N6660414R0142_Attachment_1.pdf

STATEMENT OF WORK

FOR HIGH FREQUENCY ARRAY WINDOW

1 PURPOSE

The purpose of this Statement of Work (SOW) is to define the procurement requirements for High Frequency Array (HFA) Windows for installation on United States Submarines and to provide spares to the stock system.

The HFA is an acoustic ‘window’ used in conjunction with the High Frequency Sail Array. The intent of this contract is to procure HFA acoustic windows for four (4) classes of United States Submarines (SSGN Class; SEAWOLF Class (SSN21); USS VIRGINA Class (SSN774); and second flight USS LOS ANGELES Class (SSN688I/A-RCI). The primary purpose of a HFA window is to provide an acoustically transparent interface to seawater from the HFA by allowing high frequency acoustic signals to pass through with little reflection or attenuation. Second, the window provides protection to the array from afloat debris and provides smoother conformance to the hull, thereby reducing flow noise.

1.1 Scope

The work performed under this SOW is in support of NUWCDIVNPT Sensor and SONAR Systems Department Fleet Sensors and Cables Engineering Branch (Code 1535) for the Critical Transducers Program (CTP). Funding types to be utilized to execute this tasking include Other Procurement, Navy (OPN) and Ship Construction, Navy (SCN) as received from NAVSEA Submarine Acoustic Systems Program Office (PMS401) and VIRGINIA Class Program Office (PMS450).

This SOW reflects a build-to- performance specification approach. The contractor shall design, fabricate, assemble, test, inspect, package and deliver HFA First Article and production windows to be fabricated in accordance with the referenced Critical Item Performance Specifications (CIPS) as listed in Section 2. 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 HFA 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. Additional specifications and standards applicable to this procurement are referenced in the documents identified herein.

2.1 Applicable Documents:

NAVSEA Drawing No. 53711- 7634166

Critical Item Performance Specification (CIPS) for Common HFA Window. The referenced document is unclassified with CONFIDENTIAL Appendix A removed.

00156MN Critical Transducer Program Configuration Management Engineering Change Documents Instruction Manual

2.2 Military Standards:

MIL-STD-31000 Technical Data Packages

2.3 Other Documents:

ISO 9001 Quality Management Systems - Requirements EIA-649 National Consensus Standard for Configuration Management ASME Y14.100 Engineering Drawing Practices ASME Y14.24 Types and Applications of Engineering Drawings ASME Y14.34 Associated Lists ASME Y14.35 Revision of Engineering Drawings and Associated Documents ASME Y14.5 Dimensioning and Tolerancing Jerome Lieblich Drawing Requirements Manual

2.3 Government Furnished Information (GFI):

DD Form 375 Production Progress Report

Serial Numbers Production Unit Serial Numbers

2.4 Available Government Furnished Information (GFI):

The Government will provide the below listed drawing packages upon request; however, they are for informational purposes only. Units produced to these drawing packages have been successfully qualified by NUWCDIVNPT. Qualification of new suppliers may be performed at the Government’s discretion. The Government does not warrant any of the data in the HFA production drawing package. Request for Production Engineering Drawing Packages should be made to the Contracting Officer.

NAVSEA Drawing 8192860 688I Sonar Window

NAVSEA Drawing 8192861 Virginia Sonar Window

NAVSEA Drawing 6396348 Seawolf Sonar Window

NAVSEA Drawing 4643324 SSGN Sonar Window

2.5 Government Furnished Equipment (GFE) Material:

The below listed Government Furnished Equipment (GFE) will be available for use by the contractor upon request. Suitability of mold usage will be dependent on the material proposed. Request for material should be made to the Contracting Officer.

• 688I Sonar Window Mold

• Virginia Sonar Window Mold

• Virginia Sonar Window Drill Hole Fixture

3 REQUIREMENTS

3.1 General Requirements

This SOW defines the requirements for design, fabrication, assembly, test, inspection, packaging, and delivery of First Article and Production High Frequency Array (HFA) Windows in accordance with the Applicable Documents listed in SOW paragraph 2.

3.2 Program Management

The contractor shall establish the tasks and program management to support planning, scheduling, manufacturing, and quality controls essential for fabrication, assembly, test, inspection, documentation, packaging, and delivery of First Article and Production HFA Windows. Program management shall be in effect for the duration of the contract.

