Crash_and_Salvage_Cranes_SOW_at_RFP_with_Amendment_005.pdf

NAVAL AIR WARFARE CENTER

Aircraft Division

CRASH AND SALVAGE CRANES

STATEMENT OF WORK (SOW)

Naval Air Warfare Center Aircraft Division

SE and ALRE Department

CSE/PSE Development and ISE Division

Lakehurst, New Jersey, 08733

02 May 2018

Prepared for:

Commander, Naval Air Systems Command

PMA-260

Patuxent River, MD 20670

APPROVED: ______________________________________

TITLE: DEPUTY PROGRAM MANAGER FOR CSE

(PMA-260C)

TABLE OF CONTENTS

1.0 SCOPE

1.1 BACKGROUND

2.0 APPLICABLE DOCUMENTS

2.1 ISSUES OF DOCUMENTS

2.2 DOCUMENTS

3.0 REQUIREMENTS

3.1 GENERAL

3.1.1 Design

3.1.2 Manufacturing Development

3.1.3 Test and Evaluation

3.1.4 Production

3.1.5 Operations and Support

3.2 DETAILED TASKS

3.2.1 Program Management

3.2.2 Systems Engineering

3.3 TEST AND EVALUATION

3.3.1 Responsibility for Compliance

3.3.2 Contractor Support

3.3.3 Reliability and Maintainability Demonstrations (RDEMO & MDEMO)

3.3.4 Test & Evaluation Documents

3.4 QUALITY ASSURANCE

3.4.1 Quality Management

3.4.2 Quality Assurance Plan

3.5 MANUFACTURING

3.5.1 Manufacturing Plan

3.5.2 Manufacturing and Quality Metrics

3.5.3 Counterfeit Parts and Material

3.6 CONTRACT DATA REQUIREMENTS LIST (CDRL)

4.0 INTEGRATED LOGISTICS SUPPORT (ILS)

4.1 PURPOSE

4.2 LOGISTICS GUIDANCE CONFERENCE

4.3 LOGISTICS PRODUCT DATA RECORD (LPDR)

4.3.1 Logistics Product Data Attribution Selection Sheets

4.3.2 Logistics Product Data (LPD) Candidate List

4.3.3 Task Narrative

4.3.4 Functional Requirements Identification

4.3.5 Support Equipment (SE) / Tools

4.3.6 Logistics Product Data (LPD) Reviews

4.3.7 Vendor Data Requirements

4.3.8 Supply Support

4.3.9 Provisioning Technical Documentation (PTD)

4.3.10 Interim Support Item List (ISIL)

4.3.11 Packaging, Handling, Storage, and Transportation (PHS&T)

4.3.12 Personnel Requirements

4.3.13 Packaging Requirements Data

4.3.14 Interim Support Period Requirements

4.3.15 Markings Requirement

4.3.16 Handling and Storage Requirements

4.3.17 Electrostatic Sensitive Devices (ESD)

4.3.18 Hazardous Material (HAZMAT)

4.3.19 Plastics Removal in Marine Environment (PRIME)

4.3.20 Navy Shelf Life

4.3.21 Transportation

4.3.22 Item Unique Identification (IUID) Plan/Marking of U. S. Military Property

4.4 TECHNICAL MANUALS

4.4.1 Technical Manual Updates

4.5 TRAINING REQUIREMENTS SUMMARY

4.5.1 Training Integrated Master Schedule (IMS)

4.5.2 Training Situation Analysis (TSA)

4.5.3 Initial Familiarization Training Conduct Requirements

4.5.4 DT-C1 Test Training (DT TRNG) / Train the Trainers Conduct

4.5.5 Initial (Operator / Maintainer) Factory Training (IFT) Conduct

4.5.6 Initial (Operator / Maintainer) On Site Training / Train the Trainer

4.5.7 Formal Training Course Development

4.5.8 Job Duty Task Analysis (JDTA)

4.5.9 Training Course Conduct Package (TCCP)

4.5.10 Instructional Performance Requirements Document (IPRD)

4.5.11 Instructional Media Design Package (IMDP)

4.5.12 Onscreen Lessons and Training delivery

4.5.13 Instructional Media Package (IMP)

4.5.14 Government Furnished Information (GFI)

4.6 SOFTWARE

4.7 CONFIGURATION AND OBSOLESCENCE MANAGEMENT

4.7.1 Modified Bill of Materials (BOM)

4.7.2 Diminishing Manufacturing Sources and Material Shortage (DMSMS)

4.8 WARRANTY

APPENDIX A

LOGISTICS PRODUCT DATA ATTRIBUTE SELECTION SHEET

APPENDIX B

TECHNICAL MANUAL CONTRACT REQUIREMENT (TMCR)

APPENDIX C

CONTRACT DATA REQUIREMENTS LIST (CDRL) DD 1423

APPENDIX D

PHYSICAL CONFIGURATION AUDIT PROCEDURES

APPENDIX E - ACRONYMS

1.0 SCOPE

This Statement of Work (SOW) identifies the work to be done by the contractor during the course of the Crash and Salvage Cranes contract. The Crash and Salvage Cranes include a design for

Carrier Vessel Nuclear (CVN) class ships, identified as the Carrier Crash and Salvage Crane

(CCSC), and one for Landing Helicopter, Amphibious/Landing Helicopter, Dock Class ships

(LHA/LHD), identified as the Amphibious Crash and Salvage Crane (ACSC), that meet the requirements of the Performance Specification.

