Attach 1 TPTI Production SOW 7-30-10.doc

Attachment 1

STATEMENT OF WORK for the Production of the

Turboprop Engine Test Instrumentation (TPTI) System

NAVAIR LAKEHURST

RPT-NAVAIR-481-TPTI

Engineering Statement of Work for the Production of the

Turboprop Engine Test Instrumentation (TPTI) System

SE and ALRE Systems Engineering Division

Naval Air Warfare Center Aircraft Division

Lakehurst, New Jersey 08733

30 July 2010 DISTRIBUTION AUTHORIZED TO DOD AND DOD CONTRACTORS ONLY; ADMINISTRATIVE OR OPERATIONAL USE; 01 September 2002. OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO COMMANDING OFFICER, NAVAL AIR WARFARE CENTER AIRCRAFT DIVISION LAKEHURST, NEW JERSEY 08733-5000

DESTRUCTION NOTICE. FOR UNCLASSIFIED, LIMITED DOCUMENTS, DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT.

Prepared for

Commander, Naval Air Systems Command

PMA-260

Patuxent River, MD 20670-1547

Table of Contents iiTable of Contents

Scope

11.1 Objectives:

11.2 Background

21.2.1 System Description

21.2.2 Installations

31.2.3 Facility Descriptions

31.2.3.1 A/E37T-17A Mobile Turboprop Engine Test System

31.2.3.2 A/F37T-19A Fixed Turboprop Engine Test System

Applicable Documents

42.1 Government Documents

42.2 Standards and Handbooks

42.3 Other

42.4 Non-Government Documents

42.5 List of Contract Attachments

52.6 Order of Precedence

52.7 Acronyms

Requirements

73.1 General

73.2 Changes

73.3 Duplication of Data

73.4 Program Management

73.5 Subcontractor Management

73.6 Integrated Master Plan (IMP) (CDRL A001)

83.7 Integrated Master Schedule (IMS) (CDRL A002)

83.8 Program Reporting (CDRL A003)

83.9 Conferences, Meetings and Reviews (CDRL A004)

83.10 Post Award Conference

93.11 IPT Phone Conference

93.12 Integrated Product Team (IPT) Meetings (CDRL A005)

93.13 Production Readiness Review (PRR)

93.14 Production Manufacturing Reviews / On-Site Verification (CDRL A023)

103.15 Information Assurance

103.16 Quality Assurance (QA) Program (CDRL A013)

103.17 Configuration Management (CM)

103.18 Configuration Management Plan (CDRL A006)

103.18.1 Configuration Item (CI)

113.19 Configuration Control

113.19.1 Configuration Control Board (CCB)

113.19.2 Baselines

113.20 Engineering Change Proposal (ECP), and Notice of Revision (NOR) (CDRLs A007, A008)

113.21 TPTI DAQ/TPS Software

113.21.1 Request for Deviation (RFD) (CDRL A009)

123.21.2 Pilot Production Conformity Inspections

123.21.2.1 Conformity Inspection Plan (CDRL A010)

133.21.2.2 Conformity Inspection Report (CDRL A011)

133.22 Integrated Baseline Review (IBR)

133.23 A/E37T-17A Technical Data Package (TDP) (CDRL A012)

133.24 Obsolescence

133.24.1 Obsolescence Management

143.24.1.1 Obsolescence Management Plan (CDRL A024)

143.24.1.2 Obsolescence Reports (CDRL A025)

143.24.1.3 Obsolescence / Revision Change Implementation

143.24.1.4 Trade Studies (CDRL A026)

143.24.1.5 Component Regression and Acceptance Testing (CDRL A027)

153.24.1.6 Bi-Yearly Obsolescence Review Meetings

153.25 Reliability Program

153.26 Failure Reporting, Analysis, and Corrective Action System (FRACAS) (CDRL A014)

153.27 Failure Review Board (FRB)

153.28 Hazardous Materials Management Program

153.29 Hazardous Materials Management Program (HMMP) Report (CDRL A020)

163.30 Non-Rechargeable Coin Cell Lithium Batteries

163.31 Hazmat Data List for Alternate Component/Materials Proposal

163.31.1.1 Prohibited Materials

163.31.1.2 Undesirable Materials

163.32 Engineering, Fabrication, and Integration

163.32.1.1 Engineering

163.32.1.2 Hardware Change Requests

173.32.1.3 A/F37T-19A TPTI Fixed Facility Design (CDRL A028)

173.32.1.4 T-19A Installation Control Drawings (ICD) (CDRL A029)

173.32.1.5 Legacy System Removal

173.32.1.6 Installation Hardware Kit Drawing, A/F37T-19A (CDRL A030)

173.32.1.7 Cables, Hoses and Miscellaneous Hardware

173.32.1.7.1 EAA Modifications

183.32.1.7.2 A/F37T-19A Engineering Drawing Package (CDRL A031)

183.32.1.8 Systems Engineering Technical Reviews (CDRL A032)

183.32.1.9 Fabrication, Assembly and Integration

183.32.1.10 Pilot Production Unit

183.32.1.11 T-17A TPTI System

183.32.1.12 Government Furnished Equipment (GFE)

183.32.1.13 Long Lead Items (CDRL A019)

183.32.1.14 TPS Pilot Engine Adapter Assembly

193.32.1.15 Production Units

193.32.1.16 A/E37T-17A TPTI Systems

193.32.1.17 A/F37T-19A TPTI Facility Systems

193.32.1.18 Engine Adapter Assembly (EAA)

193.32.1.18.1 T56-A-425/427 Engine Adapter Assembly

193.32.1.18.2 T56-A-427A Engine Adapter Assembly

193.33 TPTI Mobile System Installation

193.34 TPTI for Fixed Facility Installation

193.35 Component Data Delivery (CDRL A015)

203.36 Labeling

203.36.1 Serial Number Identification

