedures

The Contractor shall provide measurements and Certificates of Conformance for all in-process material inspections needed to meet the minimum requirements of the performance specification. End item testing shall be conducted on all lots presented to the Government in accordance with Attachments NQ/PD 16-02 and

NQ/CID 16-01. Only the ballistic system that has successfully completed FAT per Attachments NQ/PD 16-02 and

NQ/CID 16-01 shall be used. The Contractor shall assign lot and serial numbers to each ballistic component produced and shall be able to track those serial numbers back to Lot Acceptance Testing and raw materials. Defense

Contract Management Agency (DCMA) Quality Assurance Representative (QAR) and/or Technical Warrant Holder shall identify randomly selected serial number components to be pulled from production for purposes of Lot testing.

3.4.1.1 The Quality Assurance Letter of Instruction (QALI) (Attachment J-3) is intended to be implemented by the Defense Contract Management Agency (DCMA) at the contractors manufacturing facility. This document stipulates the requirements and expectations of the PMO for production process monitoring, in-process material inspection, ballistic sampling procedures and finished end item evaluations.

DCMA will develop and submit a Quality Assurance Surveillance Plan (QASP) to be coordinated with the PMO.

3.4.2 Testing Submissions

Lot size inspection shall be in accordance with Attachments NQ/PD 16-02 and NQ/CID 16-01 and derived per OSD protocol and ANSI/ASQ Z1.4-2008 - Sampling Procedures and Tables for Inspection by

Attributes.

3.4.3 Designated Authority

The Designated Authority (below) shall be placed in box 17 of all DD Form 1222 (Request for and Results of Tests), and the test lab shall provide the results of all testing directly to the designated authority. No lots shall be released from the Contractor’s facility prior to release of end item testing notification of acceptance from the Government (DCMA, contracting agency, or designated authority). The Designated Authority for this contract includes:

Mr. Edward Gray

Naval Sea Systems Command (NAVSEA)

1333 Isaac Hull Avenue SE

Washington Navy Yard, DC 20376-5149

TEL: 202-781-5262; DSN: 326-5262

Email: edward.gray1@navy.mil

3.4.4 Additional Testing

While the scope of QA testing is limited in requirements, threat, and conditions tested, it does not relieve the Contractor from full requirements of this contract and all associated specifications or the statement of work. Nor shall it permit the Contractor to present to the Government any items that are known or suspected to be substandard merely on the basis of acceptable lot test results or the possibility of acceptable results if tested. The

Government reserves the right conduct varied or additional QA and/or verification tests against any or all requirements of the contract and/or its specifications at any time as a condition of acceptance.

3.5 Program Management

The Contractor shall designate a Program Manager. This individual shall serve as the primary point of contact between the Government and the Contractor, and shall be responsible for the coordination of all Contractor activities related to the contract.

3.6 Post Award Conference

A Post Award Conference will be held by the Government at the Contractor’s facility within 30 days of contract award. The purpose of the conference is to ensure mutual understanding of contract requirements, dispute resolution procedures, and identification of points of contact from contractor and government organizations.

3.7 In-Process Reviews (IPRS) (CDRL A001)

The Contractor shall host and participate in IPRs, as required. Initially, IPRs will be conducted on a quarterly basis at a minimum. The IPR reviews the progress of the MSH program until production ramp-up is complete and monthly production is running consistently. After reaching and sustaining full production, IPRs will be held when deemed appropriate by the Government. IPRs shall be conducted on dates mutually agreeable to the

Contractor and the Government. The Contractor shall brief on the production status and schedule, and any issues related to contract execution.

3.8 Technical and Support Documentation

In support of the MSH fabrication effort, the Contractor shall submit the following technical and support documentation as specified below.

mailto:edward.gray1@navy.mil

3.8.1 Contract Status Report (CDRL A001)

During periods of fabrication of MSH (First Articles or production), the contractor shall prepare a monthly status report that documents the status of contractor effort towards achieving contract objectives. The report shall identify accomplishments to date and difficulties encountered, and compare the status achieved to planned goals and the resources expended. The status report shall also include a detail listing of all material purchases, including the specific cost of each item procured.

3.8.2 System Safety and Environmental Information Report (SSEIR)

3.8.2.1 System Safety (CDRL A002)

The Contractor shall identify and evaluate environmental, safety, and health hazards, define risk levels, and establish a program that manages the probability and severity of all hazards associated with development, use, and disposal of the system in accordance with MIL-STD-882. Residual risks will be evaluated by the Government in accordance with MIL-STD-882 and accepted as appropriate prior to exposing people, equipment, or the environment to known system related Environment, Safety, and Occupational Health (ESOH) risks. The

Contractor must identify all explosive safety risks as such in the system safety documentation.