3.3 Hardware

3.3.1 First Article Hardware

The contractor shall design, fabricate, assemble, test, inspect, package and deliver First Article HFA Windows. All First Article windows shall meet the performance and environmental requirements of the Functional Baseline as defined in NAVSEA Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window) and the First Article Test Baseline as defined in SOW Appendix A, paragraph 4.1.3.

3.3.1.1 Waiver of First Article Hardware

The Government reserves the right to waive the requirement for First Article and / or testing in part or in whole. In the event that First Article is waived completely, CLIN 0001 will be cancelled and all requirements and data deliverables specifically required for First Article hardware in this SOW, SOW Appendix A, and the Contract Data Requirements List (CDRL) will be cancelled.

3.3.2 Production Hardware

The contractor shall fabricate, assemble, test, inspect, package and deliver Production HFA Windows. All Production HFA Windows shall meet the requirements of the Functional Baseline as defined in NAVSEA Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window and the Product Baseline as defined in SOW Appendix A, paragraph 4.1.4.

3.4 Configuration Management

The contractor shall establish and maintain a Configuration Management (CM) program in accordance with SOW Appendix A. The contractor shall maintain configuration control of the technical data package which includes all lower level specifications and drawings, and changes thereto. The contractor shall use numbered drawing revisions prior to final drawing package delivery. The contractor shall deliver all production engineering drawings at revision "-". Once the production engineering drawing package is accepted by the Government (after all discrepancies resulting from the Functional Configuration Audit/Physical Configuration Audit are resolved and changes incorporated), the Government assumes configuration management control. 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 CM program shall be in effect for the duration of the contract.

3.4.1 First Article Test Baseline (Not Required if First Article is Waived)

The contractor shall establish the First Article Test Baseline identifying the configuration of the First Article units in accordance with SOW Appendix A paragraph 4.1.3. The First Article Test Baseline shall meet the requirements of the Functional Baseline as defined in NAVSEA Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window. The contractor shall maintain the First Article Test Baseline in the First Article Test Baseline report as defined in SOW Appendix A paragraph 4.1.3.

The contractor shall deliver the First Article Test Baseline Report in accordance with

CDRL A00D.

3.4.2 FCA/PCA

The contractor shall schedule and accommodate a concurrent Functional Configuration Audit (FCA) and Physical Configuration Audit (PCA) by the Government in accordance with SOW Appendix A paragraph 4.4. The contractor shall provide a draft copy of the production drawing package 30 days prior to the FCA/PCA in accordance with CDRL A00C. To ensure that the hardware matches the drawings, 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 B available for review during the FCA/PCA.

If First Article is waived FCA/PCA will be conducted on the first production unit.

3.4.2.1 FCA/PCA Agenda

The contractor shall develop a configuration audit agenda to meet the requirements of SOW Appendix A paragraph 4.4. The agenda shall define all information necessary for conducting the audit. The contractor shall deliver the agenda in accordance with CDRL A001.

3.4.2.2 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 provide 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.

3.4.2.3 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 reflects incorporation of FCA/PCA discrepancy resolutions. In addition, the contractor shall deliver an audit summary report in accordance with CDRL A003. The audit summary report shall include a PCA certification package as described in SOW Appendix A paragraph 4.4.3.5.

3.4.3 Product Baseline

The contractor shall establish the Product Baseline prior to first production unit delivery.

The Product Baseline shall meet the requirements specified in NAVSEA Drawing No.

53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window, and contractor-developed drawings (SOW section 3.4.3.1) and associated changes which define the production hardware configuration. The contractor shall use the Product Baseline drawings (SOW section 3.4.3.1) for material procurement and for production window assembly. The contractor shall include test/inspection procedures and manufacturing process sheets in the baseline, which the contractor shall make available for review by the Government during the FCA/PCA.