203.36.2 Unique Identification (UID) Label Requirements

203.36.3 Item Unique Identification Plan (CDRL A021)

203.36.4 IUID Construct and Method

203.36.5 UID Location and Marking

203.36.6 Permanency and Legibility

213.36.7 UID Registration

213.36.8 Records

213.36.9 Calibration Label

213.37 Engineering Support

213.38 Technical Service Representative (CDRL A033)

213.39 Engineering Support – Engineering Investigations, Drawings, Manuals, and Change Request Updates

Testing

214.1 Test Management

224.2 Integration and Production Test Plan (CDRL A016)

224.3 Acceptance Test Procedure (ATP)

224.4 Acceptance Test Report (ATR) (CDRL A017)

224.5 Pilot Production Acceptance Test

224.5.1 Un-installed TPTI Tests

234.5.2 Installed TPTI Tests

234.5.3 Calibration

234.6 Production Acceptance Test

234.6.1 T-17A TPTI Production Acceptance Test

234.6.2 T-19A TPTI Production Acceptance Test

234.6.3 T-17A and T-19A Production Calibration

244.6.4 Production Acceptance Test Report (CDRL A018)

244.6.5 T-19A Technical Verification

244.6.6 T-19A Facility Correlation

25Enclosure 1 - A/F37T-19 FACILITY

26Enclosure 2 - Request For Action (RFA) Form

27Enclosure 3–Production Readiness Review (PRR) Guidance

28Enclosure 4 – Life Cycle Predictions / Component Candidates

29Enclosure 5 – Engineering Drawing Package Guidance

31Enclosure 6 – Government Furnished Equipment

32APPENDIX A- Contract Data Requirements List (CDRL)

2TABLE 1: TPTI SYSTEM INSTALLATIONS

9Table 2: Meetings and Reviews

12Table 3 – Major TPTI/TPS Sub-Assemblies

20Table 4 – Serial Number Assignments

23Table 5 – Calibration Equipment

1 Scope

This Statement of Work (SOW) defines the program management, systems engineering, configuration control, fabrication, integration, testing, production, acceptance, and technical efforts for the Turboprop Engine Test Instrumentation (TPTI) production.

1.1 Objectives:

The objectives of this statement of work are to describe the work required to:

PILOT PRODUCTION UNIT

1. Procure, fabricate and assemble one (1) pilot production TPTI system and install it in a Government furnished A/E37T-17 cab. The pilot TPTI system shall include all hardware identified in the Technical Data Package (TDP), 3654AS7400, Attachment 2. The complete assembly (TPTI plus cab) will be identified as an A/E37T-17A.

2. Procure, fabricate, assemble one (1) pilot production Test Program Set in accordance with drawing 3654AS7500, Attachment 7, for the T56-A-427/425 engines, and one (1) pilot production Test Program Set in accordance with drawing 3654AS8800, Attachment 8, for the T56-A-427A engine.

3. After installation of the pilot system hardware and pilot TPSs in a Government provided A/E37T-17 Test Cab, perform validation/verification of the completed system in accordance with the Acceptance Test Procedures (ATP), Attachments 3 through 5 and TDP, and provide an Acceptance Test Report (ATR).

PRODUCTION UNITS

4. Following test, acceptance and delivery of the TPTI and TPSs Pilot Production Units, orders may be placed for production of additional TPTI units and TPSs. For each production unit, the contractor will perform validation/verification of the systems in accordance with the ATP and TDP, and provide an ATR.

5. Each production TPTI and TPS shall be installed in an A/E37T-17 cab.

6. If exercised, provide one production TPTI unit and TPSs and install into an A/F37T-19 facility identified in Table 1. Conduct acceptance testing in accordance with the ATP and TDP, and provide an ATR.

PILOT AND PRODUCTION UNITS

7. Provide source data as a result of any ECPs or NORs approved under this contract.

8. Provide engineering support to include troubleshooting, correction and documentation of interface issues with each installation.

1.2 Background

The TPTI System is a computer based measurement, data acquisition, and control system for the purpose of Intermediate (I) Level testing of aircraft T56 turboprop engines in either indoor or outdoor environments. The TPTI system capabilities include instrumentation, data acquisition, engine and facility control, calibration and status display. The system is an open architecture integration of Commercial Off- the-Shelf (COTS) components, a nominal amount of fabricated items, and LabVIEW based Test Program Sets (TPSs) and Data Acquisition (DAQ) software running on a Windows XP operating system. The system is designed to provide accurate measurement of engine operating parameters, data processing and performance calculations, data storage, and engine and facility control functions. The TPTI Instrument and Control (I&C) system will be a replacement for existing I-level T56 engine I&C systems operated at U.S. Navy air stations.

