SPI_Statement_of_Work_20Mar2015.pdf

PMA260

PMA260C13/4332

STATEMENT OF WORK

FOR THE

STATIONARY PENETRANT INSPECTION SYSTEM

Naval Air Systems Command

Naval Air Warfare Center, Aircraft Division

SE and ALRE Department

SE and ALRE Systems Engineering Division

Lakehurst, New Jersey 08733-5109

20 March 2015

Prepared For:

Commander, Naval Air Systems Command

PMA260

Patuxent River, MD 20670

Statement of Work for the Stationary Penetrant Inspection (SPI) System 20 March 2015 ii

REVISION HISTORY

Date Version Remarks Author 2 June 14 1.0 Release for review LSE

18 June 14 2.0 See SPI Comment Tracker for detailed changes. LSE

24 July 14 3.0 See SPI Comment Tracker for detailed changes. LSE

6 August 14 4.0 See SPI Comment Tracker for detailed changes. LSE

7 October 14 5.0 See SPI Comment Tracker for detailed changes. LSE

20 March 15 6.0 See SPI Comment Tracker for detailed changes. LSE iii

TABLE OF CONTENTS

SCOPE ...................................................................................................................................... 7 1

PURPOSE ......................................................................................................................... 7 1.1

OBJECTIVES .................................................................................................................... 7 1.2

BACKGROUND ................................................................................................................ 7 1.3

MANAGEMENT ............................................................................................................... 7 1.4

COMMUNICATIONS ......................................................................................................... 7 1.5

APPLICABLE DOCUMENTS ...................................................................................................... 7 2

REQUIREMENTS ..................................................................................................................... 10 3

PROGRAM MANAGEMENT REVIEW (PMR) .................................................................. 10 3.1

POST AWARD CONFERENCE .................................................................................... 10 3.1.1

SAFETY ......................................................................................................................... 10 3.2

SYSTEM SAFETY HAZARD ANALYSIS ...................................................................... 10 3.2.1

SYSTEM WAIVERS .................................................................................................... 12 3.2.2

QUALITY ASSURANCE .................................................................................................. 12 3.3

QUALITY MANAGEMENT ......................................................................................... 12 3.3.1

QUALITY ASSURANCE PROGRAM PLAN .................................................................. 12 3.3.2

HAZARDOUS MATERIALS MANAGEMENT .................................................................... 12 3.4

HAZARDOUS MATERIALS MANAGEMENT PROGRAM ............................................... 12 3.4.1

HAZARDOUS MATERIALS MANAGEMENT PROGRAM PLAN .................................... 12 3.4.2

HAZARDOUS MATERIALS MANAGEMENT PROGRAM REPORT ................................ 12 3.4.3

SUB-CONTRACTORS, VENDORS AND SUPPLIERS ..................................................... 13 3.4.4

LITHIUM BATTERIES .................................................................................................... 13 3.5

TECHNICAL DATA PACKAGE ........................................................................................ 13 3.6

INSTALLATION INSTRUCTION .................................................................................. 13 3.6.1

SYSTEMS ENGINEERING TECHNICAL REVIEWS............................................................ 13 3.7

CONTRACTOR SETR RESPONSIBILITIES .................................................................. 13 3.7.1

SYSTEM REQUIREMENTS REVIEW-II ....................................................................... 14 3.7.2

PRELIMINARY DESIGN REVIEW ............................................................................... 14 3.7.3

CRITICAL DESIGN REVIEW ...................................................................................... 15 3.7.4

CONTRACTOR TEST REVIEW .................................................................................... 15 3.7.5

SYSTEM VERIFICATION REVIEW/PRODUCTION READINESS REVIEW ...................... 16 3.7.6

TECHNICAL INTERCHANGE MEETINGS ........................................................................ 17 3.8

TESTING ....................................................................................................................... 17 3.9

PILOT PRODUCTION TEST PROGRAM ....................................................................... 17 3.9.1

PILOT PRODUCTION TESTING ........................................................................ 17 3.9.1.1

FAILURE REPORTING, ANALYSIS AND CORRECTIVE ACTION SYSTEM ......... 17 3.9.1.2

INDEPENDENT GOVERNMENT TESTING ......................................................... 18 3.9.1.3

CONTRACTOR SUPPORT DURING TESTING .................................................... 18 3.9.1.4

DEFICIENCY REPORTS.................................................................................... 18 3.9.1.5

PRODUCTION ACCEPTANCE TEST PROGRAM ........................................................... 18 3.9.2

PRODUCTION ACCEPTANCE TEST PROCEDURES ........................................... 18 3.9.2.1

PRODUCTION ACCEPTANCE TEST REPORT .................................................... 18 3.9.2.2

FULL-RATE PRODUCTION UNIT DELIVERY ................................................... 19 3.9.2.3

PHYSICAL CONFIGURATION AUDIT ............................................................... 19 3.9.2.4

INTEGRATED LOGISTICS SUPPORT ........................................................................................ 20 4

PURPOSE ....................................................................................................................... 20 4.1

INTEGRATED LOGISTICS SUPPORT REQUIREMENTS ..................................................... 20 4.2

CONTRACT MODIFICATIONS .......................................................................... 20 4.2.1.1

CONTRACTOR ILS MANAGEMENT ................................................................. 20 4.2.1.2

SUBCONTRACTOR(S) ................................................................................................ 21 4.2.2 iv

VENDOR DATA REQUIREMENTS .............................................................................. 21 4.2.3

GOVERNMENT/CONTRACTOR INTERFACE ............................................................... 21 4.2.4

ILSMT REVIEWS ..................................................................................................... 21 4.2.5

