PCPLT_SOW_V1_8.docx

NAWCADLKE HYD-CS-260-229

PMA260C21/4718

ENGINEERING STATEMENT OF WORK (SOW)

FOR THE

PNEUMATIC CABIN PRESSURE LEAKAGE TESTER (PCPLT)

Naval Air Warfare Center Aircraft Division SE and ALRE Department SE and ALRE Systems Engineering Division Lakehurst, New Jersey 08733-5109

Version 1.8 30 Oct 2015

Submitted by: Approved by:

Asif Yeahia, Code 4.8.6.10 David Sutherland, PMA-260C

Prepared For:

Commander, Naval Air Systems Command

PMA260

Patuxent River, MD 20670

REVISION HISTORY

PCPLT SOW 30OCT2015

TABLE OF CONTENTS

Tables

TABLE 1 - MEETINGS/REVIEWS SUMMARY 6

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 Pneumatic Cabin Pressure Leakage Tester (PCPLT) that meet the requirements of the Request for Proposal (RFP) N68335-13-R-XXXX.

Purpose The purpose of this Common Support Equipment (CSE) program is to satisfy the operational need of the United States Navy (USN) and United States Marine Corps (USMC) by providing a modified, commercially built, PCPLT as well as the requirements and services to be furnished by the Contractor in order to establish Acquisition Logistics Support (ALS) for the PCPLT. For successful support of the PCPLT it is critical that logistics support is in place with delivery of the first PCPLT to the fleet.

Objectives The Contractor shall provide a design that satisfies the requirements in the System Specification (SS) (PMA260C21/3490) and this SOW.

Deliverables All data will be provided by the Contractor In Accordance With (IAW) the Contract Data Requirements List (CDRLs) DD-1423-1. A Consolidated List of all CDRL’s is given in Appendix J.

Contract Modifications Additions, deletions or changes to this document shall be effective only after they have been jointly negotiated between the Government’s Procuring Contracting Officer (PCO) and the Contractor’s Contracting Office. Once both parties agree to the recommended changes, the Government’s PCO shall amend the original contract via contract modifications.

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 the PCPLT. The USN and USMC personnel will utilize this CSE in ship and land based hangars. The new procurement will address obsolescence issues with the legacy system and satisfy the type/model/series aircraft requirements.

The PCPLT will be used to check aircraft cabin/cockpit pressure control system components (e.g. canopy seal, pressure regulation valves, safety relief valves) for proper function and to provide troubleshooting and verification capability. The PCPLT regulates and controls the pressure and volume of air supplied to the aircraft. Pressure gauges and flow meters are used to determine if the aircraft cabin pressure control system is operating within correct parameters. The PCPLT shall consist of a main control unit and various hoses and accessories to facilitate the proper connection to an aircraft and externally supplied compressed air source.

Applicable Documents The following documents are applicable to this SOW, the appendices, and the enclosures to the extent specified herein and are in effect on the date of the RFP, unless otherwise stated. In the event of a conflict between this SOW and the references cited herein, this SOW shall take precedence. Nothing in the SOW, however, shall supersede applicable laws and regulations. All referenced documents are available upon request.

Plans

Requirements General The work required by this contract shall be performed in accordance with this SOW. This SOW identifies the specific tasks to be performed by the Contractor for the production and support of the PCPLT. The tasks cover engineering, quality assurance, configuration management, logistics, pilot production testing, delivery, and checkout of the tester. The Contractor is responsible for the PCPLT’s engineering, logistics, coordination, integration, test, performance testing of the PCPLT, initial calibration, and acceptance by the Government as covered by this SOW. The Contractor shall provide program management, engineering, fabrication, testing, technical and logistics support and other services as required by this SOW in accordance with the detailed requirements in the following paragraphs. The PCPLT procured under this contract shall meet the requirements set forth by the PCPLT System Specification PMA260C21/3490.