Two (2) CCSC Engineering Development Models (EDM) and One (1) ACSC EDM will be procured along with engineering and logistics data to support contractor testing (designated as

Development Test (DT-B1)). Following programmatic, systems engineering, test result and logistics reviews with the contractor during the engineering and manufacturing development phase of the program, the Government will conduct a Milestone C (MS-C) decision to determine whether to place additional delivery orders to procure a Low Rate Initial Production (LRIP) unit of each type (CCSC and ACSC) to support Government testing (designated as Development Test (DT-

C1)). Following programmatic, systems engineering, test result and logistics reviews with the

Contractor, the Government will conduct an independent Full Rate Production Decision Review

(FRPDR) to determine whether to proceed to production. If approved, the Government will issue delivery orders and grant release for production units. The contractor will then be required to produce, deliver, and provide logistics support for the Cranes.

1.1 BACKGROUND

The Naval Air Warfare Center Aircraft Division (NAWCAD) at Lakehurst, New Jersey, has been tasked by the Naval Air Systems Command (NAVAIR) Code PMA260 to procure new Crash and

Salvage Cranes, also called “cranes” herein. The cranes will replace the A/S32A-35A/-52, and

A/S32A-36A/-53 Aircraft Handling Salvage Cranes currently used in the fleet. They will support aircraft operations at the Organizational Level and will be maintained at the Intermediate level.

2.0 APPLICABLE DOCUMENTS

2.1 ISSUES OF DOCUMENTS

The following documents of the issue in effect on the date of the request for proposal, unless otherwise specified, form a part of this SOW to the extent specified herein. When documents conflict, this SOW shall govern.

2.2 DOCUMENTS

ANSI/ISO/ASQC Q9001-2008 Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing

ASME Y14.100 Engineering Drawing Practices

DFARS 252.223-7001 Defense Federal Acquisition Regulation System

DOD 4160.21 Defense Materiel Disposition Manual

DOD 5220.22 National Industrial Security Program Operating Manual

DOD 5230.24 Distribution Statements on Technical Documents

EIA-649-B Configuration Management Standard

FAR 23.3/FAR 52.223 Hazardous Material Identification and Material Safety Data

Federal Acquisition Regulations Section 2.101

FED-STD-313E Material Safety Data Sheets

ISO 10005:2005 Quality Management Systems - Guidelines for Quality Plans

MIL-B-117, 81705, 81997 Military Specifications for Packaging Supplies

MIL-HDBK-263B Electrostatic Discharge Control Handbook for Protection of

Electrical and Electronic Parts

MIL-HDBK-470A Designing and Developing Maintainable Products and

Systems

MIL-HDBK-781A Reliability Test Methods, Plans, and Environments For

Engineering Development, Qualification, and Production

MIL-HDBK-2155 Failure Reporting, Analysis, and Corrective Action Taken

MIL-PRF-29612B Training Data Product Specification

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

MIL-STD-129 Military Marking for Shipment and Storage

MIL-STD-1686 Identification Marking of U.S. Military Property

MIL-STD-2073 Standard Practice for Military Packaging

MIL-STD-3001-1A Preparation of Digital Technical Information for Multi-Output

Presentation of Technical Manuals

National Aerospace Standard Hazardous Materials Management Program

(NAS) 411, NASC # 7013

NAVAIR 00-25-604 Technical Manual, NAVAIR Systems Command Fleet

Support/Integrated Program Team Acquisition and

Sustainment of NAVAIR Technical Manuals

NAVAIRINST 4200.25 Management of Critical Application Items including Critical

Safety Items

SECNAV M-5510.36 Department of the Navy Information Security Program

SAE JA1000 Reliability Development Program Requirements

SAE JA1000-1 Reliability Program Standard Implementation Guide

SAE JA1010 Maintainability Program Standard

SAE JA 1010-1 Maintainability Program Standard Implementation Guide

SAE GEIA-STD-0007-B Logistics Product Data

SAE GEIA-HB-0007-B Logistics Product Data Handbook

SAE TA-STD-0017 Product Support Analysis

NAVEDTRA 132 Navy School House Testing Management Manual

NAVEDTRA 136 Naval Education and Training Command Integrated Learning

Environment Course Development and Life-cycle

Maintenance Manual

NAVEDTRA 137A Job Duty Task Analysis Management Manual

NAVEDTRA 138 Front End Analysis Management Manual

CENNAVAVNTECHTRA 1540 Curriculum Management Manual

CENNAVAVNTECHTRA 1554.1 Interactive Multimedia Instruction (IMI) Developer’s Guide.

MIL-STD-3001- 1 Preparation for Multi-output Presentation of Technical

Manuals

MIL-STD-3001-2A Description, Principles of Operation, and Operation Data

MIL-STD-3001-3A Testing and Troubleshooting Procedures

MIL-STD-3001-4A Maintenance Information with IPB

MIL-STD-3001-5A Aircraft Wiring Information http://specs4.ihserc.com/Document/Document/ViewDoc?docid=AFEEIFAAAAAAAAAA http://specs4.ihserc.com/Document/Document/ViewDoc?docid=EXXJIFAAAAAAAAAA

MIL-STD-3001-6A Structural Repair Information

MIL-STD-3001-7A Periodic Maintenance Requirements

MIL-STD-3001-8A Illustrated Parts Breakdown (IPB)

MIL-PRF-85337B Manuals, Technical: Requirements for Quality Assurance

Program

AL-855TM-GYD-000 Technical Manual Quality Assurance Program guide

Other Government Publications

DOD 5220.22-M National Industrial Security Program Operating Manual

SECNAV M-5510.36, Department of the Navy Information Security Program

DoN Policy on the use of extensible markup language (xml) .

3.0 REQUIREMENTS

This section sets forth the specific task requirements for the contractor to perform.

