N6660414R0921_Attachment_1_SOW.pdf

N66604-14-R-0921

SECTION C – STATEMENT OF WORK

1. BACKGROUND

The Naval Undersea Warfare Center Division, Newport (NAVUNSEAWARCENDIVNPT) located in Rhode Island

(RI) and the Naval Undersea Warfare Center Division, Keyport (NAVUNSEAWARCENDIVKPT) located in

Washington (WA) are responsible for supporting all life cycle phases of the Lightweight and Heavyweight Torpedo systems to include the requirements definition, design, development, integration and test of torpedo upgrades and automatic test equipment, weapon procurement and production support activities, torpedo performance analysis and operational readiness, and technical support for foreign military sales. In support of these activities, the facilities maintain corporate and scientific/engineering knowledge and specialized facilities for planning, developing, and conducting research, advanced development, production hardware assessment and operational systems development for all torpedo systems including export weapons.

The United States Navy (USN) maintains an active inventory of Mk48 Mod 6 and Mod 7 Heavyweight Torpedoes.

The current Alternators and Regulators used in the Mk48 Heavyweight Torpedoes were acquired in the mid 1980’s through the early 1990’s and recent assessments of the torpedo inventory have identified a need for the USN to acquire additional Alternators and Regulators. The Undersea Weapons Program Office (PMS 404) will be sponsoring the Naval Undersea Warfare Center for the acquisition of Alternators and Regulators.

2. SCOPE

This Statement of Work (SOW) sets forth the work efforts required by the contractor to address obsolescence and manufacturability issues, fabricate, assemble, test, inspect, package, and deliver First Article and Production

Alternators and Regulators for the Mk48 Heavyweight Torpedoes. The Alternators and Regulators shall be built in accordance with the build-to-print Technical Data Package (TDP), Attachment 1. The contractor shall address component obsolescence and manufacturability issues with an equivalent fit, form, and function component.

This contract shall include: 1.) Program, Engineering and Quality Management, 2.) First Article and Testing, 3.)

Production and Testing, and 4.) Engineering and Technical Services.

The tasking per this contract shall include:

1. Program, Engineering and Quality Management

2. Preproduction – First Article

a. Technical Program Reviews

b. Material Procurement

c. Test Plans and Procedures

d. Test Execution and Reporting

e. Integration, Qualification and IV&V Testing

f. Failure Analysis and Reporting

3. Production

a. Technical Program Reviews

b. Program Management Reviews

c. Material Procurement

d. Test Plan and Procedure

e. Test Execution and Reporting

f. Production Screening

g. Physical Configuration Audit

h. Failure Analysis and Reporting

4. Engineering and Technical Services

a. Integration, Qualification and IV&V Testing Support

b. Engineering Support

3. APPLICABLE DOCUMENTS

To the extent referenced herein, the following documents form a part of this SOW and are hereby incorporated by reference. If no revision is indicated, the revision in effect on the date of contract award applies. In the event of a conflict between the documents referenced herein and the contents of this SOW, the contents of this SOW shall take precedence. Documents and specifications provided as Government Furnished Information (GFI) are identified in

Attachment 2.

3.1 Department of Defense Handbooks:

Applicable

Document # Document # Document Title Date or Revision

3.1.1 MIL-HDBK-217 Reliability Prediction of Electronic Equipment F

3.1.2 MIL-HDBK-263 Electrostatic Discharge Control Handbook for

Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding

Electrically Initiated Explosive Devices) (Metric)

(Excluding Electrically Initiated Explosive

Devices) (Metric)

B

3.1.3 MIL-HDBK-2155 Failure, Reporting, Analysis and Corrective

Action Taken

11 December 1995

3.2 Department of Defense Standards:

Document # Document # Document Title Date or Revision

3.2.1 MIL-STD-130 Identification Marking of U.S. Military Property N

3.2.2 MIL-STD-1521 Technical Reviews and Audits for Systems, Equipments and Computer Software

B

3.2.3 MIL-STD-1686 Electrostatic Discharge Control Program for

Protection of Electrical and Electronic Parts, Assemblies and Equipment

C

3.2.4 MIL-STD-3018 Parts Management 27 October 2011

3.2.5 MIL-STD-31000 Technical Data Packages 5 November 2009

3.3 Other Government Documents:

Document # Document # Document Title Date or Revision

3.3.1 6935199 Critical Item Product Performance Specification for Alternator Assembly

25 October 2011

3.3.2 6935009 Alternator Assembly F

3.3.3 5893756 Critical Item Product Fabrication Specification for Regulator Assembly (Type C-2b)

F

3.3.4 5894200 Regulator Assembly AT

3.3.5 6114188 Automatic Electric Power Source Test Set E

3.3.6 - Government Qualification Acceptance Test Plan

(QATP), Electrical Power Source (EPS)

Draft

3.3.7 - Torpedo Systems Department Configuration

Management Plan

D

3.3.8 S0199-133-A-O-C Configuration Management Plan for Undersea

Weapons and ASW Targets Programs (PMS404)

