SAH_SOW_Final_Signed.pdf

NAVAL AIR WARFARE CENTER

Aircraft Division

SHIPBOARD AIRCRAFT HANDLER (SAH)

STATEMENT OF WORK (SOW)

Naval Air Warfare Center Aircraft Division

SE and ALRE Department

CSE/PSE Development and ISE Division

Lakehurst, New Jersey, 08733

13 October 2016

Prepared for:

Commander, Naval Air Systems Command

PMA-260

Patuxent River, MD 20670

APPROVED: David Sutherland (Digitally Signed 24 Oct 2016)

TITLE: PROGRAM MANAGER

(PMA-260C)

TABLE OF CONTENTS

1.0 SCOPE

1.1 BACKGROUND

1.2 OBJECTIVES

2.0 APPLICABLE DOCUMENTS

2.1 ISSUES OF DOCUMENTS

2.2 DOCUMENTS

2.3 ACRONYMS

3.0 REQUIREMENTS

3.1 PRIME MISSION EQUIPMENT

3.1.1 Design

3.1.2 Assemble/ Manufacture

3.1.3 Testing

3.1.4 Production

3.1.5 Support

3.2 PROGRAM MANAGEMENT/SYSTEMS ENGINEERING

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 PRODUCT DATA (LPD) REQUIREMENTS

4.2.1 Logistics Guidance Conference

4.2.2 Product Supportability Analysis Plan (PSAP)

4.2.3 Logistics Products Data Reviews

4.2.4 Logistics Product Data (LPD) Record

4.2.5 Logistics Product Data Attribute Selection Sheets

4.2.6 Logistics Product Data (LPD) Candidate List

4.2.7 Identification of Functional Requirements

4.2.8 Level of Repair Analysis (LORA)

4.2.9 Maintenance Plan (MaPl)

4.2.10 Task Narrative

4.2.11 Support Equipment/Tools

4.2.12 Maintainability Demonstration (MDEMO)

4.2.13 Provisioning Technical Documentation (PTD)

4.2.14 Interim Support Item List (ISIL)

4.3 ITEM UNIQUE IDENTIFICATION (IUID) PLAN/MARKING OF U. S. MILITARY PROPERTY30

4.3.1 Construct and Method

4.3.2 UID Location and Marking

4.3.3 Permanency and Legibility

4.3.4 UID Registration

4.3.5 UID Records

4.4 TECHNICAL MANUALS

4.4.1 Technical Manual Warranty

4.5 TRAINING REQUIREMENTS SUMMARY

4.5.1 Training Integrated Master Schedule (IMS)

4.5.2 Training Situation Analysis

4.5.3 Initial Familiarization Training Conduct Requirements

4.5.4 DT-C2 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

4.5.11 Instructional Media Design Package (IMDP)

4.5.12 Onscreen Lessons and Training delivery

4.5.13 Instructional Media Package

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 DESIGN CHANGE NOTICE (DCN)

4.9 PACKAGING, HANDLING, STORAGE AND TRANSPORTATION (PHS&T)

4.10 WARRANTY

APPENDIX A

PROVISIONING STATEMENT OF WORK (PSOW)

LPD ATTRIBUTE SELECTION SHEETS

SPECIFIC INSTRUCTIONS: TOP-DOWN BREAKDOWN GUIDELINES

SPECIFIC INSTRUCTIONS: ADDITIONAL DATA REQUIREMENTS FOR DESIGN

CHANGE NOTICES

DEMILITIZATION CODE GUIDANCE

CRITICALITY CODING GUIDANCE

APPENDIX B

TECHNICAL MANUAL CONTRACT REQUIREMENT (TMCR)

APPENDIX C

CONTRACT DATA REQUIREMENTS LIST (CDRL) DD 1423

APPENDIX D

PHYSICAL CONFIGURATION AUDIT PROCEDURES

1.0 SCOPE

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 Shipboard

Aircraft Handlers (SAHs) that meet the requirements of the Request for Proposal N68335-15-R-

0119.