The Government-provided A/E37T-17 transportable I&C cab will provide protection from extremes of temperature and humidity, as well as contamination by dust, sand, salt fog and corrosive precipitation. The integrated system will meet the I-Level maintenance tests of all T-56 Turboprop variants including the -427, -427A, -425, -16, and -14. These engines are used in the following Navy aircraft respectively: E-2C, E-2D, C-2, C-130, and P-3.

1.2.1 System Description

The primary subassemblies of the TPTI systems are:

· (2) PCs linked via an Ethernet TCP/IP network

· (2) Touch Screen Monitors

· Programmable Throttle Assembly

· Printer

· Intercom System

· Keyboard and mouse

· Electrical Junction Box

· Connection Panel

· Mechanical Junction Box

· Terminal Strip Cabinets

· Utility Console

· DAQ Instrumentation Cabinet

· Cables and Hoses

1.2.2 Installations

The TPTI System will replace the instrumentation, data acquisition, and control hardware in the existing T-17 and T-19 Engine Test Systems. Each TPTI system will be installed in a refurbished government provided T-17 test cab or a legacy T-19 Fixed Facility. Hardware required for installation will be delineated on an Installation Control Drawing (ICD). Table 1 shows the planned installations for the TPTI systems. The first system is scheduled for installation at Norfolk in May 2012, and the estimate is three to four installations per years thereafter.

TABLE 1: TPTI SYSTEM INSTALLATIONS

1.2.3 Facility Descriptions

1.2.3.1 A/E37T-17A Mobile Turboprop Engine Test System The TPTI system and engine TPS shall be installed in a T-17 I&C cab with the incorporation of all hardware necessary to test turboprop engines. The new designation for the test cell will be A/E37T-17A. The Engine Under Test (EUT) is mounted with its Quick Engine Change (QEC) assembly in an outdoor environment. The QEC is the complete power-plant assembly that mounts to an aircraft and contains the T56 turboprop engine, torque-meter assembly, reduction gearbox assembly, oil system, power-plant control system, ducting, and air starter. It is operated as a complete unit together with the appropriate test propeller. In a typical test configuration, the engine run trailer is located approximately fifty feet from the I&C cab. The Electrical Junction Box (EJB) and Mechanical Junction Box (MJB) are mounted in the EJB/MJB stand P/N 3654AS7960-1 and positioned about twenty feet from the run trailer. Fuel, torque, engine parameters and control signals are transmitted via environmentally sealed cables, which pass through the cable transit panel and connect to the terminal strip cabinets.

1.2.3.2 A/F37T-19A Fixed Turboprop Engine Test System There is a requirement for government installation of a TPTI system into an A/F37T-19 fixed facility, in accordance with the 3654AS7405 drawing. References to the A/F37T-19A Fixed Turboprop Engine Test System are contained throughout this Statement of Work. In the A/F37T-19 fixed facility configuration, the TPTI is installed in a fixed brick and mortar building where the entire system is enclosed. The facility includes an engine room, control room, fuel system, and engine exhaust augmenter/stack. The TPTI instrumentation is installed in the control room and the Engine Under Test (EUT) is mounted on an engine run trailer, adapted to the TPTI with an Engine Adapter Assembly (EAA) peculiar to the EUT. In a typical test configuration, the engine run trailer is located in the run room, which is located adjacent to the control room. A more detailed facility description is provided in Enclosure (1). If exercised, the TPTI system components will require overseas shipping to the A/F37T-19 location.

2 Applicable Documents The following documents are applicable to this Statement of Work, the Appendices, and the Attachments to the extent specified herein

1.1 Government Documents

2.1 Standards and Handbooks

2.2 Other

2.3 Non-Government Documents

2.4 List of Contract Attachments

2.5 Order of Precedence

In the event of a conflict between this Statement of Work and the references cited herein, this Statement of Work shall take precedence. Nothing in the Statement of Work, however, shall supersede applicable laws and regulations.

2.6 Acronyms

CM

COR

Configuration Management Contracting Officer’s Representative

GFM

GFP

Government Furnished Material

Government Furnished Property

3 Requirements

3.1 General

The work required by this contract shall be performed in accordance with this Statement of Work (SOW). This SOW identifies the specific tasks to be performed by the Contractor for the production and support of the TPTI Systems and Engine TPSs. The Contractor shall be responsible for Systems Engineering, QA, Configuration Management, Obsolescence management and redesign, a Build-to-Print (BTP) fabrication of hardware in accordance with the TDP, Integration, Pilot Production Testing, delivery, installation and checkout of the systems as well as Engine Test Program Sets (TPS) for the T56-A-427/425 and T56-A-427A engines. The Contractor is responsible for the coordination, integration, test, installation, checkout of the system, initial calibration, and acceptance by the Government of the system and TPSs, as covered by this SOW. The Contractor shall provide program management, systems engineering, engineering for obsolescence redesign, fabrication, technical and troubleshooting as required by this SOW to meet the performance criteria of Attachments 3 through 5 and in accordance with the detailed requirements in the following paragraphs. The Hardware Product Baseline has been established by a Physical Configuration Audit (PCA) and is documented in the Technical Data Package, Attachment 2. The Production TPTI units procured under this contract shall meet the requirements set forth by the Hardware Product Baseline and any Engineering Change Proposals (ECPs) put forth under this contract.

3.2 Changes

This document is contractually enforceable. Additions, deletions or changes to this document shall be effective only after they have been jointly negotiated by the Contractor and the Government and implemented in the contract through appropriate written contract modifications issued by the Procuring Contracting Officer or Administrative Contracting Officer.

3.3 Duplication of Data

Changes to the baseline system implemented by this contract shall be incorporated into all existing baseline TPTI data.

3.4 Program Management

The Contractor shall provide overall management, technical direction, coordination, and administration necessary to ensure the successful completion of the tasks specified herein. A single program manager shall be designated as the interface with the Navy.

An Integrated Product Team (IPT) shall be established by the Contractor and it will enhance communications within the Contractor organization and with the Government IPT. The Program Manager shall co-lead the IPT with the Government and coordinate work activities. The Program Manager and IPT will work together to:

· Implement actions necessary to achieve the work objectives of this Work Statement

· Ensure the availability of resources and information necessary to support the contract

· Perform risk analysis and implement effective risk mitigation

· Assume responsibility to obtain principals’ concurrence on issues affecting cost, quality, and schedule

· Resolve or elevate issues in a timely manner

3.5 Subcontractor Management

The Contractor shall ensure that all requirements specified in the contract are imposed on subcontractors and shall be solely responsible for the performance and quality of all subcontractors’ and vendors’ work performed in response to the requirements of this SOW. The Contractor shall honor all supplier warranties.

3.6 Integrated Master Plan (IMP) (CDRL A001)

The contractor shall develop, implement, manage to, update and maintain an IMP tailored to the work required to produce the systems in accordance with this Work Statement. The IMP for TPTI shall incorporate a Contract Work Breakdown Structure (CWBS) down to the third level. The TPTI system production, including revisions necessary as a result of ECPs, shall be developed in accordance with this IMP. The IMP shall be used throughout the contract as a management tool to assess progress and determine success in achieving program requirements. Reporting on work in progress in accordance with the IMP at each program review may be accomplished via presentation of the updated Master Schedule (3.7), accompanied with a narrative indicating significant accomplishments, problems and risks affecting the critical path, mitigation strategies, and status of open action items.

3.7 Integrated Master Schedule (IMS) (CDRL A002)

The contractor shall develop, implement, update, manage to, and maintain an IMS for the TPTI system production. All contractor schedule information delivered or presented at program reviews shall originate from the IMS. The IMS shall be traceable to the IMP and shall contain all critical events, accomplishments, and criteria, predecessors and successors, and their dependencies. The IMS shall address total program activities for the prime contractor and major subcontractors. The IMS shall integrate the work requirement specified in this SOW along with the CWBS. The IMS shall include a schedule for all CWBS efforts using a Gantt chart. The contractor shall conduct critical path analyses of the tasks and report problem areas and corrective actions required to eliminate/reduce schedule impact.

3.8 Program Reporting (CDRL A003)

Monthly status reports shall be prepared and submitted documenting the engineering, production and testing status.

3.9 Conferences, Meetings and Reviews (CDRL A004)

The Contractor shall plan for conferences, meetings and reviews to be held at the NAWCADLKE site and/or NAS Patuxent River. The contractor shall prepare an agenda and record and publish the meeting minutes and action items for all conferences and reviews in this SOW. The Contractor shall coordinate the topics for the agenda with the Government. The Government reserves the right to review the action items prior to formal release. Action items may be generated by IPT members and are approved by the IPT Co-Leaders or designated chairperson. Action Items shall identify the originator, person responsible for answering the action item, and the action due date.

The efforts to be performed under this contract include a series of systems engineering and technical reviews as outlined below. The fundamental purpose of these reviews is to review the fabrication and integration to date of the systems, and in so doing, to assess the progress towards meeting the technical and/or performance requirements set forth in this contract. As such, each review will be tailored to ensure that the emerging fabrication and integration of the System is ready to enter the next phase towards completion of this contract. Government approval of any particular review does not eliminate or modify the Contractor’s responsibility to perform in accordance with the terms and conditions of this contract. In that regard, unless expressly directed in writing by the Procurement Contracting Officer (PCO), the Contractor can adopt or reject any recommendations or advice offered by the Government during the conduct of any of the reviews.