3.4.3.1 Drawings (Not Applicable if Drawing Package (CLIN 0003) is not Ordered) The contractor shall develop engineering drawings and associated lists in accordance with applicable documents listed in paragraph 2. Associated lists shall include parts lists. The contractor shall provide a drawing tree including all product drawings. The contractor shall use the Government provided drawing template (GFI). All engineering drawings and associated lists shall reflect the approved configuration item Product Baseline. The contractor shall mark all engineering drawings and associated lists with revision "-", which reflects the approved Product Baseline. The contractor shall deliver engineering drawings as data files in “.dwg” format and in “.pdf” format on Compact Disc (CDs). The “.dwg” files shall be in a version compatible with AutoCAD 2007. The electronic data files (.dwg files and .pdf files) shall be stand-alone files which do not require supporting files. The contractor shall deliver multi-page CAD-generated drawings as individual files per drawing sheet. The electronic data files (.dwg files and .pdf files) shall make an exact reproduction of the hardcopy originals. The contractor shall deliver engineering drawings in accordance with CDRL A00C. 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 “-“.

3.4.3.2 Engineering Changes

The contractor shall develop Engineering Change Proposals (ECPs) and Requests for Deviations (RFD) in accordance with the Critical Transducer Program Configuration Management Engineering Change Documents Instruction Manual and the requirements of SOW Appendix A. The contractor shall deliver ECPs and RFDs in accordance with CDRLs A004 and A005, respectively. After NUWCDIVNPT approves the Product Baseline, the contractor shall submit all requests for changes and/or deviations to the technical data package to NUWCDIVNPT for approval. The contractor shall obtain Government approval for use of alternative part numbers and/or any other source via submission of an ECP prepared in accordance with CDRL A004. NUWCDIVNPT assumes responsibility to make drawing updates incorporating approved changes.

3.4.4 Serial Numbers

The contractor shall serialize the First Article HFA Windows as follows: FA001, FA002, and up. The Government will assign the serial numbers for the production windows after PCA completion (GFI).

3.5 Quality Assurance Program

The contractor shall establish and manage a comprehensive Quality Assurance (QA) program in accordance with ISO 9001 requirements and the Product Baseline. The contractor shall include piece part, in-process, subassembly and final inspection requirements in its QA program. The contractor shall make all internal documentation available to the Government, at the contractor’s facility, for Government review upon request. The QA program shall be in effect for the duration of the contract.

3.5.1 Nonconforming 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 nonconforming material throughout the production phase of the contract. The contractor shall only submit end-product discrepancies resulting from MRB action to NUWCDIVNPT in accordance with configuration management provisions of the contract. Local Defense Contract Management Agency (DCMA) shall approve minor discrepancies, defined as discrepancies in components or subassemblies that do not affect the form, fit, or performance of the completed windows.

3.6 Failure Reports

The contractor shall establish a Failure Review Board (FRB) that shall be responsible for analyzing all windows that fail First Article 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 deliver Failure Summary and Analysis Reports in accordance with CDRL A00A.

3.7 First Article Test and Inspection (Not Required if First Article is Waived) The contractor shall perform First Article tests and inspections in accordance with the NAVSEA Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window and the First Article Test Baseline. In the event that First Article units fail CIPS requirements, the contractor shall be responsible for redesign, rework, retest, and candidate replacement.

3.7.1 Material Qualification

The contractor shall develop a material qualification Test Plan / Schedule for Government approval for all structural materials not previously approved by the Government for use on United Sates Submarines. Material Design Verification Tests and Environmental Qualification Tests shall be performed in accordance with NAVSEA Drawing No. 53711- 7634166 Critical Item Performance Specification (CIPS) for Common HFA Window on material samples representative of the acoustic window material used for First Article windows. The Test Plan/Schedule shall be presented at the Contract Kick-off meeting as described in paragraph 3.9.1. Test data resulting from the material qualification testing shall be delivered in accordance with CDRL A00B and shall show actual measurements for each test.

3.7.2 Material / Design Analysis

The contractor shall perform material and design analysis in accordance with NAVSEA Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window. Reports for each required analysis shall be delivered in accordance with CDRL A00C.

3.7.3 First Article Test Procedures

The contractor shall prepare First Article Acceptance Test Procedures for contractor-performed test/inspections. The contractor shall establish the procedures with applicable accept/reject criteria for First Article tests and inspections to ensure that hardware meets the requirements of the Functional Baseline as defined in NAVSEA Drawing No. 53711- 7634166 Critical Item Performance Specification (CIPS) for Common HFA Window and the First Article Test Baseline. The First Article Acceptance Test Procedures shall be delivered in accordance with CDRL A006.