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

SAHs. The SAH will replace the A/S32A-32 Spotting Dolly currently used in the fleet. It will be issued to CVN, LHD and LHA-6 class ships. The SAHs are required to support aircraft operations at the Organizational Level and will be maintained at the Intermediate level. This need is based on the combination of existing, new, and future aircraft requirements.

1.2 OBJECTIVES

The objectives for this procurement are to enhance capability and performance while satisfying the mission of shipboard aircraft movement with a new state-of-the-art SAH. This is to be accomplished by replacing the existing Navy A/S32A-32 Spotting Dolly with a new more capable SAH. The five SAH Pilot Production Units (PPUs) are to be procured on the first delivery order along with engineering and logistics data to support contractor and Government testing. Following programmatic, systems engineering, test results and logistics reviews with the

Contractor during the design and development phase of the program, 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 for production units and grant release for production to the contractor. The contractor will then be required to produce, deliver, and provide logistics support for the SAHs.

2.0 APPLICABLE DOCUMENTS

2.1 ISSUES OF DOCUMENTS

The following specifications, standards and publications of the issue in effect on the date of the request for proposals, unless otherwise specified, form a part of this SOW to the extent specified herein. When specifications 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 4120.11 Functionality and Common and Feel Requirements for

NAVAIR’s Technical Manuals

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

MIL-PRF-29612B Training Data Products

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

MIL-STD-3001-6A Structural Repair Information http://specs4.ihserc.com/Document/Document/ViewDoc?docid=AFEEIFAAAAAAAAAA http://specs4.ihserc.com/Document/Document/ViewDoc?docid=EXXJIFAAAAAAAAAA

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) .

2.3 ACRONYMS

AIM Authorizing Instructional Materials

AIMD Aircraft Intermediate Maintenance Department

ALRE Aircraft Launch and Recovery Equipment

ALS Acquisition Logistics Support

APMT Assistant Program Manager for Training (Government)