3.8.2.2 Health Hazard Assessment (CDRL A002)

The Contractor shall perform and document a Health Hazard Assessment (HHA) to identify health hazards, evaluate proposed hazardous materials, and propose protective measures to reduce the associated risk to a level acceptable by the Government. The HHA shall include the minimum hazard probability and severity reporting thresholds and any selected hazards, hazardous areas, hazardous materials, or other specific items to be examined or excluded.

3.8.2.3 Hazardous Materials Management Program & Pollution Prevention

(CDRL A002)

The Contractor shall implement a Hazardous Materials Management Program (HMMP) and Pollution Prevention (P2) in accordance with NAS 411. The Contractor shall avoid the use of toxic chemicals, hazardous materials, and ozone depleting substances (ODS) in the design, operational support and disposal of the

MSH where possible. The HMMP shall establish a process to manage all requirements for asbestos, radioactive materials, cadmium, hexavalent chromium, and extremely toxic or hazardous materials in design, production, operation, and support. The use of Class I or Class II Ozone Depleting Chemicals (ODCs) is prohibited in the design or operational support of the system without specific written approval of the Contracting Officer. More information on chemicals and hazardous materials to be avoided can be obtained from the Environmental Protection Agency

(EPA). The Contractor shall make this information available to the Government upon request.

3.8.2.4 Material Safety Data Sheets (CDRL A002)

The Contractor shall provide all Material Safety Data Sheets (MSDS) to the Government for review (a) at Post Award Conference and (b) anytime thereafter if their helmet material in support of the helmet product baseline changes. A copy of the MSDS is required in accordance with FED-STD-313D Change Notice 1.

3.8.2.5 Environmental Considerations (CDRL A003)

The Contractor shall provide information on the potential for any adverse environmental impacts from the manufacturing, operation, maintenance, and disposal of the helmet. This information will be used to assist the Government in making a preliminary National Environmental Policy Act (NEPA) decision and in the preparation of formal NEPA documents, which include CATEX, EA, and EIS. Such environmental impacts include air, soil, wetlands, water, flora, fauna, endangered species, emissions and toxic waste resulting from development, maintenance (coatings and primers), operation, disposal, etc.

3.8.3 Configuration Management

3.8.3.1 Configuration Management Process (CDRL A004)

The Contractor shall maintain a configuration management (CM) process for the control of all MSH configuration documentation, media and parts representing or comprising the MSH. The principles contained in EIA-649 and MIL-HDBK-61 may be used for guidance. The Contractor's CM process shall consist of configuration identification, configuration control, configuration status accounting, and configuration audits.

Consideration for interfacing with other acquisition requirements such as design review, quality assurance, and other program related disciplines shall be addressed. The Contractor shall notify the Government of any changes at the

Contractor's facility, which affect the Contractor's established CM process.

3.8.3.2 Configuration Identification (CDRL A004)

At the Post Award Conference, the Contractor shall propose Configuration Items (CIs) to be managed by the Government and those to be managed by the Contractor at a lower level/tier. For those CIs that have been identified for Government control, the Contractor shall provide form, fit, function, and interface documentation necessary for configuration status accounting. The Contractor shall establish management practices for those lower level/tier CIs.

3.8.3.3 Configuration Status Accounting (CDRL A004)

The Contractor shall establish and maintain a Configuration Status Accounting (CSA) database, which represents the configurations of the MSH. All baselines and changes shall be documented in the

Contractor’s CSA database. The Contractor's CSA database shall permit acceptance of commercial product information; however, if requirements to report data outside of the Contractor's CSA database or format exist, the information may be delivered as a supplement to prevent disruption to their existing system. The Contractor's CSA database shall reconcile any differences between the supplier information and Contractor practices to provide the

Government with clear accountability of product information. Additionally, the CSA database shall provide a reliable source of configuration information to support test activities, including program management, systems engineering, logistics support, and modification/maintenance actions. The Government may request a report from the CSA database as needed.

3.8.4 Physical Configuration Audit Report (CDRL A005)

The Physical Configuration Audit (PCA) shall be performed to verify the MSH and its configuration items (CIs) are accurate, complete, compatible, and that the CI has achieved the performance and functional characteristics defined in the functional configuration baseline. The Government and the Contractor shall conduct the PCA jointly, at a time and place mutually agreed upon, with the Government chairing the audit. The

PCA shall verify the drawings reflect the "as-built" configuration of all newly developed or modified portions of the system; accurate form, fit, function information is provided on control drawings for non-developmental/commercial off-the-shelf items; and confirm the drawings accurately represent the "as-built" production configuration.

Whenever possible, the PCA shall be conducted incrementally, concurrent with hardware fabrication and assembly of the first production MSH. The Contractor shall provide an approach and proposed schedule for conducting the

PCA and identification of the CIs to be audited at first article production. The Contractor shall participate and assist the Government in the development of the PCA, using the guidelines contained in MIL-HDBK-61A, section 8. The

Contractor shall document the results of the PCA after each audit and shall correct all audit discrepancies documented in the configuration audit summary reports. In the event the Government finds evidence the drawings and/or documents do not adequately represent the equipment, the Government reserves the right to stop production until all discrepancies are corrected and the Government approves the configuration audit summary report. The product baseline will be established upon completion of the PCA and resolution of audit discrepancies.