D

3.3.9 - Undersea Weapons Program Office, Risk Process

Description

8 September 2003

3.3.10 TOR-2007(8583)-

6414, Volume 1

Technical Reviews and Audits for Systems, Equipment, and Computer Software

3.4 Industry Documents:

Document # Document # Document Title Date or Revision

3.4.1 ANSI/ISO/ASQ

9001-2008

Quality Management Systems - Requirements

Standard

November 2008

3.4.2 GEIA-859-A Data Management April 2012

3.4.3 EIA-649-B Configuration Management Standard April 2011

3.4.4 IPC-A-610E Acceptability of Electronic Assemblies April 2010

3.4.5 IPC/EIA-J-STD-

001E

Requirements for Soldered Electrical and

Electronic Assemblies

April 2010

3.4.6 IPC/WHMA-A-

620B

Requirements and Acceptance for Cable and

Wire Harness Assemblies

October 2012

4. REQUIREMENTS

4.1 General Requirements

The work required shall be performed in accordance with the requirements of applicable documents 3.3.1 “Critical

Item Product Performance Specification for Alternator Assembly” and 3.3.3 “Critical Item Product Fabrication

Specification for Regulator Assembly” provided in Attachment 1. This SOW defines the requirements for the

Alternator Assembly (applicable document 3.3.2, see Attachment 1) and Regulator Assembly (applicable document

3.3.4, see Attachment 1) design and the requirements to address any obsolescence or manufacturability issues if any exist, followed by fabrication, assembly, test, inspection, packaging, and delivery of First Article and Production hardware.

4.2 Program Management (All CLINs)

The contractor shall prepare and deliver a Program Management Plan (PMP) in accordance with CDRL A001. The

PMP shall contain sufficient detail to allow the Government to verify the contractor’s management and scheduling of all efforts necessary to meet the contract requirements. The contractor shall designate a Program Manager who shall have responsibility for all aspects of this contract.

Deliverables: CDRL A001 – Program Management Plan

4.2.1 Integrated Program Management Report (IPMR)

The contractor shall prepare and deliver an Integrated Program Management Report (IPMR) in accordance with

CDRL A002. The IPMR shall include the efforts of all activities, including all subcontractors and suppliers. The contractor shall supply an Integrated Master Schedule (IMS) as part of the IPMR which shall include all program activities required for the performance of this contract. The contractor shall record progress against the IPMR on a monthly basis.

Deliverables: CDRL A002 – Integrated Program Management Report (IPMR)

4.2.2 Risk Management

The contractor shall implement a comprehensive Risk Management Process that is focused on program risk areas and the program’s critical path to systematically identify and mitigate cost, schedule, and technical risks. The contractor shall use applicable document 3.3.9 “Undersea Weapons Program Office, Risk Process Description” provided in Attachment 2 to identify, quantify and track technical and programmatic risks. The contractor shall provide risk item reports, which include the identification and adjudication of risk items, within the monthly IPMR

(CDRL A002).

4.2.3 Parts Management

The contractor shall establish and maintain a Parts Management Program in accordance with the requirements of applicable document 3.2.4 “Parts Management”. The contractor shall verify that the use of parts meet the contractual requirements, reduce proliferation of parts within and across Department of Defense (DoD) weapons systems and equipment through standardization, enhance reliability and supportability to meet material readiness objectives, and reduce total life-cycle costs. Also, the contractor shall describe how the parts management process is validated, how process improvements are incorporated, and how process variation is controlled. The contractor shall prepare and deliver the Parts Management Plan in accordance with CDRL A003 covering the period of performance of this contract.

The Parts Management Plan shall address the following parts management elements:

1. Parts selection baseline

2. Parts selection and authorization process

3. Obsolescence management

4. Parts list or Bill of Materials (BOM)

5. Subcontractor management

6. Part and supplier quality

7. Part level documentation procedures

8. Substitute and alternative part procedures

9. Customer-contractor teaming

10. Counterfeit parts

11. Lead-free electronic parts

12. Long lead material

The contractor shall conduct engineering analysis of the TDP provided in Attachment 1 to identify changes required to resolve obsolescence issues, reflect current best practices, and update supplier information to ensure a producible design. The Parts Management Plan shall define the contractor’s process that mitigates the risk associated with technology obsolescence; proprietary technologies; the loss or impending loss of manufacturers or suppliers of components, assemblies, or materials used in the system; and provide rationale for reliance on a single source of supply over the life of the system. The Parts Management Plan shall contain provisions to minimize the impact of obsolescence during contract execution, effectively manage obsolescence through planned modernization, and avoid additional costs from being incurred by the Government due to obsolescence. The contractor shall recommend design changes to ensure continuous manufacturing and repairing capabilities in accordance with the Configuration

Management requirements of this contract.

Lead based solder shall be used in the construction of the Alternators and Regulators manufactured under this contract. The Government may waive this requirement if the contractor demonstrates by analysis that the use of lead free solder and any risk mitigation measures implemented in the construction will not degrade system reliability requirements. The contractor’s analysis shall be documented in accordance with the Parts Management Plan, CDRL

A003.

Deliverables: CDRL A003 – Parts Management Plan

4.2.4 Data Management

The contractor shall establish and maintain a Data Management Program in accordance with applicable document

3.4.2 “Data Management”. The contractor shall maintain a current listing of all data generated in the execution of this contract in the form of a Data Accession List (DAL). Only those items deliverable under the other CDRLs delineated in Exhibit A are excluded. All non-CDRL data generated by the contractor and subcontractors in the performance of this contract shall be made available on the DAL and, if requested by the Government, delivered to the Government at no additional cost.