AOR Annual Operating Requirements

ANSI American National Standards Institute

BOM Bill of Materials

CC Criticality Code

CCD Course Completion Date

CDR Critical Design Review

CDRL Contract Data Requirements List

CLIN Contract Line Item

CLTM Contractor Logistics/Training Manager

CM Configuration Management

CONUS Contiguous (Continental) United States

COTS Commercial-Off-The-Shelf

CAI Critical Application Item

CSE Common Support Equipment

CSI Critical Safety Item

CTR Contractor Test Review

D - Level Depot Level

DCN Design Change Notice

DMSMS Diminishing Manufacturing Sources and Material Shortages

DOD Department Of Defense

DR Deficiency Report

DT-C1 Contractor Tests

DT-C2 Government Tests

ECP Engineering Change Proposal

FACA Failure Analysis and Corrective Action

FMECA Failure Mode Effects and Criticality Analysis

FRACAS Failure Reporting, Analysis and Corrective Action System

FRP Full Rate Production

FRPDR Full Rate Production Decision Review

GFE Government Furnished Material

GFI Government Furnished Information

GSE Ground Support Equipment

HM Hazardous Material

HMMP Hazardous Materials Management Program

I - Level Intermediate Level

IAW In Accordance With

ICAPS Interactive Computer Aided Provisioning System

ILS Integrated Logistics Support

IMS Integrated Master Schedule

IOC Initial Operating Capability

IPB Illustrated Parts Breakdown

IPR In Process Review

IPT Integrated Program Team

ISIL Interim Support Item List

IUID Item Unique Identification

LMI Logistics Management Information

LAR Learning Analysis Report

MaPl Maintenance Plan

MDEMO Maintenance Demonstration

MSD Material Support Date

MTBF Mean Time Between Failures

MTTR Mean Time To Repair

NAS National Aerospace Standard

NAVAIR Naval Air Systems Command

NAVSUP WSS Naval Supply Systems Command Weapons Systems Support

NAWCAD Naval Air Warfare Center Aircraft Division

NEC Naval Enlisted Classification

NSN National Stock Number

OCONUS Outside Contiguous (Continental) United States

OEM Original Equipment Manufacturer

PAGC Post Award Guidance Conference

PCA Physical Configuration Audit

PDF Portable Document File

PDR Preliminary Design Review

PHS&T Packaging, Handling, Storage and Transportation

PLISN Provisioning List Item Sequence Number

PMR Program Management Review

PPU Pilot Production Unit

PRR Production Readiness Review

PSOW Provisioning Statement Of Work

RDEMO Reliability Demonstration

RFA Request For Action

RFI Ready For Issue / Request For Information

SA Supportability Analysis

SAE Society of Automotive Engineers

SAS Supportability Analysis Summary

SE Support Equipment

SETR System Engineering Technical Review

SAH Shipboard Aircraft Handler

SM&R Source, Maintenance and Recovery Code

SMIC Special Maintenance Item Code

SOW Statement Of Work

SRA Shop Replaceable Assembly

SRR-II System Requirements Review-II

SVR System Verification Review

TDP Technical Data Package

TM Technical Manual

TMCR Technical Manual Contract Requirement

TRB Technical Review Board

TRR Test Readiness Review

UID Unique Identification

WRA Weapons Replaceable Assembly

3.0 REQUIREMENTS

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

3.1 PRIME MISSION EQUIPMENT

3.1.1 Design

Upon contract award for the ease of Life Cycle Support (LCS) the contractor shall design a SAH that meets all requirements of the SAH 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 as practical to the

Government, with a production history and proven track record. Use of non-standard or proprietary hardware shall require prior Government approval. The new SAHs are expected to be in service for the next 25 years.

3.1.2 Assemble/ Manufacture

Upon completion of the Critical Design Review (CDR) described in paragraph 3.2.2.5 and closure of any RFAs, the contractor shall assemble/manufacture five Pilot Production Units

(PPUs) in accordance with the approved initial product baseline (PPU build baseline) for testing.

3.1.3 Testing

Upon concurrence and approval of the Contractor Test Review (CTR) described in paragraph

3.2.2.6, the contractor shall start PPU testing, know as contractor testing or DT-C1. Testing methods are detailed in Section 4.0 of the SAH Performance Specification for each Section 3.0 requirement as identified in the Verification Cross-Reference Matrix (SAH Performance

Specification Appendix A). Upon completion of the Test Readiness Review (TRR) described in paragraph 3.2.2.7, and closure of any RFAs, the contractor shall provide two PPUs to the

Government for Government Test, also know as DT-C2.

3.1.4 Production

The contractor shall incorporate all approved and verified SAH modifications identified during contractor and Government testing into the Technical Data Package prior to the SVR/PRR described in paragraph 3.2.2.8. Upon the Government's issuing orders for production units and granting release for production, the contractor shall produce and deliver the production quantities in accordance with the Delivery Schedule (Section F) of the contract. The Government shall provide the PPUs as Government Furnished Equipment (GFE) after the completion of the test program and the contractor shall refurbish and upgrade them to production configuration. The

PPUs shall be inspected and successfully pass all tests identified in the Production Acceptance

Test Procedures (CDRL T003) and delivered in production configuration in the first production lot.

3.1.5 Support

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

3.2 PROGRAM MANAGEMENT/SYSTEMS ENGINEERING

3.2.1 Program Management

The contractor shall report the schedule progress (including critical path) of the program using the 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/ Post Award Guidance Conference (SRR-II/PAGC) (paragraph 3.2.2.2). All PMRs shall be designated in the IMS and 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:

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

2) Problem and risk identification, assessment, reduction and control

3) Streamlining recommendations

4) Technical review

5) Technical Drawing Package status

6) Logistics review

7) Configuration management

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

9) Subcontract management activity status

10) Personnel and staffing level status

11) Quality and corrective action plan status

12) Action items completed, pending and forecasted

13) Required Government Furnished Equipment (GFE)

14) 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

3.2.2.1 Systems Engineering Process

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

Engineering Technical Reviews (SETRs) will be used during the procurement of the SAH. The

TIMs are 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 applicable conditions of the contract are being satisfied.