Program Management Planning The formation of an Integrated Product Team (IPT) built upon a spirit of teamwork is highly recommended and will enhance communications within the Contractor organization and with the Government IPT. A single program manager shall be designated as the interface with the Navy. The Contractor program manager will manage the Contractor team to:

· Implement actions necessary to achieve the work objectives of this SOW

· Ensure the resources and information necessary are available to support the contract

· Perform risk analysis and implement effective risk mitigation

· Resolve or elevate issues in a timely manner

· Work in conjunction with Government personnel to meet the ALS objectives of this SOW

· Monitor subcontractor(s) efforts and review data deliverables for contract compliance prior to delivery to the Government Integrated Master Schedule (IMS) The Contractor shall prepare, implement, manage, update and maintain an IMS. The IMS shall be consistent with this SOW, all appendices, and CDRLs and must be detailed sufficiently that critical and high-risk efforts are identified and planned as realistically to assure executability. The IMS shall include scheduling of all contract deliverables and when these tasks are to be performed and completed. The IMS shall be extended and expanded as the contract unfolds and additional insight is needed. The IMS shall be used throughout the contract period as a management tool to assess progress and determine success in achieving program requirements. The initial plan shall include the tasks required to produce and test the pilot production hardware and provide the CDRL deliverables IAW the IMS schedule at award. Prior to the release for production of the PCPLT, the Contractor shall provide details for the production, acceptance and delivery of the hardware to the Government. Reporting on work in progress in accordance with the IMS at each program review may be accomplished via presentation of the updated schedule, accompanied with a narrative indicating significant accomplishments, problems and risks affecting the critical path, mitigation strategies, and status of open action items.

(CDRL A001)

Task Execution Plan (TEP)/Get Well Plan (GWP) In conjunction with the submission of the IMS at the post award conference, the contractor shall provide a TEP stating the activities, procedures and resources the contractor will use in accomplishing the logistical efforts comprising the IMS. The TEP shall be consistent with this SOW, all its appendixes, and CDRLs and must be detailed sufficiently that critical and high-risk efforts are identified and planned realistically to assure execution. Any revisions to the IMS resulting in a negative impact to the TEP and/or IMS will be accompanied by a GWP outlining the efforts and activities the contractor will undertake to reduce and /or mitigate the impact. The TEP shall be revised, as required to reflect any changes during the course of the contract.

(CDRL LB01 & LB02)

Meetings and Reviews Various meetings and reviews are required to review the status of the program and to assess the progress towards meeting the technical, performance and logistics requirements set forth in this contract. Each meeting/review will list several entrance and exit criteria. All the criteria shall be met in order to start and complete each meeting/review. Unless expressly directed in writing by the PCO, the Contractor can adopt or reject any recommendations or advice offered by the Government during the conduct of any of the reviews.

TABLE 1 - MEETINGS/REVIEWS SUMMARY

(DAYS AFTER CONTRACT AWARD)

TASKS

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

Contractor Responsibilities Unless otherwise specified, each meeting shall be hosted at the Contractor's location or via teleconference. The venue for each will be chosen by the Government on a case-by-case basis.

Agenda and Presentation Prior to each meeting, an agenda shall be created by the Contractor and submitted to the Government. A draft PowerPoint presentation shall be created prior to each meeting/review. Enough background information should be provided in the presentation to bring the Government review team 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 its schedule 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 also be responsible for updating the presentation to a final revision following the meeting in order to capture any changes discussed and submit it to the Government within 5 days after the meeting/review.

(CDRLs A002 & A003) Minutes and Action Items The Contractor shall record minutes and action items from each meeting and provide tracking resolution. 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 10 days prior to the related meeting. All exit criteria shall be presented at the meeting. Failure to complete entrance/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 taking action on that problem/concern, a recommended action, urgency classification and completion date. Until all RFAs are completed (closed out), the review milestone cannot be passed. RFAs will be provided to the Contractor within 5 days after each review.

(CDRLs A004 & A005) CDRL Updates The Contractor shall be responsible for updating the following CDRLs prior to each meeting/review.

· IMS/Narrative (CDRL A001)

· TEP/GWP (CDRLs LB01 & LB02)

· Requirements Traceability Matrix (CDRL A013) System Requirements Review-II (SRR-II)/Preliminary Design Review (PDR) Within 60 DACA, the Contractor shall host a SRR-II/PDR. The SRR-II/PDR provides the Contractor with an introduction to the Government IPT and establishes a formal and informal means of communication. 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 operationally effective and suitable. This review assesses the allocated design. The Contractor shall demonstrate understanding of the underlying performance baseline set forth in the SS, identify the design approach, drawing practices, selection of components, the testing requirements/facilities and all environmental requirements while identifying any areas of risk. The review shall address the program schedule, engineering, configuration management, logistics management, ILS data development guidance and test processes. This review shall also include a full review of the SS and SOW. The Contractor shall present to the Government a Technical Data Package (TDP) representing no less than 30% of the Technical Manual (TM), a complete drawing tree and a complete component layout, at least 10 days prior to the meeting. Additionally, any preliminary questions or concerns that the Contractor has with regard to the requirements of the contract may be discussed at this time.