All reviews will have an independent Government chair who will be responsible for approval/disapproval of the review. All Requests For Actions (RFAs) generated during the review shall be completed and signed off by the chair before the review is successfully complete. Contractor shall not proceed into the next phase of the program without approval of the design review. For all reviews, participants are to assess the provided materials, document concerns by means of RFAs (see Enclosure (2)), and submit RFAs. The reviews are considered complete when all draft RFAs are signed off, and an acceptable level of program risk is ascertained. Final closure of the reviews is by approval of the Government review chair.

3.10 Post Award Conference

In order to establish a common understanding of all contract requirements, a Post Award Conference shall be held no later than 30 days after contract award. The conference shall provide an overview of any obsolescence issues, component selection, manufacturing, and quality assurance processes. The conference shall also address the IMS and IMP, systems engineering, configuration management, and test processes, with particular emphasis on the efforts required prior to the Production Readiness Review (PRR). Any potential problem areas shall be identified and a method of resolution defined.

3.11 IPT Phone Conference

IPT phone conferences shall be held weekly or as deemed necessary by the IPT. The Contractor shall be responsible for the administration and setup of the conference calls.

3.12 Integrated Product Team (IPT) Meetings (CDRL A005)

IPT meetings shall be held every two months for the first year and quarterly thereafter, or more frequently if required, to review and provide insight into technical issues, program status, configuration management, reliability program issues, and any associated risks to the program. The contractor shall provide administrative support; prepare agenda, prepare/distribute meeting minutes, and document/track action items. The meetings will be chaired by the Navy IPT lead or selected representative and co-chaired by the contractor Program Manager. The IPT chairpersons shall establish the meeting location(s). The IPT presentation material shall be available no later than 10 workdays prior to the meeting.

3.13 Production Readiness Review (PRR)

No later than the second IPT meeting, the Contractor shall hold a PRR. The review shall address the hardware design changes, drawing changes, any open ECPs, manufacturing plan for the first production units, the QA program, CM program and any risk areas. In addition, the Contractor will assure the Government that appropriate methods are used to status contract schedule, and technical progress. (See Enclosure (3) for guidance). The PRR must be completed and approved by the Government Review Chair prior to integration and assembly of the systems.

3.14 Production Manufacturing Reviews / On-Site Verification (CDRL A023) The Contractor shall provide support for Government on-site verification activities to include IPT Reviews, Manufacturing Reviews and Acceptance Testing at intervals specified in Table 2 and in accordance with the requirements of Attachments 3 through 5. The Contractor shall provide a report of the results of the verifications.

NOTE: The following are the minimum number of meetings/reviews that will be held. Additional reviews can be proposed. Where possible, Manufacturing and IPT reviews will be combined.

Manufacturing Review

(Initial Fabrication, On-site Verification)

Manufacturing Review

(Intermediate Fabrication, On-Site Verification)

Manufacturing Review (Final Fabrication, On-Site Verification) Approximately 90% complete

First production unit Uninstalled ATP

Pass Uninstalled ATP

Table 2: Meetings and Reviews

3.15 Information Assurance

The contractor will comply with:

DoDD 8500.1--Information Assurance

DoDI 8500.2--Information Assurance Implementation

3.16 Quality Assurance (QA) Program (CDRL A013)

The Contractor shall establish, comply with, and maintain the Quality Assurance (QA) Program Standard in accordance with ISO 9000 Series Instructions and MIL-I-45208A and shall provide a QA Program Plan in accordance with the CDRL and this SOW. The QA program shall insure that all hardware and documentation developed, tested, and delivered meets the requirements of the contract. The QA program shall include a review of all data items and hardware validation of all units delivered. The Contractor’s QA organization shall certify each data item or unit submitted for review or acceptance testing, with a written statement signed by an authorized QA representative. The QA program shall provide maximum assurance that quality will be maintained throughout all phases of manufacturing and testing.

3.17 Configuration Management (CM)

The TPTI system Product Baseline has been established. Formal configuration control procedures shall be maintained throughout production. Revisions to drawings, associated lists, or other configuration controlled documents shall be in the form of Engineering Change Proposals (ECPs), Notice of Revisions (NORs), or Requests for Deviation (RFDs) for all minor, major, and critical differences in hardware and/or software. Class I changes are not to be incorporated until Government approval is received.

3.18 Configuration Management Plan (CDRL A006)

The Contractor shall develop, update and maintain a Configuration Management Plan in accordance with the guidelines of ISO 10007, MIL-HDBK-61 and NAVAIRINST 4130.1.

The objectives of the Configuration Management Plan are:

· Ensure efficient, timely processing of ECPs and RFDs

· Document approved Class I ECP implementing actions

· Verify incorporation of approved ECPs into CI production affectivity

· Maintain traceability of high level hardware CIs and component parts through an accurate recording of each of the CIs by serial number and location

· Record approved RFDs documenting all as-designed and as-built variances

· Define the roles and relationships between the Contractor and the TPTI IPT.

The requirements and procedures of the TPTI CM program shall be promulgated in this document and designed to insure that:

· The configurations of the system and or items are documented

· Changes made to items in the course of production are beneficial and are effected without adverse consequences

· Changes are managed and tracked until incorporated in all items affected In addition, the Configuration Management Plan shall describe how the configuration management of the configuration items (CI) will be conducted to ensure the systematic evaluation, coordination, approval / disapproval, reporting, and recording of proposed changes to the systems. Proposed changes include those associated with: ECPs, Logistic Engineering Change Proposals (LECPs), RFDs, Engineering Investigations, drawing changes, and production contract issues. Configuration status accounting, the logistic element of the proposed changes, shall also be described in full detail by the plan.

3.18.1 Configuration Item (CI)

A CI shall be defined as any hardware, software, or combination that satisfies an end use function and is designated for separate configuration management. CIs for the TPTI include all system components specified in the TDP.

Interface control documentation shall define the specific functional or physical relationships that must exist between CIs for them to operate compatibly. These interfaces have been defined and are documented as interface control drawings and system performance specifications, maintained under Government Configuration Control, and provided in the Technical Data Package (TDP).

3.19 Configuration Control

3.19.1 Configuration Control Board (CCB)

A CCB shall be established with representation from both the Government and Contractor. The CCB shall review all proposed Class 1 changes to the baseline configuration and determine the best solution. The CCB Chair shall be the Government Configuration Manager and will have the final decision in all Class 1 changes to the baseline hardware and software configuration.

3.19.2 Baselines

The System Hardware Product Baselines have been established and are documented by the TDP. The Government has assumed configuration control of the drawing package and software. ECPs may be required due to obsolescence. Prior to the PRR, the Contractor shall conduct a thorough review of the technical data package and document any drawing deficiencies or obsolescence issues. Any changes required as a result of hardware changes shall be documented in an ECP.

3.20 Engineering Change Proposal (ECP), and Notice of Revision (NOR) (CDRLs A007, A008) The Contractor shall prepare and provide ECPs and/or NORs, (for Class I and Class II changes) with all related technical documentation including updated drawings and vendor/manufacturers data for any proposed changes to the Systems. The contractor shall prepare and submit ECPs and NORs using MIL-HDBK-61A as guidance. Class I ECPs shall be submitted on form 1629 using NAVAIR 00-25-300, Technical Directives System, as guidance for the ECP forms and Technical Directives. All class I changes will be reviewed and approved by the TPTI Configuration Control Board (CCB) prior to incorporation. Class I ECPs are engineering changes that impact form, fit, or function of the item (they usually affect either organizational or intermediate level maintenance procedures, or impact the capability of the unit components). Anticipated requirements for Class I changes shall be reported to the US Navy as early as possible. The Contractor Quality Assurance Representative (QAR) will review change documentation for proper classification and shall submit the documentation for Government approval. Class II changes will be approved by the Contractor, will not impact the contract cost, and must be documented and submitted to the Navy for information. All Class II changes will be documented, controlled and incorporated in accordance with the Contractor’s standard practices. NORs are ancillary documents to the ECP, which convey the specific changes to specific documents that are affected by the ECP (e.g. - a change to the TPTI manuals). The Contractor is responsible to identify any required changes to the logistics documentation as a result of incorporation of any ECP or NOR.

3.21 TPTI DAQ/TPS Software

The production systems shall operate with the Government-approved software baseline. Attachment 6 specifies the current required software versions for the TPTI system. The list in the attachment identifies COTS and Government-furnished software to be loaded on TPTI - 1 and TPTI - 2 computers as specified. Version numbers may change; however, the items on the list will be identified in the drawing package. Therefore, the drawing package will take precedent over the SOW for this particular list. Items with an indicated quantity require that licenses and media be purchased by the contractor and shall be provided to the Government for each system.

3.21.1 Request for Deviation (RFD) (CDRL A009)

The Contractor shall not offer items for acceptance by the US Navy that incorporate a known departure from requirements, unless a Request For Deviation (RFD) has been submitted, classified (critical, major, or minor), and approved. A Critical deviation consists of a departure involving safety. A major deviation consists of a departure involving performance, interchangeability, reliability, survivability, maintainability, durability, health, effective use/operation, and weight/size. A minor deviation consists of a departure that does not involve any of the critical and major deviation factors. Deviations classified with Government concurrence shall be submitted for information. Classification disagreements shall be referred to the Integrated Product Team (IPT) Chair and Co-chairs for decision; the PCO will document and disseminate a decision in writing. Authorized Deviations apply to a specific quantity of items and will not constitute change to the TPTI as defined by the Technical Data Package (TDP), or TPTI specification. The Contractor may process a RFD if, during or after repair of an item that incorporates a known departure from requirements, it is determined that the item is considered suitable for use “as is” or after repair by an approved method. When it is determined that a change should be permanent, a Class I ECP shall be recommended, or a Class II change shall be processed. MIL-HDBK-61A may be used for guidance.

3.21.2 Pilot Production Conformity Inspections

The Contractor and Government shall conduct periodic conformity inspections throughout the manufacturing and assembly of the Pilot production unit. The On-Site Verification will be used to conduct these inspections. The Conformity Inspections shall consist of a direct comparison of the Pilot production unit with the Technical Data Package (TDP) to establish validity of the product configuration identification. The Conformity Inspection shall validate the major sub-assemblies in accordance with the applicable drawings listed in Table 3. The acceptance criteria for each inspection shall be provided by the contractor prior to each incremental inspection, and approved by the Government prior to the inspection. The contractor shall be required to remove components at the direction of the Government for inspection, and shall reassemble the units following the inspection. The approval of the Conformity Inspection along with the approval of Pilot Production testing, will establish the Final Production Baseline with the approved ECPs to be used for the production units.