3.1 General

3.1.1 Design

The contractor shall design cranes meeting all requirements of the Crash and Salvage Cranes

Performance Specification maximizing the use of commercial items as defined in Federal

Acquisition Regulations Section 2.101. The goal is to supply commercial or modified commercial equipment and/or components, with a production history and proven track record to the

Government. Use of non-standard or proprietary hardware shall require prior Government approval. The cranes are expected to be in service for 25 years.

3.1.2 Manufacturing Development

Upon completion of the Critical Design Review (CDR) described in paragraph 3.2.2.3 and closure of any Requests for Action (RFAs), the contractor shall assemble/manufacture two (2) CCSC

EDMs and one (1) ACSC EDM in accordance with the approved initial product baseline (EDM build baseline) for testing.

3.1.3 Test and Evaluation

Upon approval of the Contractor Test Review (CTR) described in paragraph 3.2.2.4, the contractor shall start testing of the EDMs. Upon successful completion of required DT-B1 tests, and incorporation of approved design modifications, the contractor shall provide one LRIP unit of each type (CCSC and ACSC) to the Government for DT-C1. These LRIP units shall successfully pass all tests identified in the the Production Acceptance Test Procedures (CDRL T003) prior to delivery. DT-C1 will commence after closure of the Test Readiness Review (TRR) described in paragraph 3.2.2.6. The contractor shall be responsible for design changes required to resolve any transportation damage (e.g. loose hardware, performance malfunction, etc.) resulting from transportation vibration to/from the test sites.

3.1.4 Production

The contractor shall incorporate all approved design modifications, including those identified during DT-B1 and DT-C1, into the Technical Drawing Package (TDP) (CDRL P003) prior to the

System Verification Review/Production Readiness Review (SVR/PRR) as described in paragraph

3.2.2.7. Upon the Government's issuing delivery orders and granting release for production units, the contractor shall produce and deliver the production quantities in accordance with the Delivery

Schedule (Section F) of the contract. The Government will provide the LRIP units as Government

Furnished Equipment (GFE) for the contractor to refurbish and upgrade to production configuration. These refurbished LRIP units shall successfully pass all tests identified in the

Production Acceptance Test Procedures (CDRL T003) and delivered as the first production units.

3.1.5 Operations and Support

The contractor shall provide logistics and technical support throughout the program as stated in the contract

3.2 Detailed Tasks

3.2.1 Program Management

The contractor shall report the program schedule progress (including critical path) via an Integrated

Master Schedule (IMS). (CDRL P001)

3.2.1.1 Program Management Review (PMR)

The contractor shall conduct PMRs at their facility in compliance with the IMS every three months.

Adequate space should be available to accommodate the Government and contractor team members. Systems engineering and logistics data reviews shall be scheduled in conjunction with the PMRs. The first PMR shall be the combined Systems Requirements Review II (SRR-II)/Post

Award Guidance Conference (PAGC) (paragraph 3.2.2.1). All PMRs shall provide the

Government with an accurate summary of the contractor’s technical progress, program planning and overall management approach and progress. The following topics shall be addressed at all

PMRs:

Contract status, progress tracking and reporting of milestones (CDRL P001)

Problem and risk identification, assessment, reduction and control

Streamlining recommendations

Technical review

TDP status (CDRL P003)

Logistics review

Configuration management

Review of Critical Application Items (CAIs), Critical Safety Items (CSIs)

Subcontract management activity status

Personnel and staffing level status

Quality and corrective action plan status

Action items completed, pending and forecasted

Required Government Furnished Equipment (GFE)

Meeting minutes

Agendas for the PMRs will be developed jointly by the contractor and the Government and provided in accordance with CDRL P002. The presentation developed by the contractor for the

PMRs shall be provided to the Government in accordance with CDRL P002. PMR Minutes and

Action Items will be agreed to at the conclusion of each PMR and action items will be assigned to the entire team (contractor and Government). PMR Minutes and Action Items shall be prepared by the contractor and submitted in accordance with CDRL P002.

3.2.2 Systems Engineering

A systems engineering process with Technical Interchange Meetings (TIMs) and Systems

Engineering Technical Reviews (SETRs) will be used during the performance of this contract.

The TIMs can be held via teleconference or in person on an as needed basis, and on a scheduled basis in preparation for the SETRs. The SETRs are formal reviews conducted to assess technical progress toward meeting requirements, and that technical conditions of the contract are being satisfied. The SETRs are multi-disciplined product and process assessments of the engineering development against cost, schedule and technical requirements. A contractor and Government team consisting of Integrated Product Team (IPT) members, Subject Matter Experts (SME) and technical authorities will participate in the SETRs. An independent Government chair will preside over the SETR. The independent chair will report results to the Government Program Decision

Authority.

The SETRs, detailed in paragraphs 3.2.2.1, 3.2.2.2, 3.2.2.3, 3.2.2.6, and 3.2.2.7 shall be supported by the contractor as specified here in. The SETRs shall be conducted at the contractor’s facility with access to a conference call/VTC. Entrance criteria specified herein for each SETR shall be met prior to the SETR being held. Failure to complete entrance or exit criteria will result in RFAs written by the Government and provided to the contractor. All RFAs shall be closed before the next phase of the program begins. Agendas, presentations and meeting minutes for the TIMs and

SETRs will be in accordance with CDRL P002.