Entrance Criteria

· Meeting/Review Agendas (CDRL A002)

· Meeting/Review Presentations (CDRL A003)

· Submittal of Component Layout (CDRL A009)

· Submittal of Drawing Tree/Top Down Breakdown (CDRL A010)

· Submittal of Long Lead Items List for Pilot Production (CDRL A012)

· Submittal of Requirements Traceability Matrix (CDRL A013)

· Submittal of the Hazardous Material Management Program (HMMP) Plan (CDRL A015)

· Submittal of the System Allocation Document (SAD) (CDRL LB03)

· Submittal of the Preliminary Initial Calibration Procedure (ICP) Source Data (CDRL LC01)

· Submittal of the Item Unique Identification (IUID) Plan(CDRL LI01)

· Submittal of the Logistics Product Data (LPD) Candidate List (CDRL LM01)

· Submittal of the LPD Elements Input Data (CDRL LM02)

· Submittal of TM for First Review (CDRL LT02)

Exit Criteria

· Allocated Baseline established

· Risk level identified and accepted by Program/Competency leadership

· The IMS is executable

· All RFAs are resolved Critical Design Review (CDR) Within 210 DACA, the Contractor shall host a CDR. The CDR is a technical assessment establishing the initial product baseline for the PCPLT design to ensure that the system under review has a reasonable expectation of being judged operationally effective and suitable and complies with the SS. The CDR shall present a design that addresses all deficiencies identified during the SRR-II/PDR; shall be a detailed review of the hardware for the system; shall provide a traceability matrix demonstrating the design furnished at CDR implements the performance requirements of the system specification, and present the methods used to verify and validate the design. The Contractor shall present to the Government a drawing package representing the proposed pilot production units and no less than 60% of the TM at least 10 days prior to the meeting. Once the CDR is closed out any changes to the design must be reviewed and approved by the Government. Prior to closure of the CDR the Contractor is not authorized, but can assume the risk, to begin construction of the Pilot Production Units (PPUs); however, as long lead items are identified earlier during the design process the Contractor shall notify the Government to allow authorization to order those parts.

Entrance Criteria

· Meeting/Review Agendas (CDRL A002)

· Meeting/Review Presentations (CDRL A003)

· Submittal of updated Drawing Tree/Top Down Breakdown (CDRL A010)

· Submittal of an Engineering Drawing Package (CDRL A011)

· Submittal of Requirements Traceability Matrix (A013)

· Submittal of 3-D Models (CDRL A019)

· Submittal of the System Safety Hazard Analysis Report (CDRL A014)

· Submittal of the HMMP Report (CDRL A016)

· Submittal of the Reliability Prediction Report (CDRL A017)

· Submittal of the Maintainability Predictions Report (CDRL A018)

· Submittal of the Master Test Plan (CDRL T001)

· Submittal of the Pilot Production Acceptance Test Procedures (CDRL T004)

· Submittal of the Pilot Production Test (PPT) I Procedures (CDRL T006)

· Submittal of the Shock Test Plan (CDRL T010)

· Submittal of the SAD (CDRL LB03)

· Submittal of the CMRS Report (CDRL LC02)

· Submittal of the Statement of Prior Submission (SPS) (CDRL LP01)

· Submittal of the Supplemental Data for Provisioning (SDFP) (CDRL LP02)

· Submittal of the Long Lead Time Items List (LLTIL) for Production (CDRL LS01)

· Submittal of TM for Second Review (CDRL LT02)

Exit Criteria

· Initial Product Baseline established

· Risk level identified and accepted by Program/Competency leadership

· The IMS is executable

· All RFAs are resolved Contractor Test Review (CTR) Within 330 DACA, the Contractor shall host a CTR. The CTR is used to assess test objectives, test methods, procedures, scope of tests, and determine if resources have been identified. The test configuration baseline will also be established at CTR. This baseline represents the PCPLT configuration that will be formally tested to verify conformance to the requirements of the SS. At the completion of CTR the PCPLT design will be frozen for testing. The IMS submission for the CTR shall contain a detailed test schedule to include start and end dates for each test as well as test locations (name of laboratory/city, state) and estimated shipping times to/from each location.