3.7.4 First Article Test Report

Upon successful completion of First Article testing, the contractor shall prepare a First Article Test Report. The First Article Test Reports shall summarize applicable accept/reject results for contractor-performed tests/inspections cited in NAVSEA

Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window and shall show actual test results on each First Article identified by serial number. The report shall be prepared and delivered in accordance with CDRL A008.

3.7.5 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 NAVSEA Drawing No. 53711- 7634166 Critical Item Performance Specification (CIPS) (paragraph 2 Applicable Documents). In the event that First Article units fail any CIPS requirements, the contractor shall be responsible for redesign, rework, retest, and candidate replacement.

3.8 Production Test and Inspection

3.8.1 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) and NAVSEA Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window. The contractor shall utilize in-process test/inspection procedures established in the First Article sample fabrication phase, wherever feasible. The contractor may use its facilities or any commercial laboratory acceptable to the Government to conduct production tests/inspections.

3.8.2 Material Properties Testing

The contractor shall perform material properties tests in accordance with NAVSEA Drawing No. 53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window, on material samples representative of the acoustic window material used for production windows. Test data shall be delivered in accordance with CDRL A00B and shall provide actual measurements for each test.

3.8.3 Government Production Acoustic Tests (Applicable to Acoustic Test Panel (CLIN

0001EA))

The Government reserves the right to perform acoustic test of material samples representative of the production windows being built. If the Production Test Panel CLIN (0001EA) is ordered, the contractor shall provide the Government with a thirty-six inch by thirty-six inch (36” x 36”) test panel of the same thickness and manufactured by the same process to the same specification as the production windows. In the event that the test panel fails CIPS test requirements, the contractor shall be responsible for implementing corrective action which includes any necessary rework, retest, or candidate replacement of production window.

3.8.4 Government Production Subelement Tests

The Government reserves the right to perform Subelement testing. If Subelement Test Panel CLINs 0002, 0006, 0008, 0010, or 0012 are ordered, the contractor shall provide the Government with a thirty-six inch by thirty-six inch (36” x 36”) test panel of the same thickness and manufactured by the same process to the same specification as the production windows. The test panel shall have the bolt holes drilled on one edge to the specifications in accordance with Section 4.2.2.3.1.2 of the HFA Window CIPS.

3.8.5 Production Acceptance Test

The contractor shall perform production acceptance testing of all production hardware items prior to delivery to the Government. Acceptance testing shall ensure that all requirements of the technical data package, defined by NAVSEA Drawing No. 53711- 7634166 Critical Item Performance Specification (CIPS) for Common HFA Window are met. The contractor is responsible and shall ensure that all supplies and services provided conform to technical and contract requirements.

3.8.5.1 Production Acceptance Test Procedures

The contractor shall develop Production Acceptance Test Procedures for production hardware testing. Test procedures shall include procedures developed during First Article acceptance testing whenever possible. The procedures shall establish applicable accept/reject criteria for production tests and inspections to ensure that the hardware meets the requirements of the Functional Baseline defined in NAVSEA Drawing No.

53711-7634166 Critical Item Performance Specification (CIPS) for Common HFA Window and the Product Baseline. Procedures shall be delivered as a single standalone document. Acceptance Test Procedures shall be delivered in accordance with CDRL A007.

3.8.5.2 Production 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.

The reports shall identify units that failed Production Acceptance Tests or were otherwise accepted only after rework and retest. The reports shall explain the circumstances and corrective actions taken where rework occurred. The reports shall record rework and retest results. The contractor shall deliver test and inspection reports in accordance with

CDRL A009.

3.8.6 Government Testing

The Government may use its own facilities or any commercial laboratory to conduct any special tests/inspections it deems necessary.

3.8.7 Failure Reports

The contractor shall document units that fail First Article or Production acceptance testing and identify the nature of the failure and the rework accomplished leading to final acceptance. Failure Summary and Analysis Reports shall be delivered in accordance with

CDRL A00A.

3.9 Program Review/Audits

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 for approval in accordance with CDRL A003.