3.2.2.1 Systems Requirement Review II (SRR-II)/Post Award Guidance Conference (PAGC)

The SRR-II/PAGC is a SETR to ensure the contractor and Government teams understand and agree that the contract requirements, including the Performance Specification, SOW, Department of Defense (DoD) directives, statutory and regulatory guidance, and applicable public law, have been correctly and completely represented in the contractor’s proposal, and can be executed within cost, schedule and technical constraints. The understanding of technical requirements and verification methods will be characterized in a technical risk assessment of the contractor to comply with the Performance Specification. The contractor shall:

Conduct a SRR-II/PAGC at their facility in compliance with the IMS within 45 calendar days after contract award

Present any updates to their design since final proposal acceptance

Present their system design requirements traceability (includes tailored, derived, and correlated requirements) showing traceability to all requirements in the

Performance Specification (CDRL T008)

Identify any software/firmware configuration items

Present a system level review ensuring all technical and contract requirements in the solicitation are understood, have been completely addressed in their design concept, and that they can be met within program schedule constraints

Present status/ results of the Key Performance Component Analysis (CDRL T006)

Present CAI/CSI preliminary assessment

Identify any Support Equipment (SE) and Special Tools necessary for the maintenance of the cranes (paragraph 4.2.11) for approval by the Government

Present performance and/or schedule risks as well as risk mitigation plans

Present configuration management processes for drawings and documentation

Present a discussion of the contractor’s Quality Program (paragraph 3.5)

Present the production strategy including a high level layout, supply chain plans and estimated production quantity per month

Present contractor’s organizational structure and provide a detailed explanation to support the program with resources throughout the entire performance on the contract

Provide a tour of the manufacturing area during this review

Entrance Criteria for SRR-II/PAGC

SRR-II/PAGC Agenda & Presentation (CDRL P002)

IMS (CDRL P001)

Key Performance Component Analysis - draft (CDRL T006)

Requirements Traceability Matrix (RTM) (CDRL T008)

SRR-II/PAGC Closure

SRR-II/PAGC Minutes & Action Items (CDRL P002)

Requirements baseline established

All RFAs are closed

Required CDRLs (above) have been approved by the Government

3.2.2.2 Preliminary Design Review (PDR)

The PDR SETR is a technical assessment that establishes the complete physically allocated baseline to ensure that the system under review has a reasonable expectation of being judged operationally effective and suitable. The contractor shall:

Conduct a PDR at their facility

Assess the allocated design captured in subsystem and component product specifications for each configuration item in the system and ensure that the requirements have been allocated to one or more hardware/software configuration items and show requirements traceability (CDRL T008)

Ensure that the physical properties of the system (i.e. size, weight, power, etc.) have been properly allocated to sub-systems and components and identify how they accounted for design growth margins

Include a description/ specification for each hardware/software configuration item.

Descriptions of all components including their functions in the system and their interfaces are to be presented using 3-D modeling software and shall start to show the maturity of a complete detail design which culminates in a CDR

Define all interface requirements and technical criteria used for the selection of the major components. Include a detailed analysis showing how the design meets lift, and lift and move capacities, speed and braking requirements, and that it meets or exceeds the Performance Specification requirements (CDRL T006)

Present results/status (including inputs and associated safety margin) of all structural, stability and deck loading analyses (CDRL T007)

Present results of the Failure Modes, Effects, and Criticality Analysis (FMECA)

(CDRL E005)

Provide a preliminary reliability prediction (which also includes hardware) in accordance with paragraph 3.2.2.12 (CDRL E004)

Provide a preliminary maintainability prediction, in accordance with paragraph

3.2.2.12 (CDRL E004)

Show and/or demonstrate that Reliability and Maintainability (R&M) diagnostics have been completely addressed in design allocations

Describe initial test planning (tentative schedules and locations)

Present any design changes and updates from SRR-II/PAGC

Discuss the plan to develop the TDP (CDRL P003)

Present performance and/or schedule risks as well as risk mitigation plans

Show and/or demonstrate that evaluations of materials, lead times, tooling, fabrication techniques, assembly methods, test equipment, skills, processes, and inspection techniques are in place for each hardware/ software configuration items

Show the producibility assessments of key technologies/components are complete and are likely to be achieved

Describe the Quality Assurance Program Plan (CDRL P004)

Identify all single source, sole source, and diminishing source(s)

Present Top Level Software Design Description and/or Software Architecture

Description

Provide a CAI/CSI list, if applicable, with criticality justification

Ensure logistics element requirements are allocated in the design

Entrance Criteria for PDR

PDR Agenda & Presentation addresses all items above (CDRL P002)

IMS (CDRL P001)

Key Performance Component Analysis (CDRL T006)

Structural, Stability and Deck loading Analyses – draft (CDRL T007)

RTM (CDRL T008)

Failure Modes, Effects, and Criticality Analysis (CDRL E005)

PDR Closure

PDR Minutes & Action Items (CDRL P002)

Allocated baseline established

All RFAs are resolved

Required CDRLs (above) have been approved by the Government

3.2.2.3 Critical Design Review (CDR)

The CDR SETR is a technical assessment establishing the initial product baseline for the EDM design to ensure that the system under review has a reasonable expectation of being judged operationally effective and suitable, and that it complies with the Performance Specification. Upon approval of the CDR, the EDM design is frozen and any proposed changes shall have NAVAIR concurrence prior to being incorporated. The contractor shall also discuss long lead item acquisition, and other supply chain concerns related to the build schedule for the LRIP units. Long lead items are defined as those components that need to be ordered prior to release for production in order to not impact the LRI P build schedule. The contractor shall:

Conduct a CDR at their facility in compliance with the IMS

Present a detailed review of the hardware and software design for the system. The presentation shall include a description of all subsystems and major components using native/original design format (such as 3-D modeling/ rendering)

Address all deficiencies identified during the PDR and highlight details of any changes to the design since PDR

Provide requirements traceability (CDRL T008) demonstrating the design furnished at

CDR satisfies all the requirements of the Performance Specification including the methods used to verify the design

