DRAFTSOW0931.pdf

N66604-XX-XXXX

TABLE OF CONTENTS

1. BACKGROUND

2. SCOPE

3. DOCUMENTS

3.2 Reference Documents

4. REQUIREMENTS

4.1 Program Management

4.1.1 Integrated Program Management Report (IPMR)

4.2 Risk Management

4.3 Parts Management

4.4 Data Management (All CLINs)

4.5 Configuration Management

4.5.1 Technical Data Package Update

4.5.2 As Built Configuration List

4.5.3 Unique Identification

4.5.4 Serial Numbers

4.6 Technical Interchange Meetings

4.7 Quality Management

4.7.1 Electrostatic Discharge Control Program

4.8 Preproduction – First Article

4.8.1 Technical Program Reviews

4.8.1.1. Integrated Baseline Review

4.8.1.2 Test Readiness Review

4.8.1.3 Production Readiness Review

4.8.2 First Article Test Plan and Procedures

4.8.3 First Article Test Execution and Reporting

4.8.4 Integration, Qualification and IV&V Testing

4.8.5 First Article Failure Analysis and Reporting

4.8.5.1 Failure Analysis Support during First Article Testing

4.9 Production

4.9.1 Program Management Reviews

4.9.2 Factory Acceptance Testing (FAT) Test Plan and Procedure

4.9.3 Factory Acceptance Test (FAT) Execution and Reporting

4.9.4 Production Screening

4.9.5 Factory Acceptance Testing (FAT) Failure Analysis and Reporting

4.9.5.1 Pre-Factory Acceptance Test (Pre-FAT) Failures

4.9.5.2 Factory Acceptance Test (FAT) Failures

4.10 Engineering and Technical Services

4.10.1 Integration, Qualification and IV&V Testing Support

4.10.2 Engineering Services to Support Preproduction – First Article & Production Tasking

5. PROGRESS REPORTS

6. GOVERNMENT FURNISHED INFORMATION

7. ACRONYMS

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 including 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, these 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.

Currently, the United States Navy (USN) maintains an active inventory of MK48 Mod 6 and Mod 7 Heavyweight

Torpedoes. The current Warhead Electronics System (WES) and SONAR Signal Transmitter Assembly used in the

MK48 Heavyweight Torpedo were last acquired in the early 1990’s. Recent assessments of the torpedo inventory have identified a need for the USN to acquire additional WES and SONAR Signal Transmitter Assemblies. In response, NAVUNSEAWARCENDIVNPT has completed an effort to modernize the WES and SONAR Signal

Transmitter Assembly Technical Data Package (TDP) and is seeking to procure WES and SONAR Signal

Transmitter Assemblies that meet the requirements within the TDP. The Undersea Weapons Program Office (PMS

404) will be sponsoring the Naval Undersea Warfare Center for the acquisition of these WES and SONAR Signal

Transmitter Assemblies.

2. SCOPE

This Statement of Work (SOW) sets forth the work efforts required by the contractor to fabricate, assemble, test, inspect, package, and deliver First Article and Production WES and SONAR Signal Transmitter Assemblies for the

MK48 Heavyweight Torpedoes. The WES and SONAR Signal Transmitter Assemblies shall be built in accordance with the build-to-print TDP, Attachment 1. All work to be performed under this SOW shall require a secure facility and personnel with required security clearances in accordance with enclosure XXX (DD-254).

The tasking per this contract shall include program management, preproduction-first article, production, and engineering and technical services.

2.1 - Sponsors

1) PMS404

2.2 – Funding

This contract is funded used the following categories:

1) WPN

2) FMS

3) OMN

3. 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. The contractor shall perform all statement of work tasks in accordance with applicable documents identified in Table 3.1, 3.2, 3.3, and 3.4.