3.9.1 Contract Kick-off Meeting Within 45 days after contract award, a Contract Kick-off meeting shall be conducted at the contractor’s facility. In support of the Kick-off meeting the contractor shall provide the following:

• Organization chart.

• 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 proposed changes to current legacy design, if applicable.

• Material qualification Test Plan / Schedule (SOW paragraph 3.7.1)

• List of any major program or technical risks areas.

3.9.2 Preliminary Review (PR)

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

3.9.3 Critical Review (CR)

At the completion of detail design and prior to commencing First Article assembly, the contractor shall conduct a Critical Requirements Review (CR) at the contractor’s facility with the Government in attendance. The CR shall evaluate the contractor’s final proposed build configuration and documentation, and review any changes in the proposed configuration since the PR. 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 all Configuration Items.

3.9.4 Production Program Reviews

The contractor shall conduct Production Program Reviews (PPRs). PPRs are to include programmatic, technical and cost 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.

3.10 Production Progress Reports

The contractor shall deliver Production Progress Reports prepared in the format shown in DD Form 375, Exhibit B (GFI) or in an equivalent Government-approved format. The contractor shall deliver Progress Reports in accordance with CDRL A00E.

3.11 Technical Repair Standards

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

4.0 SECURITY

The security level of this work is classified CONFIDENTIAL.

5.0 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.

6.0 PACKAGING AND MARKING

See Contract Section D and SOW Appendix C: UID Marking Guidelines.

7.0 DELIVERY

See Contract Section F.

SOW APPENDIX A

ATTACHMENT 1A

CONFIGURATION MANAGEMENT REQUIREMENTS

FOR

COMMON HIGH FREQUENCY ARRAY ACOUSTIC WINDOWS

1.0 SCOPE

1.1 PURPOSE

This Appendix establishes the requirements for the contractor's Configuration Management (CM) program in accordance with EIA-649.

2.0 REFERENCED DOCUMENTS

The following documents, of the issue in effect on the date of request for proposal, form a part of this appendix to the extent specified herein. In the event of any conflict or inconsistency between this document and the reference documents, this document shall take precedence.

2.1 MILITARY STANDARDS

ASME Y14.100 Engineering Drawing Practices ASME Y14.24 Types and Applications of Engineering Drawings ASME Y14.34M Associated Lists ASME Y14.35M Revision of Engineering Drawings and Associated Documents

2.2 OTHER DOCUMENTS

EIA-649 National Consensus Standard for Configuration Management

00156MN Critical Transducer Program Configuration Management

Engineering Change Documents Instruction Manual

Drawing template Drawing template will be provided after contract award.

3.0 GENERAL REQUIREMENTS

The contractor shall provide and maintain a program for Configuration Management (CM) for the Common High Frequency Array (HFA) Windows in accordance with the guidance provided in EIA-649. The EIA-649 paragraphs cited herein include all subparagraphs including referenced appendices unless they are specifically deleted or tailored herein.

3.1 CONTRACTUAL ORGANIZATION

The contractor shall implement an internal CM system to ensure that the responsibilities for CM and the relationships with other program functional groups are defined and included in program management planning using EIA-649 as a guideline. The contractor’s CM Program shall include the following:

a. The contractor shall designate a primary and alternative representative to act as the contractor’s point of contact for all matters pertaining to configuration management in this contract.

b. The contractor’s representative shall be present, or otherwise be available, to support the contractor’s proposed Class I engineering changes and Requests for Deviation at the Government Change Control Board meetings.

c. CM shall be represented on other boards established by the contractor which meet (such as “Material Review Board”, etc.) .

d. The contractor’s CM plans and procedures for configuration baseline identification, configuration control, and configuration status accounting and configuration audits shall be defined in the contractor CM Plan.

3.1.1 Subcontractor Configuration Management Requirements

The contractor shall ensure that the requirements of this document are applied to subcontractors and suppliers, to the extent necessary to ensure that the configuration integrity of hardware meets the requirements of the SOW.

3.2 GOVERNMENT SURVEILLANCE OF CONTRACTOR CONFIGURATION

MANAGEMENT

The NUWCDIVNPT program office and on-site Government personnel (DCMC) shall have the right to monitor the contractor’s CM program to assess compliance with contractual requirements. Surveillance will begin at the time of contract award. The contractor shall make available all documents implementing the contractor’s CM program. The Government will have access to the Contractor’s internal information system used to control all engineering changes.