Present the status of the TDP Review detailed in paragraph 3.2.2.9

Present the results of any updates to design analyses (including updated Key Performance

Component Analysis (CDRL T006), Structural, Stability and Deck loading Analyses

(CDRL T007) and FMECA (CDRL E005) and operating procedures and baseline drawings, models and documentation required for fabrication

Provide updated reliability and maintainability predictions in accordance with paragraph

3.2.2.12 (CDRL E004)

Present performance and/or schedule risks as well as risk mitigation plans

Show manufacturing process and resource readiness (facility, personnel, equipment, configuration management, etc.) to proceed to EDM production (CDRL P005)

Show resolution of production engineering problems, accomplishment of production phase planning, contractor identified program risks and program schedule

Present the planned test schedule, test locations and test equipment required to execute the required testing. This presentation shall highlight any changes from the testing information presented at PDR and show that the contractor fully understands the testing required

Present results of Hazardous Materials Management Program (HMMP) Report (CDRL

E002)

Present results of System Safety Hazard Analysis (CDRL E003)

Present a list identifying all critical welds

Entrance criteria for CDR:

PDR Closure

CDR Agenda & Presentation (addresses all items above) (CDRL P002)

IMS (CDRL P001)

TDP Review conducted (CDRL P003)

Modified Bill of Materials (BOM) submitted (CDRL L011)

Structural, Stability and Deck loading Analyses (CDRL T007)

RTM (CDRL T008)

Technical Manual Outline (CDRL L006)

Logistics Product Data Candidate List (CDRL L002)

LPDR/LORA review has been conducted (CDRL L001)

CDR Closure:

CDR Minutes & Action Items (CDRL P002)

Initial product baseline established (EDM build baseline)

All RFAs are resolved

TDP Review has been successfully completed

Required CDRLs (above) have been approved by the Government

Technical Manual Outline is approved

Manufacturing readiness processes and resources (facility, personnel, equipment, configuration management, etc.) are ready to proceed to EDM production

3.2.2.4 Contractor Test Review (CTR)

The CTR is a TIM providing a detailed review of the contractor’s readiness to enter test with a high confidence that the equipment will successfully complete contractor testing, DT-B1. The

CTR will ratify the contractor test procedures. The contractor shall also discuss the status of long lead item deliveries and any changes to the design, or other supply chain concerns related to the build schedule for the LRIP units. Long lead items are defined as those components that need to be ordered prior to release for production in order to not impact the LRIP build schedule.

The contractor shall:

Conduct a CTR at their facility in compliance with the IMS and prior to beginning contractor testing DT-B1

Present a detailed test schedule that is fully resourced and includes test dependencies

Present the test article baseline detailing any design changes since CDR

Present test procedures and updates

Present Failure Reporting, Analysis and Corrective Action System (FRACAS) Plan

(CDRL T009)

Identify how the crane will be transported

Show compliance with Performance Specification Section 4.0

Present performance and/or schedule risks, as well as risk mitigation plans

Identify any long lead items

Provide a functional and operational demonstration of the crane’s capabilities.

Note: No official contractor testing shall begin until CDRL T001 is approved.

Entrance criteria for CTR

CDR closure

CTR Agenda & Presentation (CDRL P002)

IMS (CDRL P001)

EDM Test Plan and Procedures (CDRL T001)

One operational CCSC and ACSC EDM

First Technical Manual In Process Review (IPR) conducted (CDRL L006)

CTR Closure

CTR Minutes & Action Items (CDRL P002)

Test baseline established

All RFAs are resolved

Required CDRLs (above) have been approved by the Government

3.2.2.5 Initial Test Readiness Review (ITRR)

The ITRR is a detailed review of the contractor test results, and an assessment of the contractor’s readiness to support entrance into Government Testing (DT-C1). This TIM is conducted in preparation for the Government Test Readiness Review (TRR). The contractor shall:

Conduct an ITRR at their facility in compliance with the IMS and prior to shipping the

LRIP unit to the Government for DT-C1

Present results of DT-B1 tests. This draft EDM Test Report shall include results of all tests required in the Performance Specification with the exception of Electromagnetic

Vulnerability (test performed by the Government) and MDEMO (to be performed after

Government Testing is approximately 30% complete)

Present details of test failures, root causes and corrective actions proposed

Present details of any approved design changes since CTR

Present configuration status of LRIP unit to be used for DT-C1

Discuss the Production Acceptance Test Plan and Procedures (CDRL T003)

Present status of resources (LRIP unit, Tech Manual, spare parts, personnel, etc.) contractor will provide to support DT-C1

Present status of Logistics documentation

Present DT-C1 Test training status (CDRL L010)

Present performance and/or schedule risks as well as risk mitigation plans

Entrance criteria for the ITRR

CTR closure

ITRR Agenda & Presentation (CDRL P002)

IMS (CDRL P001)

Draft EDM Test Report (CDRL T002)

Production Acceptance Test Plan and Procedures (CDRL T003)

ITRR Closure:

ITRR Minutes & Action Items (CDRL P002)

3.2.2.6 Test Readiness Review (TRR)

The TRR SETR is a detailed review of overall readiness of the contractor and Government team to enter DT-C1. The contractor and Government test teams will present the resources, plans, etc.

detailing their readiness to enter DT-C1.