3.8.5 Configuration Control

The Contractor shall implement configuration control methods and procedures which maintain the integrity and traceability of an established baseline. Changes to established baselines shall only be made after

Government approval of Engineering Change Proposals (ECP) and Requests for Variance (RFV). Sufficient supporting data to evaluate the proposed change, such as drawings, supplemental drawings, sketches, specifications, or manufacturer's data sheets, shall be submitted with ECP's and RFV's. Changes shall be identified to the affected assembly serial number, or if not part of an assembly, to the affected equipment serial number. The Contractor's configuration control process shall be available for Government review. ECP, deviations, or revisions may require a new FAT. Nearly all changes to the helmet shell or retention system will require a new FAT. FAT determination will be made on a case by case basis.

3.8.5.1 Engineering Change Proposals (CDRL A006)

Engineering Change Proposals (ECP) shall be submitted by the Contractor, and shall be limited to those which are necessary or offer benefit to the Government. MIL-HDBK-61A, Section 6.2, provides guidance concerning the classification of ECP’s. The Government will review each ECP upon receipt and notify the

Contractor in writing of approval/disapproval. Major engineering changes prior to the establishment of the product baseline shall be approved by the Program Office and Contracting Officer at In Process Reviews (IPR).

Technologies that reduce the overall system weight (without degradation of other performance characteristics), and/or increases performance, durability, and service life are a priority.

3.8.5.2 Requests for Variance (CDRL A007)

The Contractor shall process Requests for Variance (RFV) from current approved configuration documentation. Authorized deviations are a temporary departure from the requirements and do not constitute a change in an approved baseline. Submission of recurring deviations is discouraged and shall be minimized. Where it is determined that a change should be permanent, the Contractor shall process an ECP. MIL-

STD-3046 provides guidance concerning the classification of RFVs.

3.8.5.3 Notices of Revision (CDRL A008)

The Contractor shall generate and submit Notices of Revision (NOR) concurrently with

ECPs when technical documentation controlled by another Contractor or Government agency requires changes following approval of an ECP.

3.8.6 Engineering Drawings (CDRL A009)

The Contractor shall develop a complete product drawing package and provide it to the

Government at FAT or with any approved ECP after FAT. This process may require the revision and update of existing drawings, and/or development of new drawings to meet the requirements of product drawings/models and associated lists. Revised and newly created drawings shall be developed to document any design change and shall reflect all changes resulting from Government approved ECPs. Existing, revised, and new product drawings and associated lists shall be used as the engineering data for procuring, controlling, and using materials, parts, and assemblies whether produced in-house or supplied by the Contractor. The drawings shall be used for the assembly, provisioning, inspection, testing, and configuration management of the materials, parts, modules, subassemblies, and assemblies of the equipment covered under this contract. The product drawings shall also include control drawings for all commercial off the shelf (COTS) items that do not conform to recognized Government or industry specifications, non-developmental items (NDI) and items developed at private expense for which the Government had not acquired unlimited rights. These control drawings shall provide the applicable performance specification of form, fit, and function and provide interface information needed for competitive re-procurement of that item or an interchangeable item. New product drawings/models shall conform to ASME Y14.100 and ASME Y14.34.

3.8.7 Test and Evaluation (CDRL A010)

First Article Test approval remains in effect and production may continue unless:

The Contractor fails Lot Acceptance Testing (LAT) requirements on two (2) consecutive lots.

Should this occur, the Contractor will immediately cease production (Stop Work) and conduct a Failure Analysis and provide such reports as required to facilitate the completion of a Corrective Actions Report (CAR) as directed by the Defense Contract Management Agency (DCMA) Quality Assurance Representative (QAR). The CAR will then be submitted to the QAR and the Contracting Officer for review no later than 15 calendar days after occurrence. The QAR and Contracting Officer will determine within five (5) working days after receipt of the CAR if production of the approved First Article Test configuration may resume or if the Contractor must conduct a new

First Article Test for the issuance of a new First Article Test Approval Letter. If a new First Article Test is required, the Contractor will submit the number of samples required to conduct a new First Article Test (at the Contractor’s expense) as directed by the Contracting Officer, for the issuance of a new First Article Test Approval Letter. All

First Article Test Reports remain the property of the Government.

3.9 Warranty

The Contractor warrants the MSH for workmanship, materials, design, and compliance with the performance specifications in accordance with industry standards.

4.0 GOVERNMENT FURNISHED INFORMATION

All GFI required to complete statement of work tasking will be provided with the Request for Proposal

(RFP).