The SETRs are multi-disciplined product and process assessments consisting of technical, logistics, and Subject Matter Experts (SME) from both the contractor and Government Integrated

Product Team (IPT). SETRs enable an independent assessment of emerging designs against plans, requirements, processes and key knowledge points in the acquisition process. A team consisting of IPT members, Government Technical Authorities and competency subject matter experts participates in these SETRs.

Entrance criteria required for each SETR shall be met prior to the SETR being held. Failure to complete entrance or exit criteria 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 that action, a recommended action and an urgency (completion) date. Until all RFAs are completed (closed out), the SETR milestone cannot be passed. The Government Systems Engineer will provide formal SETR approval to the contractor via e-mail.

The SETRs detailed in paragraphs 3.2.2.2, 3.2.2.3, 3.2.2.5, 3.2.2.7 and 3.2.2.8 will be conducted in two parts. The first part will be a Technical Interchange Meeting (TIM) conducted by the contractor at their facility to prepare for and assess readiness to enter the SETR. The timing of this TIM will be determined when the contractor is within 60 days of meeting the entrance criteria. The contractor shall conduct the SETR at their facility with access via conference call/VTC for an independent Government chair and Technical Review Board (TRB) that will act as an impartial assessor of the technical review, program progress and risk. As such, the independent chair will recommend approval/disapproval to the Government Program Decision

Authority.

Agendas, presentations and meeting minutes for the TIMs and SETRs will be in accordance with

CDRL P002.

3.2.2.2 Systems Requirements Review-II (SRR-II)/Post Award Guidance Conference

(PAGC)

The SRR-II review ensures the contractor(s) understanding of the contract requirements including the Performance Specification, SOW, DoD Directives, statutory and regulatory guidance, and applicable public law has been correctly and completely represented in the

Performance Specification and can be developed within program cost/schedule constraints.

An independent Government chair and TRB will participate in the SRR-II as an impartial assessor of the program technical progress and risk. The understanding of 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 and 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 Specification (includes tailorable, derived, and correlated requirements) showing traceability to all requirements in Performance

Specification Section 3.0, and Test (Performance Specification Section 4.0).

(T008)

Identify any software/firmware configuration items

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

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

Present CSI/CAIs identification process

Identify any Support Equipment (SE) and Special Tools necessary for the SAH

(paragraph 4.2.11) for approval by the Government

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

Present drawing/documentation configuration management processes

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

Present the SAH 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

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

IMS with critical path (CDRL P001)

Key Performance Component Analysis - draft (T006)

Requirements Traceability Matrix (T008)

SRR-II 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

3.2.2.3 Preliminary Design Review (PDR)

The PDR 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 in compliance with the IMS

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 item 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 should 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 the required draw bar pull and lift capacity verifying it will meet or exceed the

Performance Specification requirements (CDRL T006)

Present results/ status of all structural analyses (CDRL T007)

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

(CDRL E005)

Provide a preliminary reliability prediction which 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)

Ensure 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

Discuss the plan to develop the Technical Drawing Package

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.

A CSI/CAI list (see Appendix A, PSOW paragraph 20) shall be provided, if applicable, with criticality justification

Ensure Logistics Element requirements are allocated in the design

Entrance Criteria for PDR

SRR-II closure

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

IMS with critical path (CDRL P001)

Key Performance Component Analysis (T006)

Structural Analysis – draft (T007)

Requirements Traceability Matrix (T008)

Failure Modes, Effects, and Criticality Analysis (E005)

Tech Manual Outline (CDRL L007)

PDR Closure

PDR Minutes & Action Items (CDRL P002)

Allocated baseline established

All RFAs are resolved

Required CDRLs (above) have been approved by the Government

3.2.2.4 Technical Drawing Package and Review

3.2.2.4.1 Technical Drawing Package: The contractor shall deliver a Technical Drawing

Package IAW CDRL P003 that the Government will use to support and rework the SAH as required.