Entrance criteria for the TRR

LRIP unit complete and ready for DT-C1

ITRR closure

Production Acceptance Test Report (CDRL T004)

TRR Agenda & Presentation (CDRL P002)

Third Technical Manual IPR conducted (CDRL L006)

TRR Closure:

TRR Minutes & Action Items (CDRL P002)

All RFAs are resolved

Third Technical Manual IPR has been successfully completed

DT-C1 training has been successfully completed

3.2.2.7 System Verification Review / Production Readiness Review (SVR/PRR)

The SVR/PRR SETR is a product and process review that ensures the cranes can proceed into production within program schedule, risk and other system constraints. The SVR portion of this review is used for evaluating completeness of design in meeting the technical requirements, including the results of testing (DT-B1 and DT-C1), addressing all Failure Analysis and Corrective

Action Reports (CDRL T005) submitted, Deficiency Reports (DRs) submitted by the Government, addressing design changes made since CDR and any proposed design changes as a result of testing.

The SVR/PRR is used to confirm that any changes negotiated as a result of issues found during

DT-B1 and DT-C1 have been incorporated into the design baseline and that a representative unit exists with those design elements incorporated. The full, production-configured system is evaluated to determine that it correctly and completely implements all system requirements, and that the traceability of final system requirements to the final production system is maintained. All production units shall be configured to this baseline. Any future changes can only be made through full Configuration Management (CM) procedures, and as authorized by the Contracting Officer in accordance with the terms and conditions of the contract. The contractor is responsible for resolving all “in-scope” DRs. Solutions to “out-of-scope” DRs shall be negotiated with the

Government and incorporated via a contract modification.

An incremental Production Readiness Review (iPRR) is to be conducted prior to the SVR/ PRR by the Government/contractor team to assess prime contractor and/or subcontractor production planning, facilities allocation, incorporation of producibility oriented changes, identification and fabrication of tools/test equipment, long lead item acquisition, and other supply chain concerns.

Long lead items are defined as those components that need to be ordered prior to release for production in order to not impact the production build schedule. The review will be conducted at the contractor’s facility and will assess changes in design, configuration management, quality assurance or manufacturing processes that impact planned production, cost and schedule activities.

The PRR portion of this review will report on the iPRR, production acceptance test plans and detail how the contractor shall meet the production delivery schedule stipulated in the contract.

The Government decision to enter into full rate production will not be considered until the

SVR/PRR review is closed. The Contractor shall:

Conduct a SVR/PRR at their facility in compliance with the IMS

Provide an updated RTM showing how all requirements have been met and verified

Present EDM and LRIP unit test results

Discuss all DRs and their resolutions

Present all design changes made since CDR and their test/verification results

Demonstrate that all drawings and technical documents and analysis have been updated to the production baseline and put under configuration management; identify CAI/CSI components, and properly address critical and major characteristics for inspections

Describe the change control process

Discuss the Production Acceptance Test Plan and Procedures (CDRL T003)

Present performance and/or schedule risks as well as risk mitigation plans

Identify any long lead items

Present any updates to the Quality Assurance Program Plan (CDRL P004)

Present transition to Production and/or Manufacturing Plan

Entrance criteria for SVR/PRR:

TRR closure

SVR/PRR Agenda & Presentation (CDRL P002)

IMS (CDRL P001)

TDP (CDRL P003)

EDM Test Report (CDRL T002)

Production Acceptance Test Plan and Procedures (CDRL T003)

Completed Failure Analysis and Corrective Action Report (CDRL T005)

RTM (CDRL T008)

Quality Assurance Program Plan (updated if applicable) (CDRL P004)

Manufacturing Plan (updated if applicable) (CDRL P005)

SVR/PRR Closure:

SVR/PRR Minutes & Action Items (CDRL P002)

Production baseline established

All RFAs are resolved

Required CDRLs (above) have been approved by the Government

3.2.2.8 Physical Configuration Audit (PCA)

The contractor shall coordinate with the Government to conduct a PCA on a production unit within

2 months after the first production unit is complete. The objective of this TIM is to verify that the final drawing package matches the Configuration Item (production unit) being produced. A PCA is a technical audit consisting of a direct comparison of the characteristics of a sample item from the production lot with the characteristics specified on the applicable Product Configuration

Identification (drawings, associated lists, specifications, etc.). The contractor shall conduct the

PCA in accordance with Appendix D – Procedures for Physical Configuration Audit (PCA), (CLINs 0017 & 0018).

3.2.2.9 Technical Drawing Package (TDP) and Review

3.2.2.9.1 Technical Drawing Package: The contractor shall deliver a TDP for each crane (CCSC and ACSC) IAW CDRL P003 that provides the Government with unlimited data rights.

The cranes are planned to be supported by a Government organic repair depot. As such, any item identified in the Maintenance Plan with a "D" in any position of the Source, Maintenance, and

Recovery (SM&R) code shall have overhaul source data such as configuration drawings and repair/overhaul instructions, Original Equipment Manufacturer (OEM) Technical Manuals provided. (CDRL L012)

3.2.2.9.2 Technical Drawing Package Review: The contractor shall conduct a TDP Review at their facility in compliance with the IMS and a minimum of 15 days prior to the CDR. The objective of this TIM will be to discuss the Government’s findings/issues with the 3-D model and

2-D drawings, and for the Government to confirm that the TDP represents the baseline EDM configuration that will be built and tested and that it is suitable to meet the logistic documentation requirements.

3.2.2.10 Hazardous Materials Management Program (HMMP)

The contractor shall maintain a HMMP in accordance with National Aerospace Standard (NAS)

411, “Hazardous Materials Management Program.” In designing, manufacturing, testing, operating, maintaining and disposing of the cranes, all forms of pollution shall be prevented or reduced whenever feasible. The emphasis shall be on eliminating or reducing hazardous materials early in the design and properly controlling those hazardous materials which are not eliminated throughout the life cycle.

The contractor shall perform all work under this contract in full compliance with all applicable

Federal, State, and local environmental and occupational safety and health regulations.

The contractor shall utilize the Aviation Hazardous Materials List (AHML) to specify Hazardous

Materials (HAZMAT) required for operation and support of the cranes. The AHML will be supplied as Government Furnished Information (GFI) upon request. The AHML database correlates the HAZMAT requirements identified by aviation program offices with supply information and Type – Ships Hazardous Materials List (T-SHML) Allowed on Board (AOB)

Codes. Any operation and support HAZMAT not authorized on the AHML shall require

Government approval.

3.2.2.10.1 Hazardous Materials Management Program (HMMP) Plan

The contractor shall prepare a HMMP Plan (CDRL E001), which will be used to evaluate the contractor’s approach to, understanding of, and execution of a HMMP. The HMMP Plan must include the following:

a. Identification of key stakeholders and their roles and responsibilities in developing the requirements of the HMMP. The Plan must also describe the organizational and functional relationships relevant to the identification, evaluation, management, and disposal of hazardous materials.

b. Identification of prohibited hazardous materials and hazardous materials targeted for elimination, minimization and tracking and shall describe the process(es) and measures used to identify potential life cycle hazardous material risks. The plan shall also include the means used to quantify the HAZMAT used in the system.

c. A brief description of the method of analysis and basis of evaluation, as well as the processes and tools used to evaluate hazardous material cost, schedule or performance risks. When used in conjunction with a system safety program, the method of HAZMAT risk analysis shall be consistent with the method of assessing other system safety risks.

d. A description of how and to what extent HMMP identification and management requirements will be flowed down to subcontractors.

e. A list of significant HMMP Plan milestones and implementation schedule.

f. A description of the contractor’s approach to hazardous material training, including any specialized training to support the objectives of the HMMP.

3.2.2.10.2 Hazardous Materials Management Program (HMMP) Report

The contractor shall prepare a HMMP Report (CDRL E002). The report shall contain a data list that identifies all hazardous materials required for production of the cranes and all hazardous materials used or wastes generated by scheduled or unscheduled maintenance actions. The contractor shall maintain and update this database throughout the life of the contract. At a minimum, the following information shall be included for each entry:

a. Hazardous material item or substance name

b. Hazardous material category (prohibited, restricted, tracked)

c. Specification, standard, or technical documentation that requires the use of the hazardous material

d. The part number of the component that contains the hazardous material or that the hazardous material is used on and the estimated HAZMAT quantity

e. Chemical name and Chemical Abstracts Service (CAS) number for each constituent or ingredient of the hazardous material

f. A complete Material Safety Data Sheet (MSDS) or Safety Data Sheet (SDS)

If the hazardous material is or contains a NAVAIR Priority I or Priority II Chemical, the report must also include an Environment, Safety and Occupational Health (ESOH) risk evaluation for each different application of each chemical and a trade-off analysis documenting the technical and financial costs of alternative materials compared to the selected hazardous material. If use of the hazardous material is required by the Performance Specification or other Government direction, the trade-off analysis should so state.

3.2.2.11 System Safety Hazard Analysis

The contractor shall conduct a System Safety Hazard Analysis (SSHA) to identify and eliminate or control to acceptable levels all hazards. All phases of intended unit use, including, but not limited to, operation and maintenance shall be considered during the SSHA. The analysis shall be updated to reflect the safety impacts of any significant change to unit design. (CDRL E003)

CAIs including CSIs shall be identified using NAVAIR INSTRUCTION 4200.25D as guidance.

3.2.2.12 Reliability and Maintainability (R&M) Program

The contractor shall maintain a comprehensive R&M program to ensure that the cranes meet the

R&M standards set forth in the Performance Specification. The overall goal of the R&M program is to proactively influence design and logistics processes in order to achieve a high level of operational availability while optimizing life cycle cost. The contractor shall be responsible for ensuring that the R&M levels achieved by subcontractors and suppliers are consistent with the performance requirements of the Performance Specification. The contractor shall be responsible for flowing R&M quantitative requirements, analyses, and test tasks down to all Subcontractors and Suppliers, as necessary. The contractor shall deliver a R&M Program Plan in accordance with

CDRL E004.

The Reliability Program shall be planned and accomplished in accordance with SAE JA1000; SAE

JA1000-1; MIL-HDBK-781; and Section 4 of the Performance Specification.

The Maintainability Program shall be planned and accomplished in accordance with SAE JA1010, MIL-HDBK-470A, Section 4 of the Performance Specification, and this SOW.

3.2.2.12.1 Reliability/Maintainability Analysis and Predictions

Reliability predictions shall be performed in accordance with SAE JA1000-1 Reliability Method

A.32 to evaluate the system design and provide inputs into logistics support analyses. The results of the analyses shall be documented in a Reliability and Maintainability Prediction Report (CDRL

E004).

The reliability prediction shall provide a prediction of Mean Time Between Failure (MTBF) for the cranes. The prediction shall be based on failure rates in the mission environment identified in the Performance Specification for all components or assemblies. Electronic component predictions shall be extracted from the following sources: (1) vendor supplied, (2) like and similar correlations, both with appropriate derating applied per Reliability Information Analysis Center

(RIAC) System Reliability Toolkit, or (3) calculated utilizing MIL-HDBK-217, using the parts stress method as guidance. Mechanical component reliability predictions shall be based on (1) engineering design calculations (i.e. fatigue), (2) on historical or similar equipment data, (3) vendor data, or (4) Reliability Analysis Center Non-electronic Parts Reliability Database (RAC-

NPRD) data. For parts where no failure rate is available, a failure rate shall be estimated and the basis for the estimate shall be documented.