The contractor shall provide subcontractor CM documents at the Government’s request.

4.0 CONFIGURATION REQUIREMENTS

4.1 CONFIGURATION IDENTIFICATION

Baselines applicable to this procurement are the Functional Baseline, the First Article Test Baseline and the Product Baseline. These and other elements of configuration identification are described in the following paragraphs.

4.1.1 Configuration Item

The Configuration Item (CI) for this contract is the Common High Frequency Array (HFA) Window.

4.1.2 Functional Baseline

The Functional Baseline is established at contract award and consists of those documents identified in the Statement of Work and the documents referenced therein. Each configuration item shall be designed, constructed, and tested in accordance with the Functional Baseline and any authorized changes thereto, until the Product Baseline for the CI is established.

4.1.3 First Article Test Baseline

After the Critical Requirements Review (CRR), and prior to the start of First Article Testing (FAT), the contractor shall establish a First Article Test Baseline to monitor and define the hardware configuration identification during testing and shall consist of the engineering documentation that defines each CI under test. The contractor shall record the baseline in the First Article Baseline Report. The First Article Baseline Report shall include the list of drawings and their revision letters that accurately define the First Article units under test.

4.1.4 Product Baseline

The Product Baseline shall consist of the engineering documentation, including inspection and acceptance test requirements that define the CI's identified in paragraph 4.1.1. The Product Baseline shall be established upon completion of the Functional and Physical Configuration Audits (FCA and PCA) and shall reflect the correction of configuration audit deficiencies. Each configuration item shall be built in accordance with the Product Baseline and authorized changes thereto. The Product Baseline drawings revision letters shall be in accordance with SOW section

3.4.3.1. The contractor shall use the Government provided drawing template.

4.1.5 Nomenclature, Serial Number Assignments and Identification Marking

The contractor shall provide requests for revisions to Nomenclature, serial number assignments, and identification marking.

4.2 CONFIGURATION CONTROL

The contractor shall evaluate, review and implement all Government-approved changes to the approved Product Baseline, as defined in the SOW. The contractor shall prepare all Engineering Changes, Deviations, and Specification Changes to the Product Baseline established under this contract in accordance with the Engineering Changes requirement of the SOW using EIA-649 as a guideline for classification.

4.2.1 Class I ECPs and Major RFDs

Class I ECPs and Major RFDs are defined in EIA-649. The contractor shall prepare Class I ECPs and Major RFDs in accordance with the Engineering Changes requirement of the SOW using Critical Transducer Program Configuration Management Engineering Change Documents Instruction Manual and using EIA-649 as a guideline for classification. Prior to the preparation of Class I ECPs and Major RFDs, the need for a change must be established by technical investigation and analysis by the contractor. The contractor shall prepare ECPs and RFDs when the investigation has produced sufficient evidence to justify the need for an engineering change or deviation and submit them to NUWCDIVNPT Code 1535 for approval.

4.2.2 Engineering Release

The contractor shall ensure that all design releases are processed through the CM authority and that configuration identification, change control, and status accounting of engineering releases are accurately maintained to ensure compatibility, traceability, integrity, and control of configuration items.

4.2.3 Specification Change Notice (SCN)

The contractor shall request a Specification Change Notices (SCNs), when required, in the format specified by the SOW during First Article development before the Product Baseline is established.

4.2.4 Class II ECPs and Minor RFDs

Class II ECPs and Minor RFDs are defined in EIA-649. The contractor shall submit such changes in electronic format to NUWCDIVNPT for approval per the Critical Transducer Program Configuration Management Engineering Change Documents Instruction Manual.

4.3 CONFIGURATION STATUS ACCOUNTING (CSA)

The contractor shall implement a CSA system using EIA-649 as a guideline.

4.4 CONFIGURATION AUDITS

The contractor shall schedule and accommodate Functional Configuration Audits (FCAs) and Physical Configuration Audits (PCAs) by the Government for the first article units using EIA- 649 as a guideline at the times scheduled on the Government-approved milestone schedule. The FCA/PCA shall be held at the contractor's manufacturing facility.