Deliverables: CDRL A004 – Data Accession List (DAL)

4.2.5 Configuration Management

The contractor shall prepare and utilize a configuration management plan in accordance with the requirements of applicable documents 3.3.7 “Torpedo Systems Department Configuration Management Plan”, 3.3.8 “Configuration

Management Plan for Undersea Weapons Program (PMS404) PEO USW”, and 3.4.3 “Configuration Management

Standard” to establish and maintain a Product Baseline. The contractor shall deliver the configuration management plan in accordance with CDRL A005.

The contractor shall implement a Configuration Management (CM) program that provides hardware, software and documentation management, change control, and status accounting for all components under CM control of each

Alternator and Regulator deliverable or repair action during the contract period of performance.

The contractor shall submit for Government approval Engineering Change Proposals (ECP) when changes impact the TDP (See Attachment 1). The contractor shall submit changes to the TDP in accordance with the requirements of applicable document 3.2.5 “Technical Data Packages”. The contractor shall submit Request for Deviations

(RFD) for variances on any requirement(s) as needed. The contractor shall submit to the Government’s web-based

Configuration Management Database (CMPro) all changes and variances in accordance with CDRLs A006 and

A007. ECPs, CDRL A006, shall include corresponding Notices of Revision (NORs), CDRL A008. The contractor shall provide the Lead Engineering Summary (LES) and Checklist for each ECP/RFD/RFV submitted via CMPro per the Torpedo Systems Department Configuration Management Plan guidelines.

The Government may issue an ECP for any deficiency found with the TDP during the contract. The Government will notify the contractor in writing of any Government ECP so the contractor can review the change for necessity, applicability, and acceptability; and review it for cost, schedule, and technical impact. The contractor shall identify the impact of implementation by notifying the PCO in writing within 15 business days of receipt of the Government

ECP.

Deliverables: CDRL A005– Configuration Management Plan

CDRL A006 – Engineering Change Proposal (ECP)

CDRL A007 – Request for Deviation (RFD) - Request for Variance (RFV)

CDRL A008 – Notice of Revisions (NOR)

4.2.5.1 Technical Data Package Update

The contractor shall update the TDP in accordance with the following CDRLs for any and all Government approved design and specification changes. The contractor shall document any and all changes and deliver a Technical Data

Package Review Report in accordance with CDRL A00E.

Deliverables: CDRL A009 – Product Drawings/Models and Associated List

CDRL A00A – Commercial Drawings/Models and Associated Lists

CDRL A00B – Special Inspection Equipment (SIE) Drawings/Models and Associated Lists

CDRL A00C – Special Tooling (ST) Drawings/Models and Associated Lists

CDRL A00D – Program-Unique Specification Documents

CDRL A00E – Technical Data Package Review Report

4.2.5.2 As-Built Configuration List

The contractor shall prepare and deliver a complete As-Built Configuration List (ABCL) in accordance with CDRL

A00F. The list shows the as-built configuration specific to each individual end item delivered under the contract.

The list will be used to monitor contractor compliance with contractual hardware configuration requirements and as a baseline for continuous updating throughout the life cycle of the item.

Deliverables: CDRL A00F – As Built Configuration List (ABCL)

4.2.5.3 Unique Identification

The contractor shall mark and report all end or configuration items with Unique Identification (UID) as required by

DFARS 252.211-7003 and applicable document 3.2.1 “Identification Marking of U.S. Military Property”.

4.2.5.4 Serial Numbers

The contractor shall apply a Government serial number to each unit manufactured. A block of Government serial numbers will be provided by the Procuring Contracting Officer (PCO) when a contract option is exercised.

4.2.6 Government Furnished Property (GFP) Management

The Government will provide GFP per Attachment 3 to support the Alternator and Regulator procurement.

The GFP will be provided to the contractor within 90 days of receipt of contractor's written request. The request shall list the required delivery date of the GFP. The contractor shall provide accountability, security and storage for the GFP provided. The contractor shall inspect and inventory all GFP received and identify and report any discrepancies/ and deficiencies.

An “Automatic Electric Power Source Test Set” (applicable document 3.3.5, see Attachment 2) used by the

Government for testing the Alternator and Regulator will be provided to the contractor as Government Furnished

Equipment (GFE).

4.3 Engineering (All CLINs)

The contractor shall prepare and deliver a Systems Engineering Management Plan (SEMP) in accordance with

CDRL A00G. The SEMP shall fully describe the contractor’s system engineering process to be applied to the definition of system design and test requirements during the contractual effort. It shall include the system engineering required to define the system performance parameters to satisfy the contractual requirements; the planning and controls of the technical program tasks; and management of a totally integrated effort of design engineering, test engineering, logistics engineering and production engineering to meet cost, technical performance, and schedule objectives.

Deliverables: CDRL A00G – System Engineering Management Plan (SEMP)

4.3.1 Test and Evaluation Program Plan

The contractor shall prepare and deliver a Test and Evaluation Program Plan (TEPP) in accordance with CDRL

A00H. The TEPP shall fully describe the contractor's plan for conducting tests and analyzing the test results to show the Alternators and Regulators satisfy the requirements of the specifications. The contractor must receive written approval from the Government prior to implementation of the TEPP.

Deliverables: CDRL A00H – Test and Evaluation Program Plan (TEPP)

4.3.2 Reliability

The contractor shall demonstrate compliance with the Reliability requirements by preparing and delivering a

Reliability Prediction Report in accordance with CDRL A00J for the Regulator. The reliability analysis shall reflect assumptions compatible with the requirements of applicable document 3.1.1 “Reliability Prediction of Electronic

Equipment”.

Deliverables: CDRL A00J – Reliability Prediction and Documentation of Supporting Data

4.3.3 Technical Interchange Meetings

The contractor shall participate with the Government in Technical Interchange Meetings (TIM) at the leadership and working group levels to achieve program goals.

The contractor shall conduct monthly System Engineering (SE) TIM at the contractor’s facility or via telephone conferences with Government participation, which shall support the execution of the contractor’s Government-approved SEMP delivered in accordance with CDRL A00G.

The contractor shall conduct telephone conferences with Government personnel to resolve and discuss ongoing progress, status, condition of GFE, and program issues every two weeks. The contractor shall provide agendas and action items prior to each TIM and shall submit meeting minutes after each TIM. The agendas, action items and meeting minutes shall be delivered in accordance with CDRLs A00M and A00P.

Deliverables: CDRL A00M – Meeting Agenda

CDRL A00P – Report, Record of Meeting/Minutes

4.4 Quality (All CLINs)

The contractor shall implement and maintain a Quality Management System (QMS) in accordance with applicable document 3.4.1 “Quality Management Systems – Requirements”.

The contractor shall prepare and deliver a Quality Program Plan (QPP) in accordance with CDRL A00K. The QPP shall include all of the contractor’s QMS standard policies and procedures and any additional procedures required to verify appropriate quality control and compliance with all requirements of this contract. The contractor shall meet the Quality Thresholds identified in Table 1 below. The contractor shall also identify Key Quality Indicators (KQI) with associated thresholds in the QPP. The QPP shall list quantitative metrics that shall be used by this program to monitor and measure program performance including subcontractors. If the criteria are not met, the contractor shall provide an adequate rationale along with conducting investigation to determine the reason for the noncompliance.

This analysis along with recommended forward and backward corrective action shall be prepared and delivered to the Government in accordance with CDRL A00L (Corrective Action Plan) for review and disposition. The

Corrective Action Plan shall identify applicable open failure analysis and corrective action investigations and any underlying trends. If the analysis and corrective action are deemed appropriate and approved by the Government, no further action is necessary outside of implementation of the approved corrective action. If the Government concludes that the contractor’s analysis and proposed correction is inadequate, the Government may direct further analysis and correction or suspend production deliveries due to contractual noncompliance; after which production deliveries shall not resume until directed by the PCO.

Event Issue Result Quality

Threshold Quality Goal

FRACA Open (pending closure) Closure of FRACA. 3 1

Systemic

Failures

A systemic failure shall be defined as identical failure symptoms on three different units under test. If preliminary investigation cannot rule out the possibility that all three failures have the same root cause, the failures shall be considered systemic. If at any

Identification and root cause analysis on any systemic failure identified.

No more than two open systemic failure investigation at any given time.

One or fewer open systemic failure investigations at any given time.

time during production a systemic pre-FAT failure is identified, the contractor shall conduct root cause analysis or perform an engineering analysis.

Table 1 – Government Quality Thresholds

The contractor shall prepare and flow down to all of its subcontractors and vendors at all tiers, quality requirements sufficient to ensure that the end items and services provided meet all requirements of this contract.

Deliverables: CDRL A00K – Quality Assurance Program Plan - Quality Program Plan (QPP)

CDRL A00L – Corrective Action Plan

4.4.1 Construction and Workmanship

The contractor’s Printed Wiring Boards (PWBs), Cables, and Wire Harness Assemblies shall meet the Association

Connecting Electronics Industries (IPC) Class 3 Industry Standard requirements of the following applicable documents: 3.4.4 “Acceptability of Electronic Assemblies”, 3.4.5 “Requirements for Soldered Electrical and

Electronic Assemblies”, and 3.4.6 “Requirements and Acceptance for Cable and Wire Harness Assemblies”.

4.4.2 Electrostatic Discharge Control Program

The contractor shall establish and implement an effective Electrostatic Discharge (ESD) control program in accordance with the requirements of applicable documents 3.1.2 “Electrostatic Discharge Control Handbook” and

3.2.3 “Electrostatic Discharge Control Program”.

4.5 Preproduction – First Article (CLINs: 0001, 0003, 0005, 0007, 0009, 0011, 0013, 0015, 0017, and

0019)

Preproduction referred to as First Article, are samples that shall be manufactured using the methods and procedures proposed for production. These samples shall be tested for the purpose of determining that the contractor prior to starting production is capable of producing Alternators and Regulators that comply with the design and technical requirements of the contract. First Article occurs before the start of the first production run and may occur in the event of a break in production or any major design changes.

The contractor shall conduct a detailed design analysis of the Alternator and Regulator Technical Data Package

(TDP), Attachment 1, identify obsolescence and manufacturability issues, and develop design solutions that resolve any issues identified.

The contractor shall verify that any proposed design change required to resolve obsolescence and manufacturability issues does not degrade the reliability requirements by demonstrating that electronic parts or components that are replaced have equivalent or greater reliability and performance characteristics. This shall be documented in accordance with CDRL A00J – Reliability Prediction and Documentation of Supporting Data.

The contractor shall satisfy all test and performance requirements of the Build-to-Print TDP.

The contractor shall conduct First Article testing in accordance with the approved Test Plan and Procedures (CDRL

A00S). The contractor shall prepare and deliver a First Article Test Report in accordance with CDRL A00U.

Upon successful completion of the First Article acceptance testing and approval of the First Article Test Report, the contractor shall package, ship, and deliver the First Article Alternators and First Article Regulators to

NAVUNSEAWARCENDIVNPT.

4.5.1 Technical Program Reviews

The Aerospace Technical Operating Report, applicable document 3.3.10 “Technical Reviews and Audits for

Systems, Equipment, and Computer Software”, represents an update to the obsolete applicable document 3.2.2

“Technical Reviews and Audits for Systems, Equipments and Computer Software”. The contractor shall use this document as guidance for planning and execution of the reviews and audits listed in the following subsections.

4.5.1.1 Technical Exchange Meeting

The contractor shall host a post-Award Technical Exchange Meeting within 30 Days After Contract Award. The

Government will attend the Technical Exchange Meeting to answer questions about the specifications and work effort required by the contract. The contractor shall provide administrative support and access to the meeting facilities for attending Government personnel. The contractor shall propose the meeting structure and agenda in accordance with CDRL A00M for Government approval. The contractor shall prepare minutes and action items, and attendance lists for the meeting, and provide copies of all information presented in accordance with CDRL

A00N and CDRL A00P.

CDRL A00N – Presentation Material

4.5.1.2 Integrated Baseline Review

The contractor shall host an Integrated Baseline Review (IBR) after the delivery of the PMP in accordance with paragraph 4.2. Prior to the post-Award IBR, the contractor shall deliver its PMP in accordance with CDRL A001 to the Government for approval. The IBR shall cover the PMP providing details of the contractor's planning to ensure complete coverage of the work effort required by the contract, the logical scheduling of work activities, the adequacy for resourcing, the understanding of technical requirements and the identification of inherent risks.

Completion of the post-Award IBR will result in establishment of a baseline for all elements of the Alternator and

Regulator production Integrated Master Schedule (IMS) prepared and delivered in accordance with CDRL A002.

Incremental IBRs are required after the Government exercises contract options, any changes to the baseline, and any changes to any Government-approved contractor plans.

The contractor shall propose the IBR structure and agenda, in accordance with CDRL A00M for Government approval. The contractor shall prepare meeting minutes, action items, and an attendance list, and provide the

Government copies of all information presented in the IBR in accordance with CDRL A00N and CDRL A00P.

IBRs shall be held at the contractor’s facility. The IBR will be considered complete when the PCO provides notification to the contractor authorizing the contractor to proceed. The contractor shall be responsible to resolve all action items generated during the review. Resolution to open action items shall be discussed during the Technical

Interchange Meetings and during the telephone conferences that occur every two weeks.

Entrance and Exit Criteria for the IBR:

IBR Entrance Criteria:

a. An approved Program Management Plan (PMP).

b. An Integrated Program Management Report (IPMR).

c. The contractor baseline must be established and must reflect the entire scope of work documented at the appropriate level of detail before the formal IBR can be conducted.

IBR Exit Criteria:

a. Technical scope of work is fully included and is consistent with authorizing documents.

b. Key project schedule milestones are identified and supporting schedules reflect a logical flow to accomplish the work.

c. Resources (budgets, facilities, personnel, skills, etc.) are available and are adequate for the assigned tasks.

d. Tasks are planned and can be measured objectively relative to the technical progress.

e. Rationales underlying the Program Measurement Baseline are reasonable.

f. Management processes support successful execution of the project.

4.5.1.3 Critical Design Review

The Critical Design Review (CDR) is a multi-disciplined technical review establishing the initial product baseline to ensure that the system under review satisfies the requirements within the currently allocated budget and schedule.

This review assesses the final design as captured in product specifications for each Configuration Item (CI) in the system and ensures that each product specification has been captured in detailed design documentation. Within the scope of the CDR the contractor shall present to the Government the proposed Baseline (“Build To” documentation) to show that the system design documentation (Initial Product Baseline, including Item Detail Specs, Material

Specs, Process Specs) is satisfactory to begin fabrication, demonstration, and testing. The contractor shall notify the

Government 30 days prior to the milestone event to schedule the CDR. The contractor shall host, present, and support the CDR. The contractor shall prepare the CDR agenda, presentation material, meeting minutes, action items, and provide copies of all information presented in accordance with CDRLs A00M, A00N, and A00P.

The CDR will be considered complete when the PCO provides notification to the contractor authorizing the contractor to proceed to First Article manufacturing. The contractor shall be responsible to resolve all action items generated during the review. Resolution to open action items shall be discussed during the Technical Interchange

Meetings and during the telephone conferences that occur every two weeks.

Entrance and Exit Criteria for the CDR:

CDR Entrance Criteria:

a. An Integrated Baseline Review (IBR) has been successfully completed.

b. An updated Integrated Master Schedule (IMS).

c. An updated Risk Assessment.

d. An updated System and Subsystem Specification (SSS).

e. An updated Systems Engineering Management Plan (SEMP).

f. A preliminary Test and Evaluation Program Plan (TEPP).

CDR Exit Criteria:

a. An established system initial product baseline to include updated schematics, board layouts, GERBER files, parts list, analyses, and all other design documentation.

b. An updated Integrated Master Schedule (IMS).

c. An updated Risk Assessment.

d. An updated Systems Engineering Management Plan (SEMP).

4.5.1.4 Test Readiness Review

The Test Readiness Review (TRR) is a multi-disciplined technical review designed to ensure that the system is ready to proceed into First Article testing. Within the scope of the TRR the contractor shall present for Government review and approval test plans and procedures, test assets, test facilities, risks in the upcoming test period, and other related items. The contractor shall notify the Government 30 days prior to the milestone event to schedule the TRR.

The contractor shall host, present, and support the Test Readiness Review (TRR). The contractor shall prepare the

TRR agenda, presentation material, meeting minutes, action items, and provide copies of all information presented in accordance with CDRLs A00M, A00N, and A00P.

The TRR will be considered complete when the PCO provides notification to the contractor authorizing the contractor to proceed to formal First Article testing. The contractor shall be responsible to resolve all action items generated during the review. Resolution to open action items shall be discussed during the Technical Interchange

Meetings and during the telephone conferences that occur every two weeks.

Entrance and Exit Criteria for the TRR:

TRR Entrance Criteria:

a. A Critical Design Review (CDR) has been successfully completed.

b. Approved Test Plan and Procedures per CDRL A00S.

c. Approved Test Verification Matrix per CDRL A00T.

d. An updated Integrated Master Schedule (IMS).

e. An updated Risk Assessment.

f. An updated Systems Engineering Management Plan (SEMP).

g. An approved Test and Evaluation Program Plan (TEPP).

h. All required resources (people, facilities, test articles, test instrumentation) have been identified and coordinated to support the planned First Article and Production acceptance tests.

TRR Exit Criteria:

a. An updated Systems Engineering Management Plan (SEMP).

b. An updated Risk Assessment.

c. Completed identification and coordination of required test resources.

d. A system product baseline to include updated schematics, board layouts, GERBER files, parts list, analyses, and all other design documentation.

4.5.1.5 Functional Configuration Audit (CLINs: 0001 and 0003)

The Functional Configuration Audit (FCA) is the formal examination of the as-tested characteristics of the configuration item with the objective of verifying that actual performance complies with design and interface requirements in the functional baseline. The FCA is conducted by the Government concurrently with the Production

Readiness Review (PRR) or prior to the Full-Rate Production Decision. Prior to the FCA the contractor shall provide to the Government the approved Test Plan and Procedures along with the Test Verification Matrix in accordance with CDRLs A00S and A00T. The contractor shall also provide all documentation baselined prior to the

FCA.

4.5.1.5.1 Configuration Audit Plan - Functional Configuration Audit

The contractor shall prepare and deliver a Configuration Audit Plan in accordance with CDRL A00Q.

The CDRL references a Data Item Description (DID) that contains the content and preparation instructions for the

Configuration Audit Plan specific task requirements including the following as delineated in the contract.

1. Verification of Test Procedures and Test Results.

2. Performance Specification Review and Validation.

The plan shall define all information necessary for conducting the audit.

Deliverables: CDRL A00Q – Configuration Audit Plan - Functional Configuration Audit (FCA)

4.5.1.5.2 Configuration Audit Summary Report - Functional Configuration Audit

Following the completion of FCA, 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 the FCA discrepancy resolutions.

The contractor shall deliver an audit summary report in accordance with CDRL A00R.

The CDRL references a Data Item Description (DID) that contains the format, content, and preparation instructions for the Configuration Audit Summary Report that shall include the following:

1. Meeting minutes: time, place, purpose, participants, etc.

2. Action Item List reflecting all actions and suspense dates agreed too.

3. Applicable audit certifications documenting key audit review activities:

a. Specific items, systems, documents or processes reviewed.

b. Summary of discrepancies/deficiencies in each area referenced to control number of applicable audit problem write-ups (action items).

c. Definitive statements about acceptability or non-acceptability.

d. Final status of the contractor’s effort in the area being certified.

Deliverables: CDRL A00R – Configuration Audit Summary Report - Functional Configuration Audit (FCA)

4.5.1.6 Production Readiness Review

The contractor shall conduct a Production Readiness Review (PRR) to support the Government’s evaluation of the contractor's production readiness, identify existing or projected manufacturing problems, and areas of risk. The contractor shall demonstrate achievement of the following:

a. Attaining the program's production goals.

b. Elimination of manufacturing risks or known problems.

c. Plans addressing obsolescence in the TDP.

d. Mitigating all production risks.

The contractor shall show that the Alternator and Regulator design has included those key production factors (i.e.

least cost, minimum time, manufacturing simplicity and flexibility, resource availability) necessary to assure the

Alternators and Regulators can be acquired on schedule. The contractor shall host, present, and support the PRR milestone review. The contractor shall prepare the PRR agenda, presentation material, meeting minutes, action items, and provide copies of all information presented in accordance with CDRLs A00M, A00N, and A00P.

The contractor shall notify the Government 30 days prior to the milestone event to schedule the PRR when the contractor determines with Government concurrence that all of the following prerequisites for the PRR have been satisfied:

a. Successful completion and Government approval of contractor First Article testing, including

Government First Article Qualification and Validation testing and the Functional Configuration

Audit.

b. Approved Program Management Plan (PMP).

c. Approved Configuration Management Plan.

d. Approved Quality Program Plan (QPP).

e. Completed Critical Manufacturing Procedures.

f. Completed Assembly and Manufacturing Processes and Procedures.

g. Contractor approved Supply Sources and Vendors.

When the Government has determined that the PRR has been successfully completed, the contractor shall establish a baseline of all factory processes.

The PRR will be considered complete when the PCO provides notification to the contractor authorizing the contractor to proceed into factory production once a contract option is exercised. The contractor shall be responsible to resolve all action items generated during the review. Resolution to open action items shall be discussed during the Technical Interchange Meetings and during the telephone conferences that occur every two weeks.

Entrance and Exit Criteria for the PRR:

PRR Entrance Criteria:

a. A Test Readiness Review (TRR) has been successfully completed.

b. An approved Systems Engineering Management Plan (SEMP).

c. An updated Risk Assessment.

d. Approved Test Plan per CDRL A00W

e. Approved Test Procedure per CDRL A00X.

f. Approved Test Verification Matrix per CDRL A00Y.

g. Completed identification and coordination of required test resources.

h. A system product baseline to include updated schematics, board layouts, GERBER files, parts list, analyses, and all other design documentation.

PRR Exit Criteria:

a. An approved Systems Engineering Management Plan (SEMP).

b. An updated Risk Assessment.

c. An updated Integrated Master Schedule (IMS).

4.5.2 Material Procurement

The contractor shall review the TDP and identify components with lead times in excess of three (3) months that are considered to be long lead materials. This list as part of the Parts Management Plan (CDRL A003) shall be presented to the Government during the IBR for approval to proceed with procurement of long lead materials as necessary for First Article Alternators and Regulators and exercise of options, if decided by the Government.

4.5.3 First Article Test Plan and Procedures

The contractor shall prepare and deliver a comprehensive Test Plan and Procedures in accordance with CDRL A00S to satisfy all test and performance requirements in accordance with the Build-to-Print TDP, (See Attachment 1).

The contractor shall also prepare and deliver a Test Verification Matrix to demonstrate traceability between each test requirement and its associated test procedure in accordance with CDRL A00T.

The contractor shall include any proposed use of the “Automatic Electric Power Source Test Set” (applicable document 3.3.5, see Attachment 2) in the test plan and procedures.

The contractor must obtain Government concurrence and approval of the Test Plans and Procedures and the Test

Verification Matrix prior to implementation.

Deliverables: CDRL A00S – First Article Qualification Test Plan and Procedures

CDRL A00T – Specification Requirement Verification Matrix - First Article Test Verification

Matrix

4.5.4 First Article Test Execution and Reporting

The contractor shall conduct all levels of testing in accordance with the approved First Article Qualification Test

Plan and Procedures. The contractor shall electronically log and store all required test data collected in accordance with the approved procedures. Stored data formats shall be non-proprietary and shall be in the contractor’s normal format consistent with best commercial practices. After completion of First Article testing, the contractor shall deliver a First Article Test Report in accordance with CDRL A00U. The First Article Test Report shall include the results of all the testing and inspections conducted on the First Article Alternators and First Article Regulators in accordance with the approved First Article Qualification Test Plan and Procedures (CDRL A00S) and Specification

Requirement Verification Matrix (CDRL A00T).

The First Article Test Report shall clearly demonstrate the conformance to First Article requirements defined within the Technical Data Package, Attachment 1. The contractor shall host Government teams tasked to oversee, observe, and audit contractor testing efforts, as designated.

Upon Government review and approval of the First Article Test Report, the contractor shall deliver the First Article

Alternators and First Article Regulators to the Government for Integration, Qualification and Independent

Validation and Verification (IV&V) Testing.

Deliverables: CDRL A00U – Test/Inspection Report - First Article Test Report

4.5.5 Integration, Qualification and IV&V Testing

The Government will conduct Integration, Qualification and IV&V Testing for the First Article Alternators and First

Article Regulators in accordance with the requirements of applicable document 3.3.6 “Government Qualification

Acceptance Test Plan (QATP), Electrical Power Source (EPS)” provided per Attachment 2.

In the event of a failure, the contractor shall provide failure analysis support during Government Integration, Qualification and IV&V Testing. The contractor shall deliver a failure report detailing findings during this test phase and the plan for any necessary corrective actions in accordance with paragraph 4.5.6.1. Upon implementation of any corrective actions, the contractor shall redeliver any First Article Alternators and/or First Article Regulators that failed Government Integration, Qualification and IV&V Testing. Upon delivery, the Government will proceed with the continuation of conducting the tests.

Prior to the contractor redelivering the repaired Alternators and/or Regulators that failed Government Integration, Qualification and IV&V Testing, the Government will decide if the repaired Alternators and/or Regulators will require contactor First Article testing. The Government’s decision will be based on the results of the contractor’s failure analysis and corrective action.

4.5.6 First Article Failure Analysis and Reporting

The contractor shall establish, document and deliver a Failure Analysis Program Plan as part of the QPP (CDRL

A00K), which at a minimum follows the guidelines established per applicable document 3.1.3 “Failure, Reporting, Analysis and Corrective Action”.

4.5.6.1 Failure Analysis Support during First Article Testing

The contactor shall perform fault isolation and root cause of any failure or deficiency that is identified during First

Article testing and isolated to an Alternator and/or Regulator deliverable. The contractor shall prepare and deliver

Failure Reporting, Analysis, and Corrective Action (FRACA) reports in accordance with CDRL A00V. The contractor shall incorporate identified corrective actions into the Alternator and Regulator TDPs (See Attachment 1) in accordance with Section 4.2.5 – Configuration Management.

The contractor shall prepare a FRACA report for each deliverable item that fails during contractor First Article testing and Government Integration, Qualification and IV&V Testing.

Each report shall contain the required information in accordance with section 3 of the Data Acquisition Document listed in Block 4 of CDRL A00V in addition to requirements listed below as part of the Preliminary and Final

Report:

1. Date of Hardware Receipt from Government

2. Reference designator

3. Test Phase Performed (i.e. vendor, CCA First Function, FAT, pre-range, in-water, post-range, etc.)

4. Operational and environmental conditions under which the failure occurred

5. Failure analysis results including parts analysis

6. Failure history including vendor, subcontractor, factory

7. Failure trend analysis

8. Systemic failure classification (yes, no)

9. Reference to associated systemic failures (e.g. list of all failures that make it systemic)

10. Identification of root cause

11. Mission impact

12. Summary of changes

13. Criticality

Item 13, Criticality, shall be defined using the following guidelines:

Criteria: Severity of Effect

Catastrophic: A failure which would create a safety risk or undermine an existing safety feature.

Critical: A failure which will result in mission loss.

Major: A failure which would degrade in-water performance or cause reduction in availability.

Minor: A failure that would not be expected to cause failure or degrade performance in most cases, but will result in unscheduled maintenance or repair.

In addition the contractor shall address the following failure keywords:

a. Nonrelevant

b. Under Investigation

c. Unknown

d. Unverified

e. Component

f. Non valid

g. Contractor

h. Gov't Furnished Equipment

i. Gov't Furnished Material

Deliverables: CDRL A00V – Failure Analysis and Corrective Action Report (FACAR) - Factory Failures during

First Article Testing and Government Testing

4.6 Production (CLINs: 0021, 0023, 0025, 0027, 0029, 0031, 0033, 0035, 0037, 0039, 0041, 0043, 0045, 0047, and 0049)

The contractor shall fabricate, assemble, test, inspect, package, and deliver Alternators and Regulators that meet the requirements defined in the TDP.

Production will undergo a Factory Acceptance Test (FAT) to verify conformance to applicable performance specification requirements. The contractor shall conduct the FAT on all production units in accordance with the approved Test Plan (CDRL A00W) and Procedure (CDRL A00X). The contractor shall prepare and deliver a

Factory Acceptance Test Report in accordance with CDRL A00Z.

Periodic samples of the Alternator and Regulator from a production quantity that passed the FAT shall be selected at random by a Government Inspector for submission to an activity designated by the procuring agency to determine compliance with the requirements of the specifications and drawings.

4.6.1 Integrated Baseline Review

The contractor shall host an Integrated Baseline Review (IBR) after exercise of contract options, any changes to the baseline, and any changes to any Government-approved contractor plans. The IBR shall cover the Program

Management Plan (PMP) providing details of the contractor's planning to ensure complete coverage of the work effort required by the contract, the logical scheduling of work activities, the adequacy for resourcing, the understanding of technical requirements and the identification of inherent risks. Completion of the post-Award IBR will result in establishment of a baseline for all elements of the Alternator and Regulator production Integrated

Master Schedule (IMS) prepared and delivered in accordance with CDRL A002.

IBRs shall be used as necessary throughout the life of the contract to facilitate and maintain mutual understanding of:

a. The scope of the PMP.

b. Management control processes.

c. Risks in the PMP associated with cost, schedules, and resources.

The contractor shall propose the IBR structure and agenda, in accordance with CDRL A00M for Government approval. The contractor shall prepare minutes including action items, attendance list and provide the Government copies of all information presented in the IBR in accordance with CDRL A00N and CDRL A00P. IBRs shall be held at the contractor’s facility. The IBR will be considered complete when the Procuring Contracting Officer

(PCO) provides notification to the contractor authorizing the contractor to proceed. The contractor shall be responsible to resolve all action items generated during the review. Resolution to open action items shall be discussed during the Technical Interchange Meetings and during the telephone conferences that occur every two weeks.

Entrance and Exit Criteria for the IBR:

IBR Entrance Criteria:

a. An approved Program Management Plan.

b. An Integrated Program Management Report (IPMR).

c. The baseline must be established by the contractor and must reflect the entire scope of work documented at the appropriate level of detail before the formal IBR can be conducted.

IBR Exit Criteria:

a. Technical scope of work is fully included and is consistent with authorizing documents.

b. Key project schedule milestones are identified and supporting schedules reflect a logical flow to accomplish the work.

c. Resources (budgets, facilities, personnel, skills, etc.) are available and are adequate for the assigned tasks.

d. Tasks are planned and can be measured objectively relative to the technical progress.

e. Rationales underlying the Program Measurement Baseline are reasonable.

f. Management processes support successful execution of the project.

4.6.2 Program Management Reviews

The contractor shall conduct semiannual Program Management Reviews (PMRs) to be held at the contractor’s facility or at the Naval Undersea Warfare Center Division, Newport (NAVUNSEAWARCENDIVNPT). If held at the contractor’s facility, the contractor shall provide administrative support and access to the facilities to attending

Government personnel. The Government will confirm the date(s) and location no less than 30 days prior to the

PMR.

The Program Management Reviews shall include the following minimum information:

1. Completed and Planned Efforts

2. Schedule Performance

3. Risk Management Activities

4. Program Issues

5. Contractual Issues

6. Parts Issues

7. Acceptance Testing Status Related to Production Efforts

8. Status of Each Technical…