Entrance Criteria

· Meeting/Review Agendas (CDRL A002)

· Meeting/Review Presentations (CDRL A003)

· Presentation shall include a detailed discussion of any changes to the initial product baseline that was established at the CDR.

· Submittal of updated Engineering Drawing Package (CDRL A011)

· Submittal of updated requirements traceability matrix (CDRL A013)

· Submittal of updated 3-D Models (CDRL A019)

· Approved Failure Reporting, Analysis, and Corrective Action System Plan (CDRL T002)

· Approved Pilot Production Acceptance Test Report (CDRL T005)

· Approved PPT I Report (CDRL T007)

· Approved PPT II Procedures (CDRL T008)

· Approved Maintainability Demonstration (MDEMO) Test Plan (CDRL T013)

· Submittal of the Test Materials List (CDRL T015)

· All required test resources (people, facilities, test articles, test instrumentation) are identified and are available for testing

· Submittal of the SAD (CDRL LB03)

· Submittal of the Preliminary Interim Support Items List (ISIL) (LS02)

· Submittal of TM for Third Review (CDRL LT02)

· Submittal of Training Materials (CDRLs LTR01 & LTR02) Exit Criteria

· Test Baseline established

· Risk level identified and accepted by Program/Competency leadership

· The IMS is executable

· All RFAs are resolved System Verification Review (SVR) / Production Readiness Review (PRR) Within 720 DACA, the Contractor shall host a SVR/PRR. The SVR/PRR will be used to confirm that any changes negotiated during PPT and Independent Government Testing have been incorporated into the design and that a representative PCPLT exists with those design elements incorporated. The Contractor shall have a final TDP available for Government review at least 10 days prior to the SVR/PRR as well as a printed copy at the review. The final product baseline is established at this review. This baseline is the configuration to which all production PCPLTs will be built. This baseline will be represented by an updated, complete TDP representing the current configuration incorporating any changes that resulted from the PPT or Independent Government Testing failures/ Deficiency Reports (DRs). 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 (i.e. award production options on the contract) will not be considered until the SVR/PRR milestone is passed.

Entrance Criteria

· Meeting/Review Agendas (CDRL A002)

· Meeting/Review Presentations (CDRL A003)

· Submittal of Physical Configuration Audit Plan (CDRL A007)

· Submittal of an updated Drawing Tree (CDRL A010)

· Submittal of updated Engineering Drawing Package (CDRL A011)

· Submittal of updated 3-D Models (A019)

· Approved Pilot Production Test II Report (CDRL T009)

· Submittal of the Shock Test Report (CDRL T011)

· Submittal of the MDEMO Test Report (CDRL T014)

· Submittal of the Production Acceptance Test Procedures (CDRL T017)

· Submittal of the SAD (CDRL LB03)

· Submittal of the Final ICP Source Data (CDRL LC01)

· Submittal of the SDFP (CDRL LP02)

· Submittal of the Final ISIL (LS02)

· Submittal of an updated complete TM (CDRL LT02)

· Submittal of the Contractor Validation Plan (CDRL LT04) Exit Criteria

· Production Baseline established

· Risk level identified and accepted by Program/Competency leadership

· The IMS is executable (technical/cost risks)

· All RFAs are resolved Technical Interchange Meetings (TIMs) In addition to the meetings/reviews called out above, the Contractor shall be available to host in-prompt-to TIMs at their facility or via teleconference. These meetings will be used as an opportunity for Government personnel to visit the Contractor’s facility for troubleshooting, progress checks, or any other unforeseen reasons. The Contractor shall ensure that all necessary contractor and subcontractor personnel, along with any hardware or technical data, are available for each TIM.

Scheduled Formal In Process Reviews (IPR) And Acquisition Logistics Support Management (ALSM) Reviews Scheduled formal IPR and ALSM Reviews will be held relative to the initial deliverable, progress deliverables and validation/verification for technical accuracy and format of all logistics deliverables identified by a CDRL. The Deputy Assistant Program Manager of Logistics (DAPML) and Contractor ALSM will coordinate meeting times and locations which are mutually agreeable to both parties. Reviews held at the Contractor facilities will support adequate room for all required Government representatives. Bound copies of the documents to be reviewed will be provided to each individual participating in the reviews. Copies of the SAD will be provided in each binder. One hard copy of all engineering drawings will be available in the room where the review is being held. Additional reviews may be held at the discretion of the Government when scheduled TM progress reviews identify the need. Review of the Maintenance Plan (MaPl) may be held in conjunction with the Tech Manual reviews at the discretion of the DAPML.