Maintainability predictions shall be performed in accordance with SAE JA1010-1 Method C.19 and MIL-HDBK-472 to evaluate the system design in the expected maintenance environment, to provide data to estimate the amount and level of maintenance required in the field, and to provide data to determine logistical needs of the fielded system. Results from the FMECA shall be used to determine maintenance tasks, and reliability prediction data will be incorporated for use in the quantitative analysis. Modeling and prediction efforts shall assume the basis of the mission environment identified in the Performance Specification.

Reliability and maintainability predictions, updates, and documentation of supporting data shall be provided and discussed at PDR, CDR and subsequent reviews if updated. The reliability and maintainability predictions shall also address the following topics.

3.2.2.12.1.1 Reliability Critical Items

The contractor shall identify those components which are critical to the reliability of the cranes because of the demand for maintenance or logistics support or because of the adverse impact of potential failure on safety, readiness, or mission success.

3.2.2.12.1.2 Environmental Effect Analysis

The contractor shall analyze the effect the specified environments (thermal, shock, vibration, sand, dust, humidity, etc. as applicable) have on reliability. The analysis shall establish the anticipated environmental levels for each zone/compartment of the end item. Actual worst case operating temperatures, vibration, shock and other environmental data shall be used for the applicable portions of this analysis.

3.2.2.12.1.3 Reliability Block Diagram

A reliability block diagram shall be developed in accordance with SAE JA1000-1 Reliability

Method A.2 to establish the parallel/series relationships within the system for components contributing to critical failures as described in the Performance Specification.

3.2.2.12.2 Failure Mode, Effects and Criticality Analysis (FMECA)

The contractor shall perform a FMECA at the physical level to identify possible failure modes, determine the potential local and system level effects of each failure mode, and evaluate the criticality categories of each failure mode. The FMECA shall be performed using a quantitative analysis approach consistent with the maturity of the design. The FMECA shall be performed down to, and include, failure modes of lowest replaceable (at any maintenance level) hardware items and all Maintenance Significant Consumables (MSC). The reliability prediction shall serve as an input to the FMECA. The results of the FMECA shall be addressed at the design reviews.

The contractor shall use FMECA documentation/results to review failure modes and determine potential methodologies to decrease failure rates. A FMECA Report shall be submitted in accordance with CDRL E005.

3.3 TEST AND EVALUATION

The contractor shall establish, plan, maintain, conduct and support a test program to verify that the requirements in Section 3.0 of the Performance Specification are met through successful completion of all methods identified in Section 4.0 of the Performance Specification. This program will provide the quality assurance required by this document and other applicable documents referenced herein. Except as otherwise approved, the supplier shall utilize his own facilities or a commercial laboratory. Inspection and approval of the facilities by the Government technical representative is required. The contractor shall notify the Government at least 2 weeks prior to the start of each test. The Government reserves the right to witness any of the inspections, demonstrations and tests. Inspection records of the examinations and tests shall be kept complete and available to the Government as specified by the contract or order.

The contractor shall support a Government evaluation of the EDM Crash Crane for a period of one week early in the DT-B1 test phase. This evaluation will include conducting a pre-operational inspection of the Crash Crane as well as operating the crane with contractor support to evaluate the general design characteristics and performance of the crane. The Government will document the results of the inspection and provide an Interim Summary Report (internal

Government document) to the Government Program Manager that contains observations, conclusions, and recommendations. This report will be used as a basis to determine whether any design improvements should be incorporated prior to the subsequent manufacture of LRIP units.

3.3.1 Responsibility for Compliance

All items shall meet all requirements of the Performance Specification, section 3. The test and inspection set forth in the Performance Specification shall become part of the contractor's overall inspection system or quality program. The absence of any inspection or test requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract.

Appendix A of the Performance Specification contains the Verification Cross Reference Matrix.

Each requirement paragraph (Section 3) in the specification is listed in this matrix providing a reference to the verification paragraph in Section 4 that directs how the requirement is to be verified. The matrix should be referenced while writing test procedures to ensure that they correctly cover all relevant requirements.

3.3.2 Contractor Support

For all testing, including testing that may be conducted at Government facilities, full contractor support shall be required. This shall include, as a minimum, technical representative support (on an on-call basis), operating and maintenance instructions and spare parts/materials. If the

Government determines that a repair is beyond their capability or capacity, the contractor shall arrange for qualified personnel to make the repair. Consumables, periodic maintenance items, wear items, and special tools shall also be made available to support the test program. (CLINs

0005, 0006, 0009 & 0010)

3.3.3 Reliability and Maintainability Demonstrations (RDEMO & MDEMO)

A RDEMO and MDEMO are part of the overall test program. They are conducted to determine, demonstrate and assure that all specified reliability and maintainability requirements, for all modes of end item operation, of the Performance Specification have been met.

A Reliability Demonstration Test Plan and Procedures shall be prepared by the contractor as part of the EDM Test Plan and Procedures (CDRL T001). The Plan shall identify, describe, and integrate all tests, tasks, and activities that provide data for evaluating and demonstrating the reliability of the system. The Procedures shall identify and describe all detailed procedural aspects of the Reliability Demonstration, for all modes of operation for which reliability requirements have been established in the Performance Specification. All life-limited parts with an expected life

(hours) less than the total hours specified above, shall be identified to the Government for

Government approval, prior to starting the RDEMO.

NAVAIR must be notified prior to the start of the RDEMO. RDEMO data sheets documenting hours accrued shall be submitted to NAVAIR on a weekly basis. RDEMO data sheets shall be in contractor’s format but shall include, at minimum, the following data: date, operator initials, engine start time, description of operation performed (e.g., operation performed, weight towed, distance traveled), operation start time, operation end time, servicing/maintenance performed, and comments.