20131105_140039_SOW_DT_705.docx

STATEMENT OF WORK

FOR DT-705 SENSOR ASSEMBLY

1 PURPOSE

The purpose of this Statement of Work (SOW) is to define the procurement requirements for DT-705( ) sensor assemblies.

1.1 Scope

This SOW reflects a build-to-performance specification approach. The contractor shall design, manufacture, test, package, and deliver DT-705( ) First Article and Production sensor assemblies which meet the performance requirements of the DT-705( ) Critical Item Product Specification (CIPS). The Government will provide drawing packages upon request; however, they are for informational purposes only. The Government does not warrant any of the data in the DT-705( ) production drawing package.

2 DOCUMENTS AND INFORMATION

The following documents, of the issue in effect on the date of request for proposal, form a part of the SOW for this procurement to the extent stated herein.

2.1 Applicable Documents

CTP-CMP-001

Appendices D, E, F Critical Transducer Program Configuration Management Plan

ASME Y14.5

Dimensioning and Tolerancing

2.2 Government Furnished Information (GFI):

NAVSEA Drawing No. 53711-7615410C

Assembly, Top, DT-705 Note: This drawing package is available upon request for INFORMATIONAL PURPOSES ONLY. The Government does not warrant any of the data in the DT-705 Sensor Assembly production drawing package and a "build to print" approach may not constitute an adequate technical response. Request for the Production Engineering Drawing Package should be made to the Contracting Officer.

NAVSEA Drawing No. 53711-5515496D

Cable Assembly, TR-321 Transducer

2.3 Other Documents:

2.4 Definitions:

Configuration Item (CI)

The CI for this contract is the DT-705( ) sensor assembly.

3 REQUIREMENTS

The contractor shall design, manufacture, test, package, and deliver First Article and Production DT-705( ) sensor assemblies which meet the requirements of applicable document NAVSEA Drawing No. 53711-7333534E, Critical Item Product Specification for DT-705A Sensor Assembly (hereafter referred to as the DT-705 sensor assembly CIPS).

3.1 Program Reviews

Prior to each review/audit, the contractor shall submit a proposed agenda to the Government for approval in accordance with CDRL A001. At the completion of each review/audit, the contractor shall submit minutes of the review/audit meeting to the Government in accordance with CDRL A002.

· A 1-2 page Program Objectives and Milestone Schedule (POAMS), which lists the major tasks/milestones required for the First Article fabrication and test phase, including tooling/test equipment design/fabrication, Requirement Reviews and CDRL submittals required in the SOW. It shall also include a preliminary production schedule (i.e. planned build rate) for the first year production.

· Summary of changes to the proposed configuration.

· List of any major program or technical risks areas.

3.1.2 Preliminary Configuration Review (PCR)

Within 90 days after the contract award, the contractor shall conduct a Preliminary Configuration Review (PCR) at the contractor’s facility with the Government in attendance. The purpose of the PCR is to evaluate the technical adequacy of the contractor’s preliminary proposed build configuration and to ensure that it meets the requirements of the Functional Baseline. The PCR shall include Program Objectives and Milestone Schedule (POAMS) review, and risk assessment/mitigation plans for the CI.

3.1.3 Final Configuration Review (FCR)

At the completion of the final configuration and prior to commencing First Article assembly, the contractor shall conduct a Final Configuration Review (FCR) at the contractor’s facility with the Government in attendance. The purpose of the FCR is to evaluate the contractor’s final proposed build configuration and documentation, and review any changes in the proposed configuration since the PCR. The review shall include an overview of the manufacturing flow chart which identifies the manufacturing build steps, in-process tests and inspection points, and final production acceptance tests. The review shall also include review of the Program Objectives and Milestone Schedule (POAMS), and risk assessment/mitigation plans for the CI.

3.1.4 Production Program Reviews

The contractor shall conduct Production Program Reviews (PPRs). PPRs are to include programmatic and technical issues and will be held quarterly or as required by the Government. The location of the Program Reviews may alternate between the contractor’s facility and NUWCDIVNPT facilities in Newport, RI.

3.1.5 Production Progress Reports

The contractor shall prepare Production Progress Reports using DD Form 375, Exhibit B (GFI) or an equivalent government-approved format. The contractor shall submit Progress Reports in accordance with CDRL A003.

3.2 Configuration Management

The contractor shall establish and maintain a Configuration Management (CM) program using ANSI/EIA-649 for guidance. The contractor shall maintain configuration control of the technical data package which includes all specifications and drawings, and changes thereto. The contractor’s CM plans and procedures shall be defined in the contractor’s CM Plan. The contractor shall make all internal CM plans and procedures available to the Government, at the contractor’s facility, for government review upon request. The contractor shall ensure that the CM requirements are applied to subcontractors and vendors, to the extent necessary to ensure that the configuration integrity of hardware meets the requirements of the DT-705 sensor assembly CIPS. The CM program shall be in effect for the duration of the contract.

3.2.1 First Article Test Baseline Configuration

After the Final Configuration Review (FCR), and prior to commencing First Article testing, the contractor shall establish a First Article Test Baseline which meets the requirements of the Functional Baseline and which defines the hardware configuration of the CI. The contractor shall develop a First Article Test Baseline Report to include preliminary drawing numbers and drawing revisions. The contractor shall document and justify all changes to the CI which occurred between the FCR and First Article delivery in the First Article Test Baseline Report. The contractor shall submit the First Article Test Baseline Report in accordance with CDRL A004. The contractor shall make all documentation listed on the First Article Test Baseline Report available to the Government for review upon request, prior to First Article testing.

3.2.2 Product Baseline Configuration

The contractor shall establish the Product Baseline upon successful completion of the Functional Configuration Audit (FCA) and the Physical Configuration Audit (PCA), SOW section 3.4.5.3. The contractor shall manufacture the CI in accordance with the Product Baseline.

3.2.3 Engineering Changes

The contractor shall develop Engineering Change Proposals (ECPs) and Requests for Deviations (RFDs) in accordance with applicable document Critical Transducer Program Configuration Management Plan Appendices D, E, and F. The contractor shall submit ECPs and RFDs in accordance with CDRLs A005 and A006, respectively.

3.3 Quality Assurance Program

The contractor shall establish and maintain a Quality Assurance (QA) program using ISO 9001 for guidance. The contractor shall make all internal Quality Assurance (QA) documentation available to the Government, at the contractor’s facility, for government review upon request.

3.3.1 Non-conforming Material

Prior to FCA/PCA, the contractor shall establish a system, including implementation of a Material Review Board (MRB), to ensure detection, handling and disposition of non-conforming material throughout the production phase of the contract. Through email correspondence, the contractor shall obtain NUWCDIVNPT concurrence with classification of non-conforming material. If NUWCDIVNPT concurs that a discrepancy is minor (discrepancies in components or subassemblies, which do not affect the form, fit, or function of the completed sensor assembly), then contractor shall seek Local Defense Contract Management Agency (DCMA) waiver approval.

3.3.2 Failure Reports

The contractor shall establish a Failure Review Board (FRB) that shall be responsible for analyzing all sensor assemblies that failed any First Article and/or Production Acceptance Tests. The FRB shall identify the nature of each failure, and remedial and corrective action taken to prevent reoccurrence. The contractor shall submit Failure Summary and Analysis Reports in accordance with CDRL A007.

3.4 First Article Hardware

The contractor shall design, inspect, fabricate, test, package and deliver First Article DT-705( ) sensor assemblies. All First Article sensor assemblies shall meet the performance requirements of the DT-705 sensor assembly CIPS.

3.4.1 First Article Test and Inspection

The contractor shall perform First Article tests and inspections in accordance with the DT-705 sensor assembly CIPS. In the event that First Article units fail CIPS requirements, the contractor shall be responsible for redesign, rework, retest, and candidate replacement.

3.4.2 First Article Test Procedures

The contractor shall develop First Article Acceptance Test Procedures (for contractor-performed test/inspections) to the Government prior to First Article testing and submit in accordance with CDRL A008. The contractor shall include applicable accept/reject criteria (from the CIPS) for First Article tests and inspections to ensure that the CI meets the requirements of the DT-705 sensor assembly CIPS.

3.4.3 First Article Test Report

Upon successful completion of First Article testing, the contractor shall prepare a First Article Test Report. The First Article Test Report shall summarize the production inspection testing the contractor performed on First Article sensor assemblies prior to delivery to the Government. The applicable accept/reject criteria for these contractor-performed tests/inspections cited in the CIPS shall show actual test results on each First Article unit identified by serial number. The contractor shall submit the report in accordance with CDRL A009.

3.4.4 Government First Article Tests

The Government reserves the right to observe any contractor-performed First Article testing and conduct any special testing that it deems necessary. The Government will conduct specific First Article tests in accordance with the DT-705 sensor assembly CIPS. In the event that First Article units fail any CIPS requirements, the contractor shall be responsible for redesign, rework, retest, and candidate replacement. The Government reserves the right to perform additional qualifying tests, dissection, and analysis on randomly selected samples of First Article units.

3.4.5 Configuration Audits

The contractor shall schedule and accommodate Functional Configuration Audits (FCAs) and Physical Configuration Audits (PCAs) by the Government. The contractor shall host the audits at the contractor's manufacturing facility. The contractor shall provide the facilities, personnel, and documentation to conduct the audit. The contractor shall prepare a data package with applicable data required for the audit. The contractor shall prepare minutes for each audit which shall include the audit schedule. Discrepancies and action items will be recorded during the audit. All audit findings will be reviewed and assignees and due dates will be named for each action item at the end of the audit.

3.4.5.1 Audit Scope

The contractor shall disassemble the audit hardware to the lowest level possible, making all circuit card assemblies, modules, and replaceable assemblies/parts visible for the audits. The PCA shall include 100% review of all items identified as repair parts. The contractor shall accommodate any audit team requests for access to parts in various stages of assembly.

3.4.5.2 Preliminary PCA

The contractor shall accommodate a preliminary Physical Configuration Audit (PCA) prior to completing First Article fabrication. The purpose of the preliminary audit is for the Government to ensure the sub-components (as-built) that make up the first article assembly meet the drawings, to ensure that all key processes are properly documented, and to ensure the vendor has a CM program that will capture changes per audit findings. The contractor shall have a preliminary drawing package available for the preliminary PCA.

3.4.5.3 First Article FCA/PCA

Once First Article testing is completed, the contractor shall schedule and accommodate a concurrent Functional Configuration Audit (FCA) and Physical Configuration Audit (PCA). The FCA serves to verify that the First Article CI is compliant with the CIPS requirements and the PCA serves to verify that the First Article CI conforms fully to the First Article Test Baseline Report.

Prior to the FCA/PCA, the contractor shall provide the Government the First Article Test Baseline documentation which fully defines the CI to be audited. Upon resolution of all FCA issues, the contractor shall update the First Article Test Baseline documentation to reflect all changes. The contractor shall submit a draft copy of the drawing package 30 days prior to the FCA/PCA in accordance with CDRL A00A. The contractor shall have a sample of each piece part and subassembly available for inspection during the FCA/PCA. The contractor shall have additional data and documentation as defined in SOW Appendix A available for review during the FCA/PCA.

The Government will release PCA findings at the conclusion of the audit. The contractor shall prepare and submit the Audit Summary Report as described in SOW section 3.4.5.6.

3.4.5.4 FCA/PCA Agenda

The contractor shall develop a configuration audit agenda which includes all tasks necessary for conducting the audit. The contractor shall submit the agenda in accordance with CDRL A001.

3.4.5.5 FCA/PCA Minutes

At the completion of the FCA/PCA, the contractor shall summarize the FCA/PCA discussions and findings in conference minutes and shall submit the minutes of the FCA/PCA in accordance with CDRL A002. During the FCA/PCA, audit findings (discrepancies) and action items will be documented, reviewed and mutually agreed to by contractor and Government, with the Government having ultimate resolution authority.

3.4.5.6 Audit Summary Report

Following the completion of FCA/PCA, the Government will provide the contractor the list of all audit findings (discrepancies and action items). The contractor shall provide resolution comments for each discrepancy or action item and an updated production drawing package that incorporates FCA/PCA discrepancy resolutions and shall document this in an Audit Summary Report. In addition, the contractor shall include a PCA Certification Package, as described in SOW Appendix A, in the Audit Summary Report and shall submit the Audit Summary Report in accordance with CDRL A00B.

3.5 Production Hardware

The contractor shall manufacture, test, package and deliver Production sensor assemblies. All Production sensor assemblies shall meet the requirements of the DT-705 sensor assembly CIPS.

3.5.1 Serial Numbers

The contractor shall serialize the First Article DT-705( ) sensor assemblies as follows: A001, A002, and up. The Government will assign the serial numbers for the production sensor assemblies after contract award.

3.5.2 Production Test and Inspection

The contractor shall perform Production acceptance tests and inspections in accordance with the DT-705 sensor assembly CIPS.

3.5.3 In-Process Test/Inspection

The contractor shall perform in-process production tests/inspections to ensure that parts/assemblies and processes meet the form, fit, function, quality, and environmental requirements specified in the technical data package (all specifications, drawings and changes thereto, that constitute the approved Product Baseline). The contractor shall utilize in-process test/inspection procedures established in the First Article sample fabrication phase, wherever feasible.

3.5.4 Production Acceptance Test

The contractor shall perform final acceptance testing of all production hardware items prior to delivery to the Government. Through acceptance testing, the contractor shall ensure that all DT-705( ) sensor assemblies meet the requirements of the DT-705 sensor assembly CIPS.

3.5.4.1 Production Acceptance Test Procedures

The contractor shall develop Production Acceptance Test Procedures for production hardware testing and shall include procedures developed during First Article acceptance testing whenever possible. The contractor shall develop procedures which include applicable accept/reject criteria (from the CIPS) for production tests and inspections to ensure that the hardware meets the requirements of the DT-705 sensor assembly CIPS. The contractor shall develop the procedures as a standalone document and shall submit the Production Acceptance Test Procedures in accordance with CDRL A00C.

3.5.4.2Production Acceptance Test and Inspection Reports The contractor shall establish a test and inspection reporting system. The reporting system shall identify Production Acceptance Test Procedures and record actual test results for each production unit by serial number, including date of acceptance by the Government. In the Production Acceptance and Inspection Reports, the contractor shall identify units that failed Production Acceptance Tests or were otherwise accepted only after rework and retest and shall explain the circumstances and corrective actions taken where rework occurred. The report shall record rework and retest results. The contractor shall submit Production Acceptance and Inspection Reports in accordance with CDRL A00D.

3.5.5 Government Testing

The Government may use its own facilities, or any commercial laboratory to conduct any special tests/inspections it deems necessary. The Government may elect at any time to randomly select a sample of production units for the purpose of repeating any inspection or test.

3.5.6 Sensor Assembly Certification Card

The contractor shall develop a Certification Card for each DT-705( ) sensor assembly to be delivered (as shown in the DT-705 sensor assembly CIPS). This certification card serves to ensure that the DT-705( ) sensor assemblies have been constructed in accordance with the approved Product Baseline, and that they have passed all production testing. The contractor shall deliver Certification Cards in accordance with CDRL A00E. In the event that the certification card is missing or lost, the contractor shall provide a replacement card upon government request.

3.6 Drawings

The contractor shall develop engineering drawings and associated lists in accordance with ASME Y14.100, ASME Y14.24, ASME Y14.34, ASME Y14.35 and ASME Y14.5. Associated lists shall include parts lists, data lists, and index lists. The contractor shall develop and provide a drawing tree which includes all product drawings.

3.6.1 Drawing Templates

The Government will provide existing NAVSEA drawing templates to the contractor (.dwg and .pdf) upon contract award. The contractor shall use the government-provided drawing templates for all deliverable drawings. In addition, the Government will make the NAVSEA AutoCAD drawings available for the contractor to use upon request.

3.6.2 Drawing Revisions

Prior to the Product Baseline, the contractor shall mark all engineering drawings and associated lists with revision “0” which reflects the First Article Baseline. The contractor shall designate subsequent revisions as “1, 2, 3…”. The contractor shall incorporate all action items resulting from the PCA into the final engineering drawings, and shall deliver the engineering drawings to the Government prior to the start of production as revision “-“.

3.6.3 Drawing Delivery Requirements

The contractor shall deliver 2-D engineering drawings as data files in editable and in “.pdf” formats on Compact Disc (CDs) and as hardcopies. The contractor shall also deliver solid models, if available. The 2-D editable files shall be compatible with AutoCAD 2007 (“.dwg”) or SolidWorks 2007-2012 (“.slddrw”). The electronic data files shall be stand-alone files which do not require supporting files. The contractor shall deliver multi-page “.dwg” or “.slddrw” drawings as individual files per drawing sheet. The electronic data files (.dwg or .slddrw, and .pdf) shall make an exact reproduction of the hardcopy originals. When using solid models to generate the 2D engineering drawings, the dimension tolerances shall be accounted for in the model notes. The contractor shall list electronic components under the Product Baseline in the applicable parts list (PL) along with a unique manufacturer CAGE code and part number. The contractor shall procure these items from the original manufacturer specified by the CAGE code on the PL or a manufacturer-approved distributor. In addition, for each printed circuit board assembly, the contractor shall deliver a master drawing, a schematic, and a set of associated gerber files describing layer details. The contractor shall deliver engineering drawings in accordance with CDRL A00A.

3.7 Technical Repair Standards

The contractor shall develop Technical Repair Standards (TRS) and deliver the TRS in accordance with CDRL A00F.

4 SECURITY

The security level of this work is unclassified. The contractor shall have the ability to transmit all unclassified technical information via encrypted email.

5 ENVIRONMENTAL

The contractor shall be responsible for compliance with all local, state, and federal environmental regulations concerning hazardous materials and hazardous waste utilized and/or generated during the execution of this contract.

6 PACKAGING AND MARKING

See Contract Section D, CIPS, and SOW Appendix B: UID Marking Guidelines.

DRAFT DRAFT DRAFT

SOW APPENDIX A

ATTACHMENT 1A

Physical Configuration Audit (PCA) Package Contents Requirements

PHYSICAL CONFIGURATION AUDIT (PCA) PACKAGE CONTENTS REQUIREMENTS

(DATA AND DOCUMENTATION TO BE AVAILABLE

FOR REVIEW AND INSPECTION AT PCA)

NOTE: The contractor shall provide this data and documentation to the Physical Configuration Audit (PCA) Team Members or shall otherwise make it readily available for review and inspection during on-site PCA. The requirements are stated in the context of audit data and documentation intended for configuration management of the DT-705( ) Sensor Assembly production as represented by the First Article sample and separate piece parts thereof.

Appendix 1 Cover Sheet, Certification, and Table of Contents comprising identification of the DT-705( ) Sensor Assembly by nomenclature and assigned serial numbers, listing and identification of major parts, manufacturer’s certification of accuracy, and table of contents shall be included as front material in the PCA Package.

Appendix 2 Drawings of the First Article Sample DT-705( ) Sensor Assembly including descriptions of design changes and reasons for each change shall be included in or attached to the PCA Package.

Appendix 3 Configuration Accountability record describing the status of engineering drawing changes and list of materials shall be included in the PCA Package.

Appendix 4 Inspection/Test Flow Chart which illustrates where in the production chain each inspection/test is performed and an accompanying list of inspection/test criteria and procedures shall be included in the PCA Package. The inspection and procedures documentation shall be available for review as requested during PCA.

Appendix 5 Manufacturing Methods and Process Sheets which describe production procedures, processes, and fixtures used in production of the DT-705( ) Sensor Assembly shall be listed in the PCA Package. The manufacturing methods and process sheets documentation shall be made available for review as requested during PCA.

Appendix 6 Incoming Inspection Control Procedures including the contractor’s procurement specifications, list of vendors, and incoming inspection/test criteria and procedures shall be listed and described in the PCA Package. Documentation shall be made available for review as requested during PCA.

Appendix 7 Test Procedures for production and production control inspection of the DT-705( ) Sensor Assembly shall be listed and described in the PCA Package. Documentation shall be made available for review as requested during PCA.

Appendix 8 Test Methods sheets and Standards Selection Procedures describing the operation and calibration of test equipment used for production and production control tests shall be listed and described in the PCA Package. Documentation shall be made available for review as requested during PCA.

Appendix 9 Nonstandard Parts and Parts Requiring Source Control shall be listed and described in the PCA Package. Documentation shall be made available for review as requested during PCA.

Appendix 10 Worksheets in sufficient quantity for recording the details of the PCA findings and planned corrective actions shall be included in the PCA Package.

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SOW APPENDIX B

ATTACHMENT 1B

GUIDELINES FOR UID MARKING IMPLEMENTATION

1.0 SCOPE

Guidelines specified within this appendix serve to define the requirements and acceptable marking methods to be used to implement Unique Identification (UID) physical equipment marking for hardware under the Critical Transducer Program (CTP) cognizance in accordance with DFARS Clause 252.211-7003 found in Section I of the contract.

2.0 APPLICABLE DOCUMENTS

The following document, of the issue in effect on the date of request for proposal, forms a part of these guidelines to the extent stated herein. Equipment marking products, processes, and physical application shall meet the requirements identified in the following document:

MIL-STD-130 - Department of Defense Standard Practice Identification Marking of U.S. Military Property.

3.0 REQUIREMENTS

3.1 General Requirements

The contractor shall mark hardware in accordance with the reference document listed in paragraph 2. The new UID requirement shall be implemented through the use of labels.

3.1.1 Labels

The contractor shall either submit representative sample UID labels and method of reading label information for Government approval for use in production or the contractor shall use a UID label vendor that certifies readability of the labels it supplies.

3.2. Marking

Option 1: This approach utilizes a Mylar laminated tape with extra strength adhesive. The tape is available in sizes from ¼” to 1 ½” widths. Since the tape is laminated, surface scratches from handling or environmental elements do not directly affect the barcode information. The approach uses a square 2D barcode with black ink on a white background. The background has 1/8” border around the barcode for ease of readability.

Option 2: Another acceptable approach, which has been proven to be durable for human readable information, uses white Mylar labels with black ink 1.5" long x .75" high with a combination of human readable and 2D barcode information on a single label. The labels are created using a dot matrix printer with 200 dpi (or better) and are covered with a clear overlay tape to prevent degradation from the environment or handling.

3.2.2 Marking Construct

The contractor shall use Construct #2 (reference a.) which consists of four parts: Issuing Agency Code, Cage Code, Part Number; and a Serial Number which shall be unique within the product identified.

3.2.4 Marking Location

The label shall be located on the hardware near or on the existing label containing human readable information and shall not to interfere with its readability (see illustration below). Where practical, the UID label is applied in a position to make it accessible while a unit is installed. However, there are items whose acoustic properties may be impacted by the application of a UID label; in those cases, the label shall be applied in such a manner as not to interfere with acoustic capabilities. If placing the UID label in close proximity to the human readable information is not practical then other locations may be used subject to government approval.

Example of Human Readable Information with UID label on same label:

a. Nomenclature

b. Serial Number

c. National Sock Number

d. Contract Number

e. Factory Acceptance Date

f. Contractor’s CAGE Code

Example of Human Readable Information with UID label on two different labels which can be in two different locations on the item:

a. Nomenclature

b. Serial Number

c. National Sock Number

d. Contract Number

e. Factory Acceptance Date

f. Contractor’s CAGE Code

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