LOGISTICS SUPPORTABILITY REQUIREMENTS ............................................................. 21 4.3

LOGISTICS GUIDANCE CONFERENCE ....................................................................... 21 4.3.1

LOGISTICS PRODUCT DATA (LPD) CANDIDATE LIST .............................................. 21 4.3.2

LEVEL OF REPAIR ANALYSIS (LORA) ..................................................................... 22 4.3.3

MAINTENANCE PLAN INPUT DATA .......................................................................... 22 4.3.4

SUPPORT EQUIPMENT / SUPPORT MATERIAL REQUIREMENTS ................................ 22 4.3.5

PROVISIONING TECHNICAL DOCUMENTATION (PTD) ............................................. 23 4.3.6

PROVISIONING INPUT DATA .......................................................................... 23 4.3.6.1

SUPPLY SUPPORT ........................................................................................... 23 4.3.6.2

ENGINEERING DATA FOR PROVISIONING....................................................... 23 4.3.6.3

STATEMENT OF PRIOR SUBMISSION .............................................................. 24 4.3.6.4

DIMINISHING MANUFACTURING SOURCES AND MATERIAL SHORTAGE................. 24 4.3.7

PROVISIONING CONFERENCES ................................................................................. 24 4.3.8

INTERIM SUPPORT ITEM LIST ................................................................................... 24 4.3.9

SOFTWARE, SUPPORT EQUIPMENT & SPECIAL TOOLS IDENTIFICATION ...................... 25 4.4

CALIBRATION REQUIREMENTS .................................................................................... 25 4.5

CALIBRATION AND MEASUREMENT REQUIREMENTS SUMMARY ........................... 25 4.5.1

INITIAL CALIBRATION OF DELIVERABLE ASSETS ................................................... 26 4.5.2

INSTRUMENT CALIBRATION PROCEDURES SOURCE DATA ...................................... 26 4.5.3

COMMERCIAL SERVICE PROVIDER .......................................................................... 26 4.5.4

TRAINING REQUIREMENTS ........................................................................................... 26 4.6

TRAINING REQUIREMENTS SUMMARY .................................................................... 26 4.6.1

DEVELOPMENTAL TESTING TRAINING .................................................................... 26 4.6.2

INITIAL FACTORY TRAINING.................................................................................... 26 4.6.3

GOVERNMENT FURNISHED INFORMATION .............................................................. 27 4.6.4

TECHNICAL DATA ........................................................................................................ 27 4.7

TECHNICAL MANUAL REQUIREMENTS (CDRL L013) ............................................. 27 4.7.1

QUALITY ASSURANCE (QA) .................................................................................... 27 4.7.2

TECHNICAL MANUAL VALIDATION ......................................................................... 27 4.7.3

TECHNICAL MANUAL VERIFICATION ...................................................................... 28 4.7.4

FINAL TECHNICAL MANUAL DELIVERY .................................................................. 28 4.7.5

ITEM UNIQUE IDENTIFICATION MARKING OF US MILITARY PROPERTY ..................... 28 4.8

CONSTRUCT AND METHOD ..................................................................................... 28 4.8.1

UID LOCATION AND MARKING ............................................................................... 28 4.8.2

PERMANENCY AND LEGIBILITY............................................................................... 28 4.8.3

UID REGISTRATION ................................................................................................. 28 4.8.4

WARRANTY .................................................................................................................. 29 4.9

CONFIGURATION AND OBSOLESCENCE MANAGEMENT .............................................. 29 4.10

PACKAGING, HANDLING, STORAGE, AND TRANSPORTATION (PHS&T) ..................... 29 4.11

PERSONNEL REQUIREMENTS ................................................................................. 29 4.11.1

PACKAGING REQUIREMENTS DATA....................................................................... 29 4.11.2

EXISTING MULTI-APPLICATION CONTAINERS ....................................................... 30 4.11.3

NEW SPECIALIZED CONTAINERS ........................................................................... 30 4.11.4

MARKING REQUIREMENTS .................................................................................... 30 4.11.5

HANDLING AND STORAGE REQUIREMENTS .......................................................... 30 4.11.6

ELECTROSTATIC SENSITIVE DEVICES .................................................................... 30 4.11.7

HAZARDOUS MATERIAL ........................................................................................ 30 4.11.8

TRANSPORTATION ................................................................................................. 31 4.11.9 v

RETURN OF FAILED ITEMS TO DEPOT ............................................................... 31 4.11.10

PLASTICS REMOVAL IN MARINE ENVIRONMENT .............................................. 31 4.11.11

EUROPEAN UNION RESTRICTIONS REGARDING NON-MANUFACTURED WOOD 4.11.12

PACKAGING AND PALLETS

ADDITIONAL PACKAGING REQUIREMENTS ....................................................... 31 4.11.13

CONTRACT DATA REQUIREMENTS LIST ............................................................................... 31 5

DATA ITEM NUMBERS .................................................................................................. 32 5.1

DISTRIBUTION STATEMENTS ........................................................................................ 32 5.2

APPENDIX A: ACRONYMS & ABBREVIATIONS

APPENDIX B: TECHNICAL DATA PACKAGE OPTION SELECTION WORKSHEET

APPENDIX C: PROVISIONING STATEMENT OF WORK (PSOW)

APPENDIX D: TECHNICAL MANUAL CONTRACT REQUIREMENTS (TMCR)

APPENDIX E: CONTRACT DATA REQUIREMENTS LIST (CDRL)

APPENDIX F: LOGISTICS SUPPORTABILITY REQUIREMENTS

APPENDIX G: PHYSICAL CONFIGURATION AUDIT (PCA) PROCEDURES

vi

TABLES AND FIGURES

Tables

TABLE 1 - HAZARD RISK CRITERIA

TABLE 2 - MAINTENANCE PLAN INPUT DATA DEFINITIONS

TABLE 3 - PROVISIONING INPUT DATA DEFINITIONS

Figures

FIGURE 1 - TDP OPTION SELECTION WORKSHEET

SCOPE 1

PURPOSE 1.1

This Statement of Work (SOW) identifies the contractor’s tasks required during the various phases of the program to design, manufacture, assemble, test, produce and support the Stationary Penetrant Inspection (SPI)

System. All reference to “days” herein shall be considered calendar days.

OBJECTIVES 1.2

This SOW is designed to accomplish the following objectives:

a. Establish valid contractual minimums relative to design requirements and facilitate planning, management, execution of the SPI System program.

b. Influence the SPI System’s design to the maximum extent possible, within program schedules, relative to design and supportability.

c. Provide a specific SOW that will permit the Contractor to respond with valid cost, schedule, and resource commitments to satisfy SPI System program requirements.

BACKGROUND 1.3

The U.S. Navy and Marine Corps require the use of a Stationary Penetrant Inspection (SPI) System that will provide the capability to perform Type I, Post-Emulsifiable Hydrophilic (Method D) Penetrant Inspections as defined in NAVAIR 01-1A-16-1 to detect discontinuities such as cracks, laps, cold shuts, corrosion, and porosity that are open or connected to the surface being inspected.

MANAGEMENT 1.4

The Contractor shall provide the organization, management and administrative services as required to design, develop, manufacture, test, inspect and produce the SPI System. The organization shall be established with authority delegated at appropriate levels to effectively accomplish the objectives of the program within schedule, and performance requirements. The Contractor is responsible for monitoring and controlling their subcontractors’, suppliers’ and vendors’ performance to ensure that their products, services and data meet all of the requirements of this SOW and the contract.

COMMUNICATIONS 1.5

The Contractor shall establish a procedure to report the status of key events, problems and achieved milestones as they occur rather than rely solely on the various scheduled periodic reviews.

APPLICABLE DOCUMENTS 2

Below is a list of external documents applicable to this SOW. This SOW takes precedence if a conflict exists between this SOW and any other document specified herein. Equivalent or better specifications and standards may be substituted upon approval of the Navy. Unless otherwise noted, the most recent revision at the time of contract award shall apply for each document.

Government

Standards

FED-STD-313 Federal Standard Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials

Furnished to Government Activities

MIL-STD-31000 Technical Data Packages

MIL-STD-882E System Safety Report Requirements

MIL-STD-130N Department of Defense Standard Practice Identification Marking of U.S. Military Property

MIL-STD-2073-ID Department of Defense Standard Practice for Military Packaging

MIL-STD-129P Department of Defense Standard Practice Military Marking for

Shipment and Storage

GEIA-STD-0007-A Logistics Management Information

Manuals

NAVSEA S9310-AQ-SAF-010 Technical Manual for Batteries, Navy Lithium Safety Program

Responsibilities and Procedures

NAVAIR 17-35NCE-1 Navy Calibration Equipment (NCE) List

NAVAIR 17-35QAC-01 Naval and Marine Corps Calibration Laboratory

Audit/Certification Manual

NAVAIR 01-1A-16-1 Nondestructive Inspection Methods, Basic Theory

Specifications

MIL-B-81997 Detail Specification Pouches, Cushioned, Flexible, Electrostatic-

Protective, Transparent

MIL-B-117& MIL-DTL-117 Detailed Specification Bags, Heat-Sealable

MIL-PRF-81705 Performance Specification Barrier Materials, Flexible, Electrostatic Protective, Heat Sealable

PMA260C13/4334 System Specification (SS) for the Stationary Penetrant

Inspection System

Handbooks

MIL-HDBK-61 Configuration Management Guide

MIL-HDBK-1839C Calibration and Measurement Requirements

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

MIL-HDBK-263 & MIL-STD-1686 Military Handbook, Electrostatic Discharge Control Handbook for

Protection of Electrical and Electronic Parts, Assemblies and

Equipment (Excluding Electrically Initiated Explosive Devices)

GEIA-HB-0007A Logistics Product Data Handbook

Instructions

NAVAIRINST 13640.1B Naval Aviation Metrology and Calibration Program

NAVSUPINST 4030.46 Protection of Items Susceptible to Damage from Electrostatic

Discharge

OPNAVINST 3960.16 Navy Test and Monitoring System (TAMS)

Data Item Descriptions

DI-ADMN-81250A Conference Minutes

DI-CMAN-80639C Engineering Change Proposal

DI-CMAN-80640C Request for Deviation (RFD)

DI-MGMT-81650 Integrated Master Schedule (IMS)

DI-MGMT-81398C Hazardous Materials Management Program Plan

DI-MISC-81397C Hazardous Materials Management Program Report

DI-QCIC-80278A Calibration and Measurement Requirement Summary

DI-SAFT-80101B System Safety Hazard Analysis

DI-SESS-81002F Developmental Design Drawings/Models and

Associated Lists

DI-SESS-81315B Failure Analysis and Corrective Action Report

Other

TMCR 13-008 Technical Manual Contract Requirement

DFAR Clause 252.211-7003 Item Identification and Valuation

26003062009.0 PMA-260 Configuration Management Plan for Aviation Support

Equipment

Non-Government

ANSI/ISO/ASQ Q9001-2008 Quality management Systems Requirements Standard

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

SAE JA1000 Reliability Program Standard

SAE JA1000-1 Reliability Program Standard Implementation Guide

SAE JA1010-1 Maintainability Program Standard Implementation Guide

ASME Y14.34 Associated Lists

AIA/NAS 411, Rev 3 Hazardous Materials Management Program

REQUIREMENTS 3

PROGRAM MANAGEMENT REVIEW (PMR) 3.1

The Contractor shall present Program Management Reviews (PMRs) to the Government Program Manager and team. Integrated Logistics Support Management Team (ILSMT) review meetings and Systems Engineering

Technical Review (SETR) meetings will be scheduled in conjunction with the PMRs. The first PMR shall be the Post Award Guidance Conference (see 3.1.1). All PMRs shall be hosted by the Government unless otherwise directed. The Contractor shall provide the Government with an accurate summary of the

Contractor’s technical progress, program planning and overall management approach and progress. This shall be presented in the form of a PowerPoint presentation as described in CDRL A006. Topics to be addressed at the PMRs shall include but are not limited to:

1. Contract status, progress tracking and reporting of milestones

2. An Integrated Master Schedule (IMS)

3. Problem and risk identification, assessment, reduction and control

4. Technical review

5. Logistics review (ILSMT)

6. Subcontract management

7. Action items completed, pending and forecasted

The Contractor along with a Government representative will co-chair PMRs. Minutes and action items taken by the Contractor will be agreed to at the conclusion of each PMR and distributed by the Contractor in the

Government approved format, to the entire team (Contractor and Government representatives) within 7 calendar days of conclusion of meeting (Contract Data Requirement Lists (CDRL) A018). The viewgraph

(slide) presentations developed by the Contractor for the PMRs shall be provided to the Government

(Lakehurst) Program Manager and Systems Engineer at least 30 calendar days prior to the review (CDRL

A006) unless otherwise stated.

POST AWARD CONFERENCE 3.1.1

Within 30 Days After Contract Award (DACA), the Government shall host a Post Award Conference (PAC).

The PAC provides the contractor with an introduction to the government Integrated Product Team (IPT) and establishes a formal and informal means of communication. This meeting will include a full review of the

Integrated Master Schedule (IMS) (CDRL A017) to ensure agreement between both parties. During the PAC, all requirements of the SOW, CDRLs, SS, and any other salient contract requirements will be discussed.

Additionally, any preliminary questions or concerns that the contractor has with regard to the requirements of the contract may be discussed at this time. The viewgraph (slide) presentation for the PAC shall be developed by the Contractor and shall be provided to the Government (Lakehurst) Program Manager and Systems

Engineer at least 15 calendar days prior to the review (CDRL A006).

SAFETY 3.2

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. In addition, the contractor shall be responsible for ensuring that all vendors, suppliers, and subcontractors similarly perform all work under this contract in full compliance with all applicable Federal, State, and local environmental and occupational safety and health regulations.

SYSTEM SAFETY HAZARD ANALYSIS 3.2.1

The contractor shall perform and document a system safety hazard analyses to identify potential system hazards and all safety features of the hardware system design and to identify procedural and hardware related hazards that may be present in the system including specific procedural controls and precautions that should be followed. Each identified hazard is comprised of the expected severity and frequency of occurrence. A

Hazard Risk Index (HRI) and associated risk level shall be assigned to all hazards in accordance with Table 1.

The contractor shall obtain appropriate decision authority concurrence from the government for all identified hazards. The analyses shall include the identification of operating and support hazards and their controls. All phases of intended unit use, including but not limited to operation and maintenance shall be considered when incorporating safety features for the unit. System safety design guidance precedence of MIL-STD-882E shall be followed for the unit, its components, and all of its man and machine interfaces. A system Safety Hazard

Analysis (SHA) shall be submitted to the procuring activity in accordance with CDRL A001.

Table 1 - Hazard Risk Criteria

S E V E R I T Y

CATASTROPHI

C

(1)

Death or permanent total disability; system loss or mishap damage >

$10,000,000;

irreversible severe environmental damage that violates law or regulation

CRITICAL

(2)

Severe injury, occupational illness, or permanent partial disability; mishap damage (>

$500,000 but <

$10,000,000); or irreversible environmental damage that violates law or regulation

MARGINAL

(3)

Minor injury or minor occupational illness

(no permanent effect); mishap damage (> $50,000 but < $500,000);

NEGLIGIBLE

(4)

Less than minor injury or occupational illness

(no lost workdays);

mishap damage (<

$50,000), minimal environmental damage not violating law or regulation.

F R

E Q

U E

N C

Y

FREQUENT (A)

100/100K flt hrs

(P 1x10 -3

1 3 7 13

PROBABLE (B)

10-99/100K flt hrs

(1x10 -3

P 1x10 -4

2 5 9 16

OCCASIONAL (C)

1-9.9/100K flt hrs

(1x10 -4

P 1x10 -5

4 6 11 18

REMOTE (D)

0.1-0.99/100K flt hrs

(1x10 -5

P 1x10 -6

8 10 14 19

IMPROBABLE (E)

0.1/100K flt hrs

(1x10 -6

P)

12 15 17 20

RISK

LEVEL

HRI RISK CATEGORY DECISION AUTHORITY FOR

RESIDUAL RISK ACCEPTANCE

HIGH 1 – 5 Unacceptable Component Acquisition Executive (CAE)

SERIOUS 6 – 10 Undesirable Program Executive Officer (PEO) or equivalent

MEDIUM 11 – 17 Acceptable with Review Program Manager (PMA) or equivalent

LOW 18 - 20 Acceptable PMA

SYSTEM WAIVERS 3.2.2

Waivers to safety requirements in the SS shall require prior and written approval of the procuring activity.

Waivers will be granted only upon demonstration that the equipment has been tested in accordance with the appropriate Underwriters Laboratories (UL), government, or other industry consensus tests to demonstrate its safety for use in the military environment.

QUALITY ASSURANCE 3.3

QUALITY MANAGEMENT 3.3.1

The contractor shall continually manage and improve the quality of all products and services delivered under this contract and the processes by which they are realized. The system used by the contractor to manage quality shall be compliant with all requirements of, and at a minimum be functionally equal to, a current active version of the ANSI/ISO/ASQ Q9001-2008, Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing. The Government shall have the right to audit the contractor's quality system for ANSI/ISO/ASQ Q9001-2008 compliance. The Government shall have access, for review and analysis purposes, to contractor QMS documents; raw data that have not been subjected to processing or any other manipulation; summarized, tabularized, or graphical depictions of the data; and records under this contract.

QUALITY ASSURANCE PROGRAM PLAN 3.3.2

The contractor shall prepare and maintain a Quality Assurance Program Plan commensurate with ISO

10005:2005, Quality Management Systems - Guidelines for Quality Plans, for product and service deliverables under this contract.

HAZARDOUS MATERIALS MANAGEMENT 3.4

HAZARDOUS MATERIALS MANAGEMENT PROGRAM 3.4.1

The contractor shall be responsible for maintaining an effective Hazardous Materials Management Program

(HMMP) in accordance with the Aerospace Industries Association/National Aerospace Standard for the

HMMP (NAS 411). In designing, manufacturing, testing, operating, maintaining and disposing of the unit, 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 hazardous materials, which cannot be eliminated. In the event that a hazardous material must be used, the contractor must have the approval of the government. Approval for use of Restricted Chemicals as defined in the SS will not be given. Approval for use of Targeted Chemicals as defined in the SS shall require documentation of absence of suitable alternative.

HAZARDOUS MATERIALS MANAGEMENT PROGRAM PLAN 3.4.2

The contractor shall prepare a HMMP Plan. The plan shall be used to evaluate the contractor’s approach to, understanding of, and execution of an HMMP. (CDRL A002)

HAZARDOUS MATERIALS MANAGEMENT PROGRAM REPORT 3.4.3

A HMMP Report shall be prepared by the contractor in accordance with the Hazardous Materials Management

Program Report (CDRL A003). The report shall contain a well-defined table that identifies and lists all

HAZMAT as defined in the SS. As a minimum, the following information is required.

a) HAZMAT nomenclature/name

b) Technical documentation and/or specification that require the use of the HAZMAT, if applicable

c) Name and Part Number of the component/part that contains the HAZMAT or is associated with the use/generation of the HAZMAT

d) Process associated with the use or generation of the HAZMAT

e) Safety Data Sheets (SDS)/Material Safety Data Sheets (MSDS) for each HAZMAT

f) Chemical name(s) of hazardous component(s). (Sometimes found on SDS/MSDS)

g) Chemical Abstract Service (CAS) number(s) of each hazardous component(s)

h) Waste and disposal codes/regulations for the HAZMAT when appropriate

i) Weight of HAZMAT (as Parts Per Million (PPM) or per system/component as appropriate using best engineering judgment)

The contractor shall maintain and update this report throughout the life of the contract. Documentation justifying use of Targeted Chemicals shall also be included in the report.

SUB-CONTRACTORS, VENDORS AND SUPPLIERS 3.4.4

The contractor shall ensure that all vendors and suppliers including those of sub-contractors provide all information to accurately and fully complete the HMMP requirements.

LITHIUM BATTERIES 3.5

The use of lithium batteries as a part of the SPI System shall be documented in accordance with NAVSEA

S9310-AQ-SAF-010, “Technical Manual for Batteries, Navy Lithium Safety Program Responsibilities and

Procedures.” All documentation will be submitted to the Naval Ordnance Safety and Security Activity

(NOSSA) by the NAVAIR program office after the data is received from the contractor. (CDRL A004)

TECHNICAL DATA PACKAGE 3.6

The contractor shall develop a Technical Data Package (TDP) to support the government’s review of the SPI

System’s design. The TDP will allow the government to assess the contractor’s approach to meeting the requirements of the SS. During review of the TDP, any potential risk areas seen by the government will be brought to the attention of the contractor. However, it is ultimately the contractor’s responsibility to pass the verification requirements of the SS and therefore the contractor alone is responsible for making design decisions based on assessment of risk. The TDP shall be developed based on the form found in Appendix B, Figure 1 (as described in MIL-STD-31000) and delivered in accordance with CDRL A005.

INSTALLATION INSTRUCTION 3.6.1

The Contractor shall provide a complete installation instruction with figures for a complete assembly and disassembly of the SPI System. All the tools that are required for assembly, installation and disassembly of the

SPI System shall be listed in the installation instruction manual. This instruction manual shall be prepared and submitted to the Government in accordance with this SOW and CDRL A014.

SYSTEMS ENGINEERING TECHNICAL REVIEWS 3.7

A systems engineering process with Systems Engineering Technical Reviews (SETRs) will be used during the procurement of the SPI System. The technical reviews are conducted so the contractor can show progress toward meeting desired requirements in the form of a design solution and that the conditions of the contract are being satisfied. The SETRs are multi-disciplined product and process assessments consisting of technical, logistics, and Subject Matter Experts (SMEs) from the contractor and government IPT. Each SETR review will have an Independent Government Chair and Technical Review Board (TRB) who will act as impartial assessors of program progress and risk as well as entrance and exit deliverables. The Independent Chair will also have the final approval/disapproval decision of the review. Completion of each SETR should be entered as a milestone on the IMS (CDRL A017). The SETRs will be spaced out according to the contract schedule and will be reviewed with the contractor at the PAC.

CONTRACTOR SETR RESPONSIBILITIES 3.7.1

Prior to each SETR, a PowerPoint presentation shall be created for each SETR (CDRL A006). Enough background information should be provided in the presentation to bring the independent chair and TRB up to speed with the program. The presentation shall also include a slide each for any real or potential risks to the program’s execution within schedule and budget that have been identified by the contractor. Each risk slide shall include a description of the risk, the potential impact, and the contractor’s intended strategy to mitigate the risk. The contractor shall record minutes and action items from each meeting and provide tracking resolution (CDRL A018). Unless otherwise noted, the contractor shall be responsible for ensuring that each item identified as an entrance criterion is provided to the government at least 30 days prior to the related

SETR. All exit criteria should be completed by the SETR and should be presented at the meeting. Failure to complete entrance/exit criteria by the time the meeting is held will result in Requests For Action (RFAs) written by the government and provided to the contractor. Each RFA will indicate the specific problem/concern, the individual responsible for taking action on that problem/concern, a recommended action, and an urgency (completion) date. Until all RFAs are completed (closed out), the SETR milestone cannot be passed. RFAs will be provided to the contractor within 5 days after each SETR.

SYSTEM REQUIREMENTS REVIEW-II 3.7.2

The System Requirements Review-II (SRR-II) is used to ensure that the contractor understands the requirements of the SS, Statements of Work, statutory and regulatory guidance, and applicable public laws.

This meeting shall include a full review of the SS, and this SOW. During the meeting, contractor questions and concerns related to their contractual obligations will be addressed. This SETR shall be conducted concurrently with PAC.

Entrance Criteria

SRR-II Presentation (CDRL A006)

Updated IMS with critical path shown (CDRL A017)

Exit Criteria

All performance requirements are understood by the contractor

Understanding of logistics programs integration with the unit development, i.e. what elements are needed when

Risk level identified and accepted by Program/Competency leadership

The IMS is executable

PRELIMINARY DESIGN REVIEW 3.7.3

The Preliminary Design Review (PDR) is used to ensure that the contractor has mapped each requirement to a design solution. The Physical Allocated Baseline will be established at the PDR. This baseline defines the configuration items making up the SPI System and how the system function and performance requirements are allocated across those configuration items. The contractor shall present to the government a TDP representing at least 60% of the SPI System’s design at least 30 days prior to the SETR (CDRL A005). This SETR shall be conducted no later than 120 DACA. PDR shall be hosted at the government's location or via teleconference.

PDR Presentation (CDRL A006)

Updated IMS with critical path through the Critical Design Review (CDR) shown (CDRL A017)

First submittal of the System SHA (CDRL A001)

Submittal of the HMMP Plan (CDRL A002)

Initial submittal of the HMMP Report (CDRL A003)

Submittal of the Requirements Traceability Matrix Level I (CDRL A007) st submission of TDP (CDRL A005)

First Technical Manual submission (CDRL L013)

The preliminary design satisfies the top-level requirements

The presented design is considered 60% complete

A Physical Allocated Baseline configuration has been established

A final design solution is achievable by the CDR date

Acceptance of 1 st Technical Manual submission (L013)

Accepted first submittal of the System SHA (CDRL A001)

Acceptance of the Requirements Traceability Matrix Level I (CDRL A007)

A Physical Allocated Baseline configuration has been established (TDP Approved)

Risk level identified and accepted by Program/Competency leadership

The IMS is executable

CRITICAL DESIGN REVIEW 3.7.4

The Critical Design Review (CDR) is used to determine that the SPI System’s design is complete, baselined, and will meet the requirements of the contract. The Requirements Traceability Matrix (CDRL A007) is updated at this point to outline each performance requirement, a design solution to the performance requirement, and the verification method for the requirements. The TDP shall be at least 90% complete prior to this review (CDRL A005). This package will represent the Initial Product Baseline for the SPI System. The

Initial Product Baseline represents the configuration baseline to which Pilot Production Units (PPUs) will be built. Once the CDR is complete, the Initial Product Baseline is frozen and any changes must be reviewed and approved by the government. Prior to closure of the CDR the contractor is not authorized to begin construction of the PPUs; however, as long lead items are identified earlier during the design process the contractor should notify the government to allow authorization to order those parts. This SETR shall be conducted no later than

300 DACA. CDR shall be hosted at the government's location or via teleconference.

CDR Presentation (CDRL A006)

Updated IMS with critical path through testing shown (CDRL A017)

All previous SETR exit criteria has been met, all RFAs are closed out

Second submittal of the System SHA (CDRL A001)

Second submittal of the HMMP Report (CDRL A003)

Submittal of Engineering Data For Provisioning (EDFP) (CDRL L003)

Submittal of the Requirements Traceability Matrix Level II (CDRL A007) nd submission of TDP (CDRL A005)

Second Technical Manual submission (CDRL L013)