The SAH is 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 SM&R code shall have overhaul source data such as configuration drawings and repair/overhaul instructions provided.

(CDRL L013)

3.2.2.4.2 Technical Drawing Package Review: The contractor shall conduct a Technical

Drawing Package Review at their facility in compliance with the IMS and 15 or more days prior to the CDR. The objective of this review 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 Technical

Drawing Package represents the baseline PPU configuration that will be built and tested and is suitable to meet the logistic documentation requirements.

3.2.2.5 Critical Design Review (CDR)

The CDR is a technical assessment establishing the initial product baseline for the PPU design to ensure that the system under review has a reasonable expectation of being judged operationally effective and suitable and complies with the SAH Performance Specification. Upon approval of the CDR the PPU design is frozen and any proposed changes shall have NAVAIR concurrence prior to being incorporated.

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 implements the performance requirements of the Performance Specification and the methods planned to verify the design

Present the status of the Technical Drawing Package Review (CDRL P003)

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

Component Analysis (CDRL T006), Structural Analysis (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

3.2.2.12.1

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 pilot production (CDRL P005)

Validate design readiness, resolution of production engineering problems, accomplishment of production phase planning, contractor identified program risks and program schedule

Present the planned test schedule, test locations, 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 System Level Hazard Analysis (CDRL E002)

Present results of System Safety Hazard Analysis (CDRL E003)

Entrance criteria for CDR:

PDR Closure

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

IMS with critical path (CDRL P001)

Technical Drawing Package Review conducted (CDRL P003)

Structural Analysis (T007)

Requirements Traceability Matrix (T008)

First Technical Manual In Process Review (IPR) conducted (CDRL L007)

Logistics Product Data Candidate List (CDRL L003)

CDR Closure:

CDR Minutes & Action Items (CDRL P002)

Initial product baseline established (PPU build baseline)

All RFAs are resolved

Technical Drawing Package Review has been successfully completed

Required CDRLs (above) have been approved by the Government

First Technical Manual IPR has been successfully completed

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

3.2.2.6 Contractor Test Review (CTR)

The CTR is a detailed review conducted to confirm there is a high probability the equipment shall successfully complete contractor testing, DT-C1. This review will ratify the completeness of the test procedures and compliance with test requirements of the Performance Specification

Section 4.0.

The contractor shall:

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

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

Present any design changes since CDR

Present summary of test procedures

Show compliance with test requirements of the Performance Specification Section 4.0

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

Provide a tour of the SAH assembly area

Provide a functional and operational demonstration of the SAH'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 with critical path (CDRL P001)

Pilot-Production Test Plan and Test Procedures (CDRL T001)

One operational SAH PPU

CTR Closure

CTR Minutes & Action Items (CDRL P002)

Test baseline established

All RFAs are resolved

Required CDRLs (above) have been approved by the Government

3.2.2.7 Test Readiness Review (TRR)

The TRR is a detailed review of the contractor testing conducted in preparation for Government

Testing. The contractor shall:

Conduct a TRR at their facility in compliance with the IMS and prior to shipping PPUs for Government Test DT-C2

Present results of tests (required as entrance criteria below)

Present details of any failures that have occurred

Present details of any design changes since CTR

Present configuration status of PPUs to be used for DT-C2

Present status of resources (PPUs, spare parts, personnel, etc.) contractor will provide to support DT-C2

Present DT-C2 Test Training Status (CDRL L011)

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

Entrance criteria for the TRR

CTR closure

TRR Agenda & Presentation (CDRL P002)

IMS with critical path (CDRL P001)

Third Technical Manual IPR conducted (CDRL L007)

Maintenance Plan review conducted in concurrence with Third TM IPR

Pilot Production Test Report (draft - including successful results of the below mentioned tests) (CDRL T002)

The following Performance Specification tests shall be successfully completed:

Visual Examination of Unit

Functional Demonstrations

Draw Bar Pull

Lift Capacity Test

Tow bar interface DBP Test

Speed Tests

Braking Tests

Lifting / Tie Down Test

Shipboard Vibration Test

Shipboard Shock Test

Low/High Temperature Operation Tests

Salt Fog Test

Storage in Wind Test

EMI Compatibility Test

HERO Test

Emergency Manual Disengage Test

Towing Test

Fault Detection / Isolation Test

TRR Closure:

TRR Minutes & Action Items (CDRL P002)

All RFAs are resolved

Required CDRLs (above) have been approved by the Government

Third Technical Manual IPR has been successfully completed

DT-C2 Training has been successfully completed (CLIN 0004)

Maintenance Plan review has been successfully completed

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

The SRV/PRR is a product and process review that ensures the SAH 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 the Pilot Production tests (contractor and Government testing), 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 the Pilot Production tests. The SVR/PRR is used to confirm that any changes negotiated as a result of issues found during contractor testing or Government testing 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.

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

An Incremental Production Readiness Review (iPRR) shall be conducted prior to 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.

The review shall also be conducted to assess changes in design, configuration management, quality assurance or manufacturing processes that impact planned production, cost and schedule activities.

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 Requirements Taceability Matrix (RTM) showing how all requirements have been met and verified

Present PPU 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 analysies have been updated to the production baseline and put under configuration management; identify CAI/CSI components, and properly address critical and major classifications for inspections

Describe 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

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 with critical path (CDRL P001)

Technical Drawing Package (CDRL P003)

Pilot Production Test Report (CDRL T002)

Production Acceptance Test Plan and Procedures (CDRL T003)

Completed Failure Analysis and Corrective Action Report (CDRL T005)

Requirements Traceability Matrix (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

3.2.2.9 Physical Configuration Audit (PCA)

The contractor shall coordinate with the Government to conduct a Physical Configuration Audit

(PCA) on a production unit within 2 months after the first production unit is complete. The objective 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). (CLIN 0007)

3.2.2.10 Hazardous Materials Management Program (HMMP)

The contractor shall maintain a Hazardous Materials Management Program (HMMP) in accordance with National Aerospace Standard (NAS) 411, NASC Number 7013, “Hazardous

Materials Management Program.” In designing, manufacturing, testing, operating, maintaining and disposing of the SAH, 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 and all vendors, suppliers, and subcontractors 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 be responsible for ensuring vendor, supplier, and subcontractor performance.

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. A description of the organization and functional relationships relevant to the identification, evaluation, management, and disposal of hazardous materials.

b. A brief description of the processes and methods that the contractor shall use to identify hazardous materials used during the manufacture, operation, or maintenance of the unit.

c. A brief description of the regulations relevant to hazardous material at each location where activities will be performed (i.e. pre-production activities, contractor testing, production activities) and the plans for compliance with those regulations.

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 SAH 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/waste name

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

c. If a hazardous material, the part number of the component that contains the hazardous material or that the hazardous material is used on

d. If a waste, the process which generates the waste

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)

g. If applicable at the time of delivery, any U.S. statutory phase-outs or bans for the hazardous material or any ingredient or constituent.

If the hazardous material is or contains a Priority II Chemical, the Report must also include 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)

3.2.2.12 Reliability and Maintainability (R&M) Program

The contractor shall maintain a comprehensive R&M program to ensure that SAH meets the

R&M standards set forth in the SAH 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 SAH 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 Reliability and

Maintainability 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 SAH Performance Specification.

The Maintainability Program shall be planned and accomplished in accordance with SAE

JA1010, MIL-HDBK-470A, Section 4 of the SAH Performance Specification, and the SAH

ALSSOW.

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 SAH system design and provide inputs into logistics support analyses. The reliability prediction shall provide a prediction of Mean Time Between Failure (MTBF) for the

SAH. 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 SAH Performance Specification.

Reliability and maintainability predictions 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 SAH because of the demand for maintainence 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 SAH 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 SAH 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.

3.3.1 Responsibility for Compliance

All items shall meet all requirements of 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 PPU 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.

(CLIN 0006)

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 PPU Test Plan and Procedures (CDRL T001).