Additionally, the Government may call for the contractor to schedule and accommodate configuration audits on occasions such as the following:

a. On the configuration change portion of a major engineering change when the modification to the equipment consists of a functional change to the Product Baseline.

b. Following a major change in the manufacturing process.

c. When the released engineering documentation does not fully and accurately reflect the configuration being produced.

d. To verify the correction of major discrepancies identified in a previous PCA.

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. The Government-approved plan 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.

4.4.l Audit personnel

The audit team will consist of Government personnel. The audit team will be chaired by the Critical Transducer Program (CTP) Configuration Manager (a Government person) or his designated representative.

The audit team chairman will have the authority to accept or reject the equipment.

The contractor shall document and include in the audit minutes, recommendations for rejection and disapproval by the audit team and the specific deficiencies shall be noted for further CTP Configuration Manager review.

4.4.2 Functional Configuration Audit (FCA)

A Functional Configuration Audit (FCA) serves to verify that the system is compliant with the requirements of the CIPS. The contractor shall host the Government functional audit using EIA- 649 as a guideline. Prior to the beginning of the FCA the contractor shall provide to the Government the First Article Test Baseline documentation which fully defines the CI to be audited, and as defined in paragraph 4.1.3 of this appendix. Upon resolution of all FCA problem areas, the contractor shall update the First Article Test Baseline documentation to reflect all necessary changes.

4.4.3 Physical Configuration Audit (PCA)

The hardware PCA shall verify that the first article test unit as-built hardware conforms fully to the First Article Test Baseline Report. The FCA shall have been successfully completed prior to the beginning of the PCA. All drawings and documentation that were baselined (frozen from further changes) prior to the beginning of the FCA shall be delivered to the Government along with all other documentation that the Government requests prior to PCA. The Government shall conduct the PCA using EIA-649 as a guideline. Once the PCA is completed and the Government acceptance received, then the contractor shall be responsible to maintain the established Product Baseline for each CI that has passed PCA. The FCA and PCA may be held concurrently.

4.4.3.1 Change Moratorium

When the PCA is conducted, a moratorium on changes shall be imposed during the period of audit. The contractor shall present all changes in the process of being incorporated into the hardware and documentation to the audit team as the listing of outstanding changes.

4.4.3.2 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. Access to the equipment in various stages of assembly may be requested by the audit team.

4.4.3.3 Workmanship Discrepancies

In the event that the PCA should disclose a workmanship problem as opposed to a difference between the hardware and Product Baseline documentation, the problem shall be documented as part of the PCA Certification Package (section 4.4.35).

4.4.3.4 Equipment Retest

The contractor shall conduct a Government-approved retest of the audited items after the discrepancies have been identified to ensure that no faults were induced during PCA process.

Production of units shall not commence until all audit discrepancies between the baseline and final documentation identified in paragraph 4.1.4 above have been resolved and the resolution approved by the Government.

4.4.3.5 PCA Completion

The Government will release PCA findings to the contractor at the conclusion of the audit. Upon completion of the PCA, the contractor shall prepare and submit, as part of the audit report, the PCA Certification Package. The PCA Certification Package shall contain all the discrepancies found during the PCA, changes required to the Product Baseline as a result of the audit and implementation status of all discrepancies affecting the as-built hardware, and provide proof of incorporation. Such changes shall be appropriately flagged for ready identification, and the contractor shall certify that all such changes are flagged.

SOW APPENDIX B

ATTACHMENT 1B

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: This data documentation shall be provided to Physical Configuration Audit (PCA) Team Members or otherwise made 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 HFA Window 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 HFA Window 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 HFA Window 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 HFA Window 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 HFA Window 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.

SOW APPENDIX C

ATTACHMENT 1C

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:

a) 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

3.2.1 Marking Approach

All hardware under CTP cognizance is currently required to have human readable plates or labels that identify the manufacturer’s cage code, part number, serial number, National Stock Number, contract number, and factory acceptance date of the item. This marking requirement shall remain in effect in addition to the new UID marking requirement (also known as 2D Barcode or Data Matrix symbols). Two acceptable options are described below.

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

3.4.4 Serial Numbers