Program Harness Box

Test Control Console

3654AS7510

3654AS9200

Terminal Strip Cabinet

TPTI Terminal Strip Cabinet

3654AS9600

3654AS9950

Table 3 – Major TPTI/TPS Sub-Assemblies

3.21.2.1 Conformity Inspection Plan (CDRL A010)

The Contractor shall prepare and submit a Conformity Inspection Plan using EIA-649 and MIL-STD-483 as guidance. As a minimum, the plan shall address the following:

1. The sequence of fabrication and assembly that provides access to all components for the purpose of inspection of conformance to the drawing package.

2. Definition of fabrication progress at each of the 30%, 60% and 90% Conformity Inspections. Early inspections, e.g., the 30% inspection, may be limited to inspection of parts, for comparison to the drawings. The Contractor shall define the hardware/subassemblies that will be available for inspection. Each inspection shall be a subset of the PCA process. In subsequent inspections, continuity checks or other tests may be possible.

3. Identification of the final drawing package and any changes / revisions to be used during the conformity inspection.

4. Identification of the applicable technical documentation, component test plans and acceptance criteria, test data, and software specifications.

a. General description of the facilities and equipment to be used during the audit

b. Procedures for implementing changes required as a result of the inspection

c. All ECPs, Notice of Revisions (NORs), and the associated documentation, i.e. drawings, specifications, source information for manual updates, etc.

3.21.2.2 Conformity Inspection Report (CDRL A011)

The Contractor shall prepare and submit a Conformity Inspection Report, which shall document the findings of the inspections. Any deviations from the plan shall be included.

3.22 Integrated Baseline Review (IBR)

The Contractor shall conduct an Integrated Baseline Review following any major change to the baseline. The Government will verify during the IBR, and follow-on IBRs, when required, that the Contractor has established and maintains a reliable performance measurement baseline. The Contractor will ensure that the baseline includes the entire contract technical scope of work consistent with the contract schedule requirements, and has adequate resources assigned. The IBR will be used to achieve a mutual understanding of the baseline plan and the underlying management processes used for planning and controlling the project.

3.23 A/E37T-17A Technical Data Package (TDP) (CDRL A012)

The TDP consists of Component Performance Specifications, Software Product Specifications, Interface Control Specifications and the engineering drawing package for the A/E37T-17A Mobile Turboprop Engine Test System. The TDP is under Government configuration control, however as changes / modifications documented by ECP/NOR require, the engineering drawings shall be updated in accordance with ASME Y14.100-200 using standard commercial drawing software approved by the IPT. Updated / new drawings are to be provided to the Government on CD-ROM in AUTOCAD Release 14 (or later version). All other TDP elements shall be provided in an IPT approved electronic format.

3.24 Obsolescence

NAVAIR has tracked parts obsolescence and revision issues for the TPTI system throughout the prototype development, and finds it necessary to manage these changes throughout the life of the systems. The US Navy will work with the Contractor, instrument/component vendors, and sub-vendors to ensure that repair capability remains current and economical for the TPTI systems.

The contractor shall provide obsolescence-engineering solutions for all TPTI components in accordance with trade-off studies. The contractor shall proactively forecast, identify, and recommend corrective actions (including the development of resulting ECPs) for all known or anticipated problems associated with parts obsolescence, reliability, and Commercial-Off -the -Shelf (COTS) incompatibilities.

3.24.1 Obsolescence Management

Since the TPTI system is an integration of Commercial Off-the-Shelf (COTS) items, which are subject to obsolescence, revisions, and/or updates, a proactive system to track, analyze, and predict updates is required. The Contractor shall develop and maintain an obsolescence management program that will proactively forecast, identify, and recommend corrective actions for all known or anticipated problems associated with diminishing sources, and parts obsolescence.

Although the system product baselines are defined in the TDP, it is expected that several components may be obsolete at the time of contract award or become obsolete during the production period. The NAVAIR life cycle prediction for obsolescence management is provided in Enclosure (4). This preliminary data is provided for long term planning to track obsolescence/change issues for the systems. The Contractor shall be required to continue to proactively identify any obsolete/revised items throughout the life of the systems within this contract.

3.24.1.1 Obsolescence Management Plan (CDRL A024)

The Contractor shall develop and maintain an Obsolescence Management Plan that shall include detailed information on the procedures for proactively identifying diminishing sources of supply, assessing, managing, and mitigating the risks resulting from revisions, upgrades, and obsolescence of COTS components.

3.24.1.2 Obsolescence Reports (CDRL A025)

The Contractor shall establish a proactive process to identify diminishing sources of supply and obsolescence issues as soon as possible to allow trade studies and redesign as required. The process shall include tracking of changes to COTS items including hardware, firmware, and software. Quarterly reports shall be submitted which provide a forecast of the continuing likelihood of parts and support availability. Likely candidates for monitoring and proactive action shall be highlighted in the report.

3.24.1.3 Obsolescence / Revision Change Implementation

As the proactive forecasting identifies obsolescence candidates, the Contractor shall initiate research for alternative solutions. Each obsolescence issue shall be managed and tracked separately. The alternatives proposed shall meet the requirements in the TPTI specifications, drawings, and test procedures.

Any revision or modification that affects TPTI or TPS functionality shall be submitted to the Government as an ECP, NOR, SCP, etc., which shall include required modifications to the system to accommodate the modified COTS item, documentation changes, part number changes and regression testing.

3.24.1.4 Trade Studies (CDRL A026)

Each obsolescence issue investigated shall have a trade study report developed. The report shall address the costs, testing, schedules, risks, and benefits of each alternative. The objective of all decisions is to preserve the TPTI systems and TPS compatibility, form, fit, and function to the maximum extent possible. Each item identified via the trade study report shall be analyzed to recommend one of the following solutions. The solutions outlined below are listed in order of preference:

(1) Recommend using an existing substitute product or capability, modifying an existing substitute product or capability

(2) Recommend a Life of Type Buy to meet all future TPTI requirements

(3) Recommend applying a new technology approach/redesign to replace either the product or the capability currently used to meet systems needs

(4) Recommend modifying the systems performance requirement so that a substitute product can be used.

The Contractor shall be responsible for identifying any parts, components, and/or subsystems that change configuration in any way that would affect the functionality of Government furnished DAQ and TPS software. Any parts, components, and/or subsystems that have been revised through updates or upgrades by a vendor without change to part number shall be evaluated for its impact on functionality and Government furnished DAQ and/or TPS software. In situations where a vendor part, component, and/or subsystem have been made available with updated firmware, drivers, etc., it must be evaluated for functionality and impact on Government furnished DAQ and/or TPS software.

Once an alternative has been agreed upon from the trade study, the Contractor, upon approval from the COR, shall enter into a rapid prototype and test to determine technical feasibility, performance, and interface impacts. The Navy maintained TPTI Development Station may be used by the Contractor with Government assistance for this testing. The COR shall approve and oversee all prototyping actions. This work, as well as preparation and submittal of all data, studies, and reports, is part of the task of Obsolescence Management under this contract. All data associated with the trade study shall be delivered to the Government.

3.24.1.5 Component Regression and Acceptance Testing (CDRL A027) Once an alternative has been agreed upon from the trade study and prototype testing, the Contractor shall provide a test plan that delineates the interface and regression testing that is required as a result of the ECP. All hardware, software, and/or firmware CIs that are identified as requiring acceptance testing through the ECP process, shall be tested on a Navy maintained TPTI Station by the Contractor with Government assistance. The test plan shall also include a description of the regression testing required of software as a result of changes to hardware and/or software. The TPTI Development System Hardware and Software will be maintained in accordance with the baselined configuration and will be consistent with the TDP. Upon completion of the testing, a report shall be provided which documents the testing performed and all findings.

3.24.1.6 Bi-Yearly Obsolescence Review Meetings

The Contractor shall provide representation to Obsolescence Reviews which shall be conducted twice a year at various locations within the continental United States. The representative shall have obsolescence case management experience and configuration management knowledge. Meetings will not exceed two days each.

3.25 Reliability Program

The Contractor shall provide a Reliability Program for the duration of the contract, using their existing failure tracking, reporting, and corrective action system, which shall:

(1) Provide a relationship between reliability and unit/component production & delivered failures. Generate data to identify reliability performance trends.

(2) Assess impact of Contractor generated Class I and II changes on the system and related adapter assemblies to ensure existing reliability performance levels are maintained or improved.

(3) Identify reliability problems, impact on system performance, and provide recommended solutions.

(4) Provide a database for recording, tracking and reporting the status of actions to resolve problems at the IPT reviews.

(5) Monitor subcontractors to ensure their products meet or exceed current reliability performance and that subcontractors implement corrective actions resulting from the reliability program.

3.26 Failure Reporting, Analysis, and Corrective Action System (FRACAS) (CDRL A014) A closed-loop system for reporting and tracking all incidents that occur during the testing specified in this SOW and all installed systems up until the end of warranty shall be established and maintained. The contractor shall provide incident reports within 24 hours of any test incident that occurs during testing they are performing, Government test engineers shall provide the incident reports for any tests they are conducting, and Fleet personnel shall provide reports via the EI system for fielded systems. The Failure Review Board (FRB) shall review each incident for classification. The contractor shall analyze and provide corrective actions, modifications or changes in design, material, processes, vendors, etc as appropriate to preclude the failure reoccurrence for all incidents reported.

3.27 Failure Review Board (FRB)

A Failure Review Board (FRB) shall be established as the governing body of the FRACAS and shall consist of Government and Contractor participants. The FRB shall classify each failure/incident and determine the appropriate course of action to eliminate or mitigate the problem occurrence.

3.28 Hazardous Materials Management…