Submittal of the Pilot Production Testing (PPT) Test Procedures (CDRL A008)

The presented design is considered complete

Witnessed complete design through technical data package

Accepted second submittal of the System SHA (CDRL A001)

Accepted second submittal of the HMMP Report (CDRL A003)

Acceptance of the submission of EDFP (CDRL L003)

Acceptance of 2 nd

Technical Manual submission (L013)

Acceptance of the Requirements Traceability Matrix Level II (CDRL A007)

An Initial Product Baseline configuration has been established (2 nd submission of TDP Approved)

Risk level identified and accepted by Program/Competency leadership

The IMS is executable

CONTRACTOR TEST REVIEW 3.7.5

The Contractor Test Review (CTR) is used to assess test objectives, test methods, procedures, scope of tests, and determines if resources have been identified. During CTR, the contractor is ensured to have complete and detailed test procedures and compliance with test plans. The Test Configuration Baseline will also be established at CTR. This baseline represents the SPI System configuration that will be formally tested to verify conformance to the requirements of the SS. The Test Configuration Baseline will be represented by an updated, complete TDP representing the current configuration (CDRL A005). Formal testing will not be allowed to begin until the CTR milestone is passed. This SETR shall be conducted no later than 360 DACA.

CTR shall be hosted at the contractor's location with a capability of teleconference.

CTR Presentation (CDRL A006) o Presentation shall include a detailed discussion of any changes to the initial product baseline that was established at CDR.

Updated IMS (CDRL A017) o Full test schedule to include prep time, shipping time (to/from test locations), and actual test time.

o CTR delivery of CDRL A017 shall be made 30 days prior to the SETR.

All previous SETR exit criteria has been met, all RFAs are closed out

Submittal of the Requirements Traceability Matrix Level III (CDRL A007)

Approval of PPT Procedures (CDRL A008) rd submission of TDP (CDRL A005)All required test resources (people, facilities, test articles, test instrumentation) are identified and are available for testing

Acceptance of the Requirements Traceability Matrix Level III (CDRL A007)Logistical needs identified and available for contractor and government testing o Spare parts availability

A Test Configuration Baseline configuration has been established (3 rd submission of TDP Approved)

Risk level identified and accepted by Program/Competency leadership

The IMS is executable

SYSTEM VERIFICATION REVIEW/PRODUCTION READINESS REVIEW 3.7.6

The System Verification/Production Readiness Review (SVR/PRR) will be used to confirm that any changes during Pilot Production Testing and Independent Government Testing have been incorporated into the design and that a representative SPI Systems exists with those design elements incorporated. The contractor shall have a final TDP available for government review at least 30 days prior to this SETR as well as a printed copy at the review. The Final Product Baseline is established at this review. The Final Product Baseline is the configuration to which all production units will be built. The Final Product Baseline will be represented by an updated, complete TDP representing the current configuration incorporating any changes that resulted from

PPT or Independent Government Testing failures/DRs (CDRL A005). At this review, the IPT shall also review the readiness of the manufacturing processes, the Quality System, and the production planning (i.e.

facilities, tooling and test equipment capacity, personnel development and certification, process documentation, inventory management, supplier management, etc). The government decision to enter into full rate production decision review (i.e. award production options on the contract) will not be considered until the

SVR/PRR exit criteria are met. The SVR/PRR shall occur no later than 60 days after the successful completion of the Independent Government Testing. SVR/PRR shall be hosted at the contractor's location with a capability of teleconference.

SVR/PRR Presentation (CDRL A006)

Updated IMS (CDRL A017)

All previous SETR exit criteria has been met, all RFAs are closed out

Submittal of the Requirements Traceability Matrix Level IV (CDRL A007) th submission of TDP (CDRL A005)

All pilot production testing has been successfully completed

Submittal of the PPT Test Report (CDRL A009)

Submittal of Technical Manual fourth submission (L013)

Submittal of DR Resolution Reports (CDRL A010)

Production Representative SPI System is available

Submittal of Production Acceptance Test Procedure (CDRL A012)

Acceptance of the Requirements Traceability Matrix Level IV (CDRL A007)

All agreed upon DR resolutions have been incorporated into the PPUs and/or logistics documentation.

The design solution satisfies all requirements from the SS

The detailed design is producible within the production budget

A Final Product Baseline configuration has been established (4 th submission of TDP Approved)

Risk level identified and accepted by Program/Competency leadership

The IMS is executable

Approved Production Acceptance Test Procedures (CDRL A012)

TECHNICAL INTERCHANGE MEETINGS 3.8

In addition to the SETRs called out above, the contractor shall be available to support impromptu teleconferences. These teleconferences will be used as an opportunity for government personnel to troubleshoot, conduct contractor's progress checks, or discuss any other unforeseen events. The contractor shall ensure that all necessary contractor and Subcontractor personnel, along with any hardware or technical data, are available for each teleconference. For each teleconference, the government shall be responsible for recording the meeting minutes, as required.

TESTING 3.9

The contractor shall begin PPT immediately after closure of CTR. Independent Government Testing shall begin after the completion and government approval of PPT. The contractor shall allow the government to witness all testing. The contractor may forgo requested government testing with previous or equal test data after prior government approval. The government will determine whether supplied data is sufficient to forgo testing.

PILOT PRODUCTION TEST PROGRAM 3.9.1

The contractor shall produce two (2) PPUs 360 DACA for use during PPT. If calibration is required for the

SPI System, both PPUs shall be calibrated by the contractor prior to PPT. Additionally, any follow-on calibration required during the testing phase (PPT and Independent Government Testing) shall also be performed by the contractor. Both PPUs shall undergo all PPT testing in accordance with paragraph 3.9.1.1.

Once PPT is completed the contractor shall use one PPU for configuration control and maintain it at the contractor’s facility and ship the other PPU for use in Independent Government Testing in accordance with paragraph 3.9.1.3. Upon completion of testing the contractor shall refurbish both PPUs to production level standards and tested in accordance with the Acceptance Test Procedures (ATPs) in accordance with paragraph

3.9.2.1. These units, along with the technical data package, will represent the Final Product Baseline and will serve as models to which all production units will be built.

PILOT PRODUCTION TESTING 3.9.1.1

PPT will be used to test all requirements of the SS ensuring the SPI System can perform its mission in a standard environment as well as being subjected to environmental extremes. The contractor shall compile PPT procedures (CDRL A008) based on the PPT selected requirements in paragraph 4.0, Table 2 of the SS and the approved Requirements Traceability Matrix. The contractor may substitute commercial acceptance procedures as PPT procedures following government approval. PPT shall not begin until government approval of the PPT procedures and successful completion of CTR. The contractor will have 90 days to complete PPT and deliver a complete test report (CDRL A009) to the government. The Government reserves the right to witness and perform any of the inspections and tests where such tests and inspections are deemed necessary to ensure supplies and services conform to prescribed requirements. If, as a result of PPT, changes are needed to the

PPUs the contractor shall complete the modification and verify the modifications through follow-on testing.

FAILURE REPORTING, ANALYSIS AND CORRECTIVE ACTION SYSTEM 3.9.1.2

The contractor shall utilize a closed loop Failure Reporting, Analysis and Corrective Action System

(FRACAS) system for reporting, analyzing, and correcting failures that occur throughout development, testing and production down to the lowest replaceable assembly level. The contractor shall identify procedures for initiating failure reports; analyzing failures; and feeding of corrective action back into the design, manufacturing, and test processes. The FRACAS shall include provisions that ensure timely contractor-implemented corrective actions, and that provide for follow-up audits. The audits shall review all open failure reports, failure analyses, and corrective action suspense dates. The contractor shall notify the government of all failures within 24 hours. False alarms and failure to detect and/or isolate a failure shall be included in the

FRACAS program.

The contractor shall pass all FRACAS requirements to their sub-contractors. All subcontractors shall have the responsibility to pass the FRACAS requirement down to their subcontractors. Subcontractor FRACAS information shall be made available for government review and must be included in the prime contractors

FRACAS reports to the government.

Included in the FRACAS reporting shall be quantities of components that fail to pass quality assurance at the sub-contractors manufacturing facility and how many fail to pass acceptance test at the prime contractors facility. The contractor will notify the government immediately if a “Bad Actor” component from a sub-contractor impacts the IMS. If such an impact occurs the government shall work with the prime contractor to determine schedule slips and work around to ensure the successfully fielding of the SPI System. (CDRL

A011)

INDEPENDENT GOVERNMENT TESTING 3.9.1.3

The contractor shall send one PPU to the government for Independent Government Testing. The testing will allow government testers to analyze the PPU for fleet personnel suitability/supportability and further verify SS and SOW requirements. Upon completion of Independent Government Testing and release for Full Rate

Production (FRP), the PPU will be returned to the contractor for refurbishment after the first full monthly production quantity delivery has been received by the government. Both refurbished PPUs will be delivered as part of the final production quantity. Refurbishment shall include replacement of missing and/or damaged components. The contractor will be responsible for arranging and funding shipment of the PPU to and from the Independent Government Testing location which will be located at Jacksonville, Florida. The exact shipping address and point of contact will be provided prior to shipment.

CONTRACTOR SUPPORT DURING TESTING 3.9.1.4

The Contractor shall establish a support program for the SPI System. The Contractor shall supply, at no cost to the government, spare and repair parts required to correct failures/discrepancies/damage that occur during government testing. This testing is to include Pilot Production testing, verification and validation for the SPI

System. Appropriate consumables for periodic maintenance shall also be made available to support this effort.

This support shall be provided by the contractor within 72 hours of being notified of the requirement/need.

The Contractor may deploy technical representatives required to meet the performance requirements of the contract after coordination with the PCO.

DEFICIENCY REPORTS 3.9.1.5

Government testers will document any suitability, requirement, and supportability deficiencies in the form of

Deficiency Reports (DRs), which will then be supplied to the contractor. The contractor shall analyze and develop a resolution strategy for each DR (CDRL A010). Resolution strategies will be reviewed by the government and a decision on the course of action will be made. If the DR resolution results in a redesign of the unit, the contractor is required to repeat any PPT or government tests unless waived by the Government.

PRODUCTION ACCEPTANCE TEST PROGRAM 3.9.2

PRODUCTION ACCEPTANCE TEST PROCEDURES 3.9.2.1

The contractor shall provide a list of production ATPs for government approval. The acceptance test procedures are simple performance checks of SS requirements that the two refurbished PPUs and each production SPI System shall meet. The contractor shall compile ATPs based on the requirements indicated in the SS, Paragraph 4.0, Table 2. (CDRL A012)

PRODUCTION ACCEPTANCE TEST REPORT 3.9.2.2

The contractor shall provide a Production Acceptance Test Report detailing the results of each production unit and the two refurbished PPUs. The Production Acceptance Test Report shall display successful passing, failure, and failure resolution of all ATPs for all units tested. (CDRL A013)

FULL-RATE PRODUCTION…