3.1 Applicable Documents:

Applicable

Document

Document # Document Title Date or

Revision

Applicable SOW

Task

3.1.1 N/A

Torpedo MK 48 Warhead

Electronics System (WES)

Assembly SONAR Signal

Transmitter Assembly Technical

Data Packages

N/A

4, 4.5, 4.5.1, 4.8.1.3, 4.8.2, 4.8.3, 4.8.5.1, 4.9, 4.9.2

3.1.2 6934830

ELECTRONIC ASSEMBLY WES

MARK 22 MOD 1

22 MOD 0

E 4

3.1.3 6934832 (Classified

Document)

TORPEDO MK 48 ADCAP

CRITICAL ITEM PRODUCT

FUNCTION SPECIFICATION

FOR ELECTRONIC ASSEMBLY

WES MARK 22 MOD 1 (TYPE

C2a)

- 4

3.1.4 6934828 (Classified

Document)

TOPREDO MK48 ADCAP

CRITICAL ITEM PRODUCT

FABRICATION

SPECIFICATION FOR

ELECTRONIC ASSEMBLY,

WES MARK 22 MOD 1

(TYPE C2b)

B 4, 4.9.4

3.1.5 5728260 SONAR Signal Transmitter

Assembly Drawing P 4

3.1.6 5728264 (Classified

Document)

TORPEDO MK48 CRITICAL

ITEM PRODUCT FUNCTION

SPECIFICATION FOR SONAR

TRANSMITTER ASSEMBLY

(C2a)

C 4, 4.9.4

3.1.7 8595319

TORPEDO MK48 CRITICAL

ITEM PRODUCT

FABRICATION

SPECIFICATION FOR THE

MOD 7 COMMON

BROADBAND ADVANCED

SONAR SYSTEM (CBASS)

ANALOG TRANSMITTER

ASSEMBLY (TYPE C2b)

- 4, 4.9.4

3.1.8 MIL-STD-130

Identification Marking of U.S.

Military Property N 4.5.3

3.1.9 MIL-STD-3018 Parts Management

27 October

4.3

3.1.10 MIL-STD-31000 Technical Data Packages

5 November

4.5

3.1.12 -

TORPEDO SYSTEMS

DEPARTMENT

CONFIGURATION

MANAGEMENT PLAN

D 4.5

3.1.13 S0199-133-A-O-C

Configuration Management Plan for Undersea Weapons Program

(PMS404)

D 4.5

3.1.14 - Undersea Weapons Program

Office, Risk Process Description

8 September

4.2

3.1.15 6370639 WAS/WES Test Set

4.8.2, 4.9.2

3.1.16 6238331

ANALOG TRANSMITTER TEST

SET

4.8.2, 4.9.2

3.1.17

ANSI/ISO/ASQ 9001-

Quality Management Systems -

Requirements Standard

November

4.7

3.1.18 GEIA-859-A Data Management April 2012 4.4

3.2 Reference Documents:

Applicable

Document # Document # Document Title Date or Revision

Applicable

SOW Task

3.2.1 MIL-STD-1521

Technical Reviews and Audits for

Systems, Equipment, and Computer

Software

B 4.8.1

3.2.2 MIL-STD-1686

Electrostatic Discharge Control Program for Protection of Electrical and

Electronic Parts, Assemblies and

Equipment

C 4.7.1

3.2.3 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 4.7.1

3.2.4 QATP201220003

MK 48 Heavyweight Torpedo Advanced

Capability (ADCAP) Warhead

Electronics System (WES) Government

Qualification Acceptance Test Plan

(QATP)

A 4.8.4

3.2.5 QATP20130004

MK 48 Heavyweight Torpedo Advanced

Capability (ADCAP) Transmitter

Government Qualification Acceptance

Test Plan (QATP)

A 4.8.4

3.2.6 MIL-HDBK-2155

Failure, Reporting, Analysis and

Corrective Action Taken

11 December

4.8.5, 4.9.5

3.2.7

-TOR-2007(8583)-

6414,Volume 1

Technical Reviews and Audits for

Systems, Equipment, and Computer

Software

1 8.1

3.2.8 EIA-649-B Configuration Management Standard April 2011 4.5

4. REQUIREMENTS

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

Item Product Fabrication Specification for Warhead Electronics System,” 3.3.2 “Critical Item Product Function

Specification for Warhead Exploder System,” 3.3.4 “Critical Item Product Fabrication Specification for Analog

SONAR Signal Transmitter Assembly,” and 3.3.5 “Critical Item Production Function Specification for Analog

SONAR Signal Transmitter Assembly” provided in Attachment 1. This SOW defines the requirements for the WES

(applicable document 3.3.3, see Attachment 1) and SONAR Signal Transmitter Assembly (applicable document

3.3.6, see Attachment 1) fabrication, assembly, test, inspection, packaging, and delivery of First Article and

Production hardware. The contractor shall perform all statement of work tasks in accordance with applicable documents identified in Table 3.1 and 3.2

No substitutions of parts specified in the Build-to-Print TDP are permitted without prior written approval of the

Government.

The contractor shall apply engineering processes to comply with 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.

The requirements defined in sections 4.1 thru 4.7 shall be applicable throughout the period of performance of the contract including Preproduction – First Article and Production.

4.1 Program Management

The contractor shall prepare and deliver a Program Management Plan (PMP), 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 (PMP)

4.1.1 Integrated Program Management Report (IPMR)

The contractor shall prepare and submit an Integrated Program Management Report (IPMR), CDRL A002, to 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 Risk Management

The contractor shall implement a comprehensive Risk Management Process to include program risk areas and the program’s critical path to systematically identify, quantify, track and mitigate cost, schedule, and technical risks.

The contractor shall provide risk item reports, which include the identification and adjudication of risk items, within the monthly IPMR, CDRL A002.

4.3 Parts Management

The contractor shall establish and maintain a Parts Management Program. The contractor shall use parts that meet contractual requirements. 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, CDRL A003.

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 Parts Management Plan shall define the contractor’s processes that mitigate 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.

Deliverables: CDRL A003 – Parts Management Plan

4.4 Data Management

The contractor shall establish and maintain a Data Management Program. 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 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 ordered by the Government, delivered to the Government.

Deliverables: CDRL A004 – Data Accession List (DAL)

4.5 Configuration Management

The contractor shall prepare and utilize a Configuration Management (CM) plan to establish and maintain a Product

Baseline.

The contractor shall implement a CM program that provides hardware, software and documentation management, change control, and status accounting for all components under CM control of each WES and SONAR Signal

Transmitter Assembly deliverable or repair action during the contract period of performance. (Refer to Clause HQ-

C-2-0012 CONFIGURATION MANAGEMENT (NAVSEA) (APR 2004)).

The contractor shall submit for Government approval Engineering Change Proposals (ECP) when changes impact the TDP (See Attachment 1). The contractor shall submit Request for Deviations (RFD) for variances on any requirement(s) as needed for Government approval. The contractor shall submit to the Government’s web-based

Configuration Management Database (CMPro) all changes and variances in CDRLs A005 and A006. ECPs, CDRL

A005, shall include corresponding Notices of Revision (NORs), CDRL A007. The contractor shall provide the completed Lead Engineering Summary (LES) and CMPro ECP/RFV Checklist for each ECP/RFD/RFV submitted via CMPro per the Torpedo Systems Department Configuration Management Plan guidelines. If the Government is unable to provide or the Contractor is unable to receive access to the CMPro Database, the Contractor shall submit each deliverable in Adobe PDF (.pdf, searchable) and applicable Microsoft Office 2010 (.docx, .xlsx, etc.) formats.

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 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 – Engineering Change Proposal (ECP)

CDRL A006 – Request for Deviation (RFD) - Request for Variance (RFV)

CDRL A007 – Notice of Revisions (NOR)

4.5.1 Technical Data Package Update

The contractor shall update the TDP to incorporate all contractor initiated ECPs approved by the Government, CDRLs A008 thru A00C. The contractor shall document any and all changes and deliver a Technical Data Package

Review Report, CDRL A00D.

Deliverables: CDRL A008 – Product Drawings/Models and Associated Lists

CDRL A009 – Commercial Drawings/Models and Associated Lists

CDRL A00A – Special Inspection Equipment (SIE) Drawings/Models and Associated Lists

CDRL A00B – Special Tooling (ST) Drawings/Models and Associated Lists

CDRL A00C – Program-Unique Specification Documents

CDRL A00D – Technical Data Package Review Report

4.5.2 As Built Configuration List

The contractor shall prepare and deliver a complete As-Built Configuration List (ABCL), CDRL A00E. 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 lifecycle of the item.

Deliverables: CDRL A00E – As-Built Configuration List (ABCL)

4.5.3 Unique Identification

The contractor shall mark and report all items listed in attachment X with Unique Identification (UID).

4.5.4 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.

4.6 Technical Interchange Meetings

The contractor shall conduct Technical Interchange Meetings (TIM) every other month at the contractor’s facility or via telephone conference with Government participation, which shall include leadership and working group levels, to achieve program goals. The action items and meeting minutes shall be delivered, CDRLs A00F.

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 CDRLs A00F.

Deliverables:

CDRL A00F – Report, Record of Meeting Minutes

4.7 Quality Management

The contractor shall implement and maintain a Quality Management System (QMS).

The contractor shall generate and deliver a Quality Program Plan (QPP), CDRL A00G. 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, and conduct an investigation to determine the reason for the noncompliance. This analysis along with recommended corrective action shall be prepared and delivered to the Government, CDRL

A00H (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. 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 Open

FRACAs

1 Open

FRACA

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

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.

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 A00G – Quality Assurance Program Plan - Quality Program Plan (QPP)

CDRL A00H – Corrective Action Plan

4.7.1 Electrostatic Discharge Control Program

The contractor shall establish and implement an effective Electrostatic Discharge (ESD) control program.

4.8 Preproduction – First Article

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 WES and SONAR Signal Transmitter Assemblies that comply with the design and technical requirements of the contract. First Article manufacturing and testing shall be successfully completed before the start of the manufacturing of production units.

The contractor shall manufacture, test, and deliver Preproduction – First Article units in accordance with applicable documents XX.

The contractor shall conduct First Article testing in accordance with the Government approved Test Plan and

Procedures. The contractor shall prepare and deliver a First Article Test Report.

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 WES and SONAR Signal Transmitter Assemblies to

NAVUNSEAWARCENDIVNPT.

4.8.1 Technical Program Reviews

The Aerospace Technical Operating Report, reference document 3.3.14 “Technical Reviews and Audits for Systems, Equipment, and Computer Software”, updates reference document 3.2.2 “Technical Reviews and Audits for

Systems, Equipment, and Computer Software”. The contractor shall use these documents as guidance for planning and execution of the reviews and audits listed in the following subsections.

4.8.1.1. 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, 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 Once the IBR is approved by the Government, the documents, plans and schedules resulting from the post-Award IBR shall serve as a baseline for all elements of the WES and SONAR Transmitter Assembly production IMS prepared and delivered, 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, CDRL A00J 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, CDRL A00K and CDRL A00F. 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 telephone conferences that occur every two weeks.

Entrance/Exit Criteria for the IBR:

IBR Entrance Criteria:

a. An approved Program Management Plan (PMP), CDRL A001.

b. An Integrated Program Management Report (IPMR), CDRL A002.

c. An approved Parts Management Plan per, CDRL A003

d. 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. Government accepts rationales underlying the Program Measurement Baseline as reasonable.

f. Management processes support successful execution of the project.

Deliverables: CDRL A00J – Meeting Agenda

CDRL A00K – Presentation Material

CDRL A00F– Report, Record of Meeting Minutes

4.8.1.2 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 no less than 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 the TRR, CDRLs A00J, A00K, and A00F.

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 telephone conferences that occur every two weeks.

The Entrance and Exit Criteria for the TRR is:

TRR Entrance Criteria:

a. Approved Test Plan and Procedures, CDRL A00L

b. Approved Test Verification Matrix, CDRL A00M

c. An updated Integrated Master Schedule (IMS).

d. An updated Risk Assessment.

e. 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 Risk Assessment.

b. Completed identification and coordination of required test resources.

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

CDRL A00F – Report, Record of Meeting/Minutes

4.8.1.3 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. Plans and resources will be in place to attain the program's production goals, prior to PRR approval.

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 WES and SONAR Signal Transmitter Assembly design has included those key production factors (i.e. least cost, minimum time, manufacturing simplicity/flexibility, resource availability) necessary to assure the WES and SONAR Signal Transmitter Assemblies can be acquired on schedule and at minimum cost. 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 the PRR, CDRLs A00J, A00K, and A00F.

The contractor shall notify the Government no less than 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 Integration, Qualification and Independent Validation and Verification

(IV&V) testing.

b. Approved Program Management Plan (PMP), CDRL A001.

c. Approved Quality Program Plan (QPP), CDRL A00G.

d. Completed Critical Manufacturing Procedures.

e. Completed Assembly and Manufacturing Processes and Procedures.

f. 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 of open action items shall be discussed during the Technical Interchange Meetings and 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 updated Risk Assessment.

c. Approved Test Plan, CDRL A00Q.

d. Approved Test Procedure, CDRL A00R.

e. Approved Test Verification Matrix, CDRL A00S

f. Completed identification and coordination of required test resources.

g. 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 updated Risk Assessment.

b. An updated Integrated Master Schedule (IMS).

CDRL A00F – Report, Record of Meeting/Minutes

4.8.2 First Article Test Plan and Procedures

The contractor shall prepare and deliver a comprehensive Test Plan and Procedures, CDRL A00L to verify 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, CDRL A00M.

The contractor shall include any proposed use of the “Torpedo MK48 WAS/WES Test Set” and “Torpedo MK48

Analog SONAR Signal Transmitter Test Set” (applicable document 3.1.15 and 3.1.16, see Attachment 2) in the test plan and procedures in compliance with Attachment 3.

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

Verification Matrix prior to implementation.

Deliverables: CDRL A00L – First Article Qualification Test Plan and Procedures

CDRL A00M – Specification Requirement Verification Matrix - First Article Test Verification

Matrix

4.8.3 First Article Test Execution and Reporting

The contractor shall conduct all levels of testing in accordance with approved 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, CDRL A00N. The First Article Test Report shall include the results of all the testing and inspections conducted on the First Article units in accordance with the approved First Article Qualification Test Plan and

Procedures, CDRL A00L, and Specification Requirement Verification Matrix, CDRL A00M.

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.

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

Transducer Array/Nose Shell Assemblies to the Government for Integration, Qualification and Independent

Validation and Verification (IV&V) Testing.

Deliverables: CDRL A00N – Test/Inspection Report - First Article Test Report

4.8.4 Integration, Qualification and IV&V Testing

The Government will conduct Integration, Qualification and Independent Validation and Verification (IV&V)

Testing for the First Article WES and SONAR Signal Transmitter Assemblies in accordance with the requirements of applicable document 3.3.9 “Government Qualification Acceptance Test Plan (QATP), Warhead Electronic

Section and 3.3.10 “Government Qualification Acceptance Test Plan (QATP),SONAR Signal Transmitter” provided per Attachment 4.

In the event of a failure, the contractor shall be responsible for providing failure analysis support during Government

Integration, Qualification and IV&V. Responsibility shall include delivering 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 action for the WES and SONAR Signal Transmitter Assembly, the contractor shall redeliver any First Article units that failed Government Integration, Qualification and IV&V. Upon delivery, the

Government will proceed with the continuation of conducting the tests.

Prior to the contractor redelivering the repaired units that failed Government Integration, Qualification and IV&V, the Government will decide if the repaired units 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.

4.8.5 First Article Failure Analysis and Reporting

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

A00G, which, at a minimum, follows the guidelines established per applicable document 3.1.2 “Failure, Reporting, Analysis and Corrective Action”.

4.8.5.1 Failure Analysis Support during First Article Testing

The contactor shall perform fault isolation and root cause analysis of any failure or deficiency that is identified during First Article testing and isolated to a WES and SONAR Signal Transmitter Assembly deliverable. The contractor shall prepare and deliver Failure Reporting, Analysis, and Corrective Action (FRACA) reports, CDRL

A00P. The contractor shall incorporate identified corrective actions into the WES and SONAR Signal Transmitter

Assembly TDP (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 Independent Validation and Verification (IV&V). Each report shall contain the required information in accordance with section 3 of the Data Acquisition Document listed in Block 4 of CDRL A00P and the additional required information 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 FRACA report 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 A00P – Failure Analysis and Corrective Action Report (FACAR) - Factory Failures during

First Article Testing and Government Testing

4.9 Production

The contractor shall fabricate, assemble, test, inspect, package, and deliver WES and SONAR Signal Transmitter

Assemblies 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 A00Q, and Procedure, CDRL A00R. The contractor shall prepare and deliver a Factory

Acceptance Test Report, CDRL A00T.

Periodic samples of the WES and SONAR Signal Transmitter Assemblies 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.

4.9.1 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, RI (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. Any changes to the Contract baseline established during the IBR

2. Any changes to Government approved plans

3. Establish the baseline for executed contract options

4. Completed and Planned Efforts

5. Schedule Performance

6. Risk Management Activities

7. Program Issues

8. Contractual Issues

9. Parts Issues

10. Acceptance Testing Status Related to Production Efforts

11. Status of Cost and Schedule Performance Data by Product-Oriented Work Breakdown Structure

(WBS)

12. Status of Each Technical Instruction including:

a. Authorized Funding/Hours

b. Expected Funding/Hours

c. Percentage of Work Complete

d. Estimate at Completion

The contractor shall deliver a PMR agenda, meeting minutes and presentations, CDRLs A00J, A00K, and A00F.

The PMR will be considered complete when the Procuring Contracting Officer (PCO) provides notification to the contractor. The contractor shall be responsible to resolve all action items generated during the review. Resolution of open action items shall be discussed during the Technical Interchange Meetings and telephone conferences that occur every two weeks.

CDRL A00F – Report, Record of Meeting/Minutes

4.9.2 Factory Acceptance Testing (FAT) Test Plan and Procedure

The contractor shall prepare and deliver a comprehensive Factory Acceptance Test (FAT) Plan and Procedure, CDRLs A00Q and A00R to satisfy all test and performance requirements in accordance with the Build-to-Print

TDP, (See Attachment 1).

The contractor shall prepare and deliver a Test Verification Matrix to demonstrate traceability between each test requirement and its associated test procedure, CDRL A00S.

The contractor shall include any proposed use of the “Torpedo MK48 WAS/WES Test Set” and “Torpedo MK48

Analog SONAR Signal Transmitter Test Set” (applicable document 3.3.7 and 3.3.8, see Attachment 1) in the test plan and procedures in compliance with Attachment 3

Government concurrence and written approval of the Test Plans, Procedures, and the Test Verification Matrix shall be required prior to implementation by the Contractor.

Deliverables: CDRL A00Q – Test Plan - Factory Acceptance Test Plan

CDRL A00R – Test Procedure - Factory Acceptance Test Procedures

CDRL A00S – Specification Requirement Verification Matrix - Factory Acceptance Test

Verification Matrix

4.9.3 Factory Acceptance Test (FAT) Execution and Reporting

The contractor shall conduct all levels of testing in accordance with the Government approved test plan and procedures. The contractor shall electronically log and store all required test data collected in accordance with the

Government 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 FAT, the contractor shall submit a

FAT Report, CDRL A00T. The FAT Report shall include the results of all the testing and inspections conducted on the Production units in accordance with the approved FAT Plan, CDRL A00Q, FAT Procedure, CDRL A00R, and

Specification Requirement Verification Matrix, CDRL A00S.

Deliverables: CDRL A00T – Test/Inspection Report - Factory Acceptance Test Report

4.9.4 Production Screening

The contractor shall perform production screening in accordance with applicable documents 3.3.1 “Critical Item

Product Fabrication Specification for Warhead Electronics System,” 3.3.2 “Critical Item Product Function

Specification for Warhead Exploder System,” 3.3.4 “Critical Item Product Fabrication Specification for Analog

SONAR Signal Transmitter Assembly,” and 3.3.5 “Critical Item Production Function Specification for Analog

SONAR Signal Transmitter Assembly.” The screening shall consist of temperature cycling, random vibration and

Production Inspection Reliability Test (PIRT) on 100% of production units.

The contractor shall deliver individual reports detailing the test results for each test phase; temperature cycling, random vibration, and PIRT, CDRL A00U.

Deliverables: CDRL A00U – Reliability Test Reports - Production Inspection Reliability Test Report

4.9.5 Factory Acceptance Testing (FAT) Failure Analysis and Reporting

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

A00G, which at a minimum follows the guidelines established per applicable document 3.1.2 “Failure, Reporting, Analysis and Corrective Action”.

4.9.5.1 Pre-Factory Acceptance Test (Pre-FAT) Failures

The contractor shall document and submit a summary report on factory failures and non-conformances that occur throughout production prior to Factory Acceptance Test, CDRL A00V.

For any systemic failure as defined by Section 4.4, the contractor shall fault isolate each non-conformance to the lowest level to determine Root Cause Corrective Action (RCCA). The contractor shall validate any proposed corrective action and verify the effectiveness of corrective and preventive actions.

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

Final Report:

1. Reference designator

2. Test Phase Performed (i.e. vendor, CCA First Function, temperature, vibration, etc.)

3. Operational and environmental conditions under which the failure occurred

4. Failure history including vendor, subcontractor, factory

5. Failure trend analysis

6. Systemic failure classification (yes, no)

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

8. Identification of root cause

9. Summary of changes

10. Criticality

Item 10, Criticality, shall be defined using the following guidelines:

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

b. Under Investigation

c. Unknown

d. Unverified

e. Component

f. Non valid

g. Contractor

Deliverables: CDRL A00V – Failure Analysis and Corrective Action Report (FACAR) - Factory Failures prior to Factory Acceptance Test

4.9.5.2 Factory Acceptance Test (FAT) Failures

The contractor shall fault isolate each non-conformance that is found during FAT to the lowest level to determine

Root Cause Corrective Action (RCCA). The contractor shall validate any proposed corrective action and verify the effectiveness of corrective and preventive actions.

The contractor shall document and deliver FRACA reports for any FAT non-conformances, CDRL A00W.

The contractor shall prepare a FRACA report for failures on any periodic sample that is selected at random by the

Government during production for submission to an activity designated by the procuring agency to determine compliance with the specifications and drawings. Each report shall contain the required information in accordance with section 3 of the Data Acquisition Document listed in Block 4, CDRL A00W and the additional required information listed below as part of the Preliminary and Final Report:

1. Date of Hardware Receipt from Government

2. Reference designator

3. Operational and environmental conditions under which the failure occurred

4. Failure analysis results including parts analysis

5. Failure history including vendor, subcontractor, factory

6. Failure trend analysis

7. Systemic failure classification (yes, no)

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

9. Identification of root cause

10. Mission impact

11. Summary of changes

12. Criticality

Item 12, Criticality, shall be defined using the following guidelines:

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

b. Under Investigation

c. Unknown

d. Unverified

e. Component

f. Non valid

g. Contractor

Deliverables: CDRL A00W – Failure Analysis and Corrective Action Report (FACAR) – Factory Failures during Factory Acceptance Test, Periodic Testing and Government Testing

4.10 Engineering and Technical Services

Upon issuing of TIs, the contractor shall provide engineering and technical services in accordance with Section H clause 5252.242-9115 TECHNICAL INSTRUCTIONS (APR 1999). The types of TIs issued under this contract may include the following:

a. Integration, Qualification and IV&V Testing Support

b. Engineering Services to Support Preproduction – First Article & Production Tasking

4.10.1 Integration, Qualification and IV&V Testing Support

The contractor shall provide engineering services and on-site engineering to support all Government IV&V test and integration activities for the First Article WES and First Article SONAR Signal Transmitter Assemblies. The engineering support services includes: FIR, Section and System level hardware integration; System level Automated

Test Equipment (ATE) integration and System level operational testing.

4.10.2 Engineering Services to Support Preproduction – First Article & Production

Tasking

The contractor shall provide engineering services to conduct studies, testing, and analyses of design to address preproduction – first article and production related issues in support of the testing and production of the WES and

SONAR Signal Transmitter Assemblies.

5. PROGRESS REPORTS

The contractor shall deliver monthly cost and performance reports in accordance with the basic contract clause C16

– COST AND PERFORMANCE REPORTING.

6. GOVERNMENT FURNISHED INFORMATION

The Government will provide the contractor the following as Government Furnished Information (GFI) as identified in Attachment 2.

7. ACRONYMS

ABCL

As Built Configuration List

ATE

Automated Test Equipment

BOM

Bill of Material

CCA

Circuit Card Assembly

CDR

Critical Design Review

CDRL

Contract Data Requirements List

CI

Configuration Item

CLIN

Contract Line Item Number

CM

Configuration Management

DAL

Data Accession List

DID

Data Item Description

DoD

Department of Defense

ECP

Engineering Change Proposal

EPS

Electrical Power Source

ESD

Electrostatic Discharge

FACAR

Failure Analysis and Corrective Action Report

FAT

Factory Acceptance Test

FIR Functional Item Replacement

FRACA

Failure Reporting, Analysis, and Corrective Action

GFE

Government Furnished Equipment

GFI

Government Furnished Information

IBR

Integrated Baseline Review

IMS

Integrated Master Schedule

IPC

Association Connecting Electronics Industries

IPMR

Integrated Program Management Report

IRS

Interface Requirements Specification

KQI

Key Quality Indicator

LES

Lead Engineering Summary

NAVUNSEAWARCENDIVKPT Naval Undersea Warfare Center Division, Keyport

NAVUNSEAWARCENDIVNPT Naval Undersea Warfare Center Division, Newport

NOR

Notices of Revision

PCO

Procuring Contracting Officer

PIRT

Production Inspection Reliability Test

PMP

Program Management Plan

Pre-FAT

Pre-Factory Acceptance Test

PRR

Production Readiness Review

PWB

Printed Wiring Board

QATP

Qualification Acceptance Test Plan

QMS

Quality Management System

QPP

Quality Program Plan

RCCA

Root Cause Corrective Action

RFD

Request for Deviation

RFV

Request for Variance

SOW

Statement of Work

SSS

System/Subsystem Specification

TDP

Technical Data Package

TEPP

Test and Evaluation Program Plan

TIM

Technical Interchange Meetings

TRR

Test Readiness Review

UID

Unique Identification

USN

United States Navy

WBS

WES

Work Breakdown Structure

Warhead Electronics System