SOWARRAY_presol.docx

N66604-XX-XXXX

TABLE OF CONTENTS

SECTION C – STATEMENT OF WORK

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 Transducer Array/Nose Shell Assembly used in the MK48 Heavyweight Torpedo was last acquired in the early 1990’s. Recent assessments of the torpedo inventory have identified a need for the USN to acquire additional Transducer Array/Nose Shell Assemblies. In response, NAVUNSEAWARCENDIVNPT has completed an effort to modernize the Transducer Array/Nose Shell Assembly Technical Data Package (TDP) and is seeking to procure Transducer Array/Nose Shell 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 Transducer Array/Nose Shell Assemblies.

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 Transducer Array/Nose Shell Assemblies for the MK48 Heavyweight Torpedoes. The Transducer Array/Nose Shell 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.

Sponsors This contract is sponsored by the following organizations:

1) PMS404

Funding This contract is funded used the following categories:

1) WPN

2) FMS

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.

Applicable Documents:

Reference Documents:

(Excluding Electrically Initiated Explosive Devices) (Metric)

REQUIREMENTS

The work required shall be performed in accordance with the requirements of applicable document 3.3.1 “Critical Item Product Function Specification for Transducer Array/Nose Shell Assembly” and 3.3.2 “Critical Item Product Fabrication Specification for Transducer Array/Nose Shell Assembly” provided in Attachment 1. This SOW defines the requirements for the Transducer Array/Nose Shell Assemblies (applicable document 3.3.3, 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, 3.2, 3.3, and 3.4.

No substitutions of parts specified in the Build-to-Print TDP shall be permitted without prior written approval of the Government.

The contractor shall apply system 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.

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)

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)

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.

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 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 last-time buys, life-time buys and obsolescence monitoring. 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 Transducer Array/Nose Shell Assemblies 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

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)

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 Transducer Array/Nose Shell 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 Engineering Change Proposals (ECP) for Government approval 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 and 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.

Technical Data Package Update The contractor shall update the TDP to incorporate all contractor imitated 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.

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)

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

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.

Technical Interchange Meetings The contractor shall conduct Technical Interchange Meetings (TIM) every other month at the contractor’s facility or via telephone conferences 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 GFP, 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 action items and meeting minutes shall be delivered, CDRLs A00F.

Deliverables: CDRL A00F – Report, Record of Meeting Minutes

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

The contractor shall prepare 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 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, 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; after which production deliveries shall not resume until directed by the PCO.

Event

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

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

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 Transducer Array/Nose Shell 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 Transducer Array/Nose Shell Assemblies to NAVUNSEAWARCENDIVNPT.

Technical Program Reviews The Aerospace Technical Operating Report, reference document 3.3.9 “Technical Reviews and Audits for Systems, Equipment, and Computer Software”, updates reference document 3.2.2 “Technical Reviews and Audits for Systems, Equipments 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.

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 Transducer Array/Nose Shell 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 and 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, 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.

CDRL A00F– Report, Record of Meeting Minutes

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.

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 Transducer Array/Nose Shell Assembly design has included those key production factors (i.e. least cost, minimum time, manufacturing simplicity and flexibility, resource availability) necessary to assure the Transducer Array/Nose Shell 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).

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 “Nose Array Test Set” (applicable document 3.1.12, 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.

First Article Test Execution and Reporting The contractor shall conduct all levels of testing in accordance with the 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 Transducer Array/Nose Shell Assemblies 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

Integration, Qualification and IV&V Testing The Government will conduct Integration, Qualification and IV&V Testing for the First Article Transducer Array/Nose Shell Assemblies in accordance with the requirements of applicable document 3.3.5 “Government Qualification Acceptance Test Plan, 52 Element Transducer Array/Nose Shell” provided per Attachment 2.

In the event of a failure, the contractor shall be responsible for providing 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 Transducer Array/Nose Shell Assemblies 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 Transducer Array/Nose Shell Assemblies that failed Government Integration, Qualification and IV&V Testing, the Government will decide if the repaired Transducer Array/Nose Shell Assemblies 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.

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”.

First Article and Qualification Testing Failures 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 Transducer Array/Nose Shell 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 Transducer Array/Nose Shell 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 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 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

Production The contractor shall fabricate, assemble, test, inspect, package, and deliver Transducer Array/Nose Shell 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 Transducer Array/Nose Shell 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.

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.

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 ADCAP Depot/Factory Test Equipment Nose Array Test Set” (applicable document 3.3.4, see Attachment 2) in the test plan and procedures in compliance with Attachment 3.

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

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 deliver 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

Production Screening The contractor shall perform production screening in accordance with applicable document 3.3.2 “Critical Item Product Fabrication Specification for Transducer Array/Nose Shell Assembly.” The screening shall consist of temperature cycling, random vibration and Production Inspection Reliability Test (PIRT) on 100% of production.

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

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.

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:

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.

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 prior to Factory Acceptance Test

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 of CDRL A00W 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. 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:

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.

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

Engineering and Technical Services Upon issuing of Technical Instructions (TI), 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

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 Transducer Array/Nose Shell 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.

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 Transducer Array/Nose Shell Assembly.

PROGRESS REPORTS

The contractor shall deliver monthly cost and performance reports in accordance with the basic contract clause C16 – COST AND PERFORMANCE REPORTING.

GOVERNMENT FURNISHED INFORMATION

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

ACRONYMS

ABCL

As Built Configuration List

ASW

Anti-Submarine Warfare

ATE

Automated Test Equipment

BOM

Bill of Material

CCA

Circuit Card Assembly

CDRL

Contract Data Requirements List

CLIN

Contract Line Item Number

CM

Configuration Management

DAL

Data Accession List

ECP

Engineering Change Proposal

ESD

Electrostatic Discharge

FACAR

Failure Analysis and Corrective Action Report

FAT

Factory Acceptance Test

FMS

Foreign Military Sales

FRACA

Failure Reporting, Analysis, and Corrective Action

GFI

Government Furnished Information

GFP

Government Furnished Property

IBR

Integrated Baseline Review

IMS

Integrated Master Schedule

IPC

Association Connecting Electronics Industries

IPMR

Integrated Program Management Report

IV&V

Independent Validation and Verification

KQI

Key Quality Indicator

LES

Lead Engineering Summary

NOR

Notices of Revision

PCO

Procuring Contracting Officer

PIRT

Production Inspection Reliability Test

PMP

Program Management Plan

PMR

Program Management Review

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

TATF

Transducer Array Test Facility

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

Work Breakdown Structure