Post Award/Logistics Guidance Conference The Contractor shall attend a Post Award/Logistics Guidance Conference within 30 calendar days after contract award. At a minimum, the following personnel are required: Contractors Supportability and Engineering personnel, Maintenance Planner, Logistician and Engineer. The purpose of this meeting is to ensure a comprehensive understanding of the total logistics program, all supportability analysis requirements and deliverable requirements already on contract between the Contractor and Government.

Technical Data Package (TDP) The Contractor shall develop a TDP to support the Government’s review of the PCPLT’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 include the following elements:

Configuration Management (CM) The Contractor shall develop a CM program, using NAVAIRINST 4130.1D for guidance. Any change affecting the PCPLT’s form, fit or function after CDR and prior to CTR will require the Contractor to inform the Government of the change. Any change affecting the PCPLT’s form, fit or function after CTR will require Government approval. This must also identify any changes required to technical manuals, LPD Record, drawings, specifications, SDFP etc. Source Control Drawings must be provided as part of the request. If noncompliance with the requirements of the configuration identification and/or the established baseline becomes necessary, the Contractor shall request a deviation or waiver. The Contractor shall manage obsolescence issues throughout performance on this contract. This includes ongoing review and identification of actual and potential obsolescence problems for all components and piece parts of the PCPLT. The Contractor shall be responsible for all costs associated with obtaining replacement parts if and when parts become obsolete. The Contractor shall have the responsibility to interface with vendors and Original Equipment Manufacturers (OEMs) to ensure continued operation and support under the contract.

Design Change Notice (DCN) Each production PCPLT shall be identical to the approved final PPU configuration. The Government must be notified of and approve any configuration change at least 30 calendar days prior to implementation of the change. Configuration changes are defined as additions, deletions, supersedures or modification of the PCPLT or any part of it during the performance of the contract. If the change is approved, the Government will update provisioning data by submitting a DCN using the information provided by the Contractor.

(CDRL A006)

Request for Deviation (RFD) The Contractor shall not offer items, for acceptance by the Government, that incorporate a known departure from requirements, unless an RFD has been submitted, classified (critical, major, or minor), and approved. A critical deviation consists of a departure involving safety; major deviation consists of a departure involving performance, interchangeability, reliability, survivability, maintainability, durability, health, effective use/operation, and weight/size; minor deviation consists of a departure that does not involve any of the critical and major deviation factors. Deviations classified with Government concurrence shall be submitted for information. Classification disagreements shall be referred to the IPT chair and co-chairs for decision; the PCO will document and disseminate a decision in writing. Authorized deviations apply to a specific quantity of items and will not constitute change to the PCPLT baseline as defined by the TDP, or SS. The Contractor may process a RFD if, during or after repair of an item that incorporates a known departure from requirements, it is determined that the item is considered suitable for use “as is” or after repair by an approved method.

Engineering Change Proposals (ECP) Upon delivery of production PCPLTs to the Government, changes to the PCPLT design shall require an ECP. When it is determined that a change should be permanent, a Class I ECP shall be recommended or Class II change shall be processed, see MIL-HDBK-61A for guidance.

Physical Configuration Audit (PCA) The Contractor shall hold a PCA to compare the PCPLT’s hardware to its drawing package. The Contractor shall use Section 8.2.2 of MIl-HDBK-61 for guidance. The drawing package and any other applicable data shall be modified to reflect the PCPLT. The resultant drawing package shall serve as the PCPLT’s baseline configuration and all PCPLTs shall be configured to this baseline. The PCPLT used during the PCA serves as the model which all other production PCPLTs will copy and it shall be delivered as the last PCPLT. The Government reserves the right to witness the PCA and the Contractor shall notify the Government at least 14 days prior to the start of PCA to allow reasonable preparation time. The contractor shall submit a PCA Plan that fully describes the procedures and methodologies used to conduct the PCA. The contractor shall submit a PCA Report that fully describes all discrepancies in the drawing package and gives results of the PCA. All corrective actions to the PCPLT and drawings shall be fully described in this report. Raw data and worksheets shall be included in the report.

(CDRLs A007 & A008)

Layout of Components The Contractor shall prepare and deliver a diagram showing the rough layout of the components.

(CDRL A009)

Drawing Tree Structure/Top Down Breakdown The Contractor shall prepare and deliver a diagram showing the drawing tree structure. In developing the drawing tree structure the Contractor shall keep in mind that the drawing package will also support the Integrated Logistics Support (ILS) program (top down breakdown). See Appendix B for guidelines/instructions.

(CDRL A010)

Engineering Drawing Package The Contractor shall provide a NAVAIR formatted engineering drawing package for the PCPLT (format and content is provided in NAWCADLKE-DDR-486600-0004). The drawing package shall be used to support the Logistics Management Information (LMI) database and be used as SDFP. As such, the drawing package should include a top down breakdown of the PCPLT from the end article to the lowest repairable level required. The package shall include all repairables. As referenced in NAWCADLKE-DDR-486600-0004 the cognizant engineer shall be defined as the Government Principle Engineer and shall determine whether to create a Vendor Item Control Drawing for given commercial part.

(CDRL A011)

3-D Models The contractor shall prepare and submit 3-D solid models of the PCPLT in STEP format.

(CDRL A019)

Long Lead Items List for Pilot Production The Contractor shall prepare a list of long lead time items to be used in the manufacturing of the PPUs. The list is to contain items with long production lead times that would impact the schedule for manufacturing pilot production units. Government approval shall be required prior to purchasing items.

(CDRL A012)

Requirements Traceability Matrix A Requirements Traceability Matrix shall be maintained showing, by paragraph, how each requirement of sections 3 & 4 of the SS will be met by the system/system components. The Matrix shall be a grid format. The matrix shall be broken into four submissions, or “levels,” with each containing information as outlined below:

Level I – Shall be three columns. The first column shall contain all requirements from the SS (one requirement paragraph per row). The second column shall contain a description of the proposed design solution for all of the requirements. The third column shall provide the test level (PPT I/PPT II) at which the requirement will be verified.

Level II – Shall contain the three columns from Level I. A fourth column shall be added for the verification method to be used to show compliance with the requirement (i.e. test, analyze, demonstrate, or inspect per the SS). Any test or analysis verification shall also contain a brief description of the verification (e.g. call out the MIL-STD test procedure; describe what data will be used for analysis).

Level III – Shall contain four columns from Level II, updated as required, with a fifth column added with a reference to the PPT I or PPT II procedure step/paragraph number wherein the requirement will be verified.

Level IV – Shall contain the five columns from Level III, updated as required, with four additional columns added. The sixth column shall contain a reference to the PPT I or PPT II report paragraph number wherein the requirement verification is given. The seventh column shall give the serial number of the PPU used for testing. The eighth column shall contain the test date(s). The ninth column shall provide the test results with a Pass/Fail indication as well as numeric results as applicable. Any test failures and retests shall also be shown in this level through providing the serial number/test date(s), Pass/Fail and results for all verification attempts.

(CDRL A013)

Safety 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 (SSHA) The Contractor shall perform a SSHA. The SSHA shall be a comprehensive evaluation of the safety risks associated with testing, operation, and maintenance of the PCPLT. The contractor shall develop and document the specific hazard controls for each safety risk. The results of the SSHA shall be documented in a SSHA Report. The SSHA and associated report shall be updated following any change to the PCPLT design that does or may affect the risks associated with operation and maintenance of the PCPLT.

(CDRL A014)

Hazardous Materials Management Program (HMMP) The Contractor shall be responsible for maintaining an effective HMMP in accordance with Aerospace Industries Association (AIA) National Aerospace Standard (NAS) 411. In designing, manufacturing, testing, operating and maintaining the PCPLT, 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 that cannot be eliminated. The Contractor shall ensure that all vendors and suppliers including those of subcontractors provide all information to accurately and fully complete the HMMP requirements.

Hazardous Materials Management Program (HMMP) Plan The Contractor shall prepare a HMMP Plan. The plan shall document the Contractor’s method to identify, prohibit, restrict, eliminate, minimize, and/or control hazardous materials.

(CDRL A015)

Hazardous Materials Management Program (HMMP) Report A HMMP Report shall be prepared by the Contractor and it shall contain a data list that identifies all hazardous materials, as defined in the SS, contained in the delivered system and used during the manufacture, operation, or maintenance of the PCPLT. The Contractor shall maintain and update the HMMP Report throughout the life of the contract to reflect changes in design. At a minimum, the following information shall be included in the HMMP Report for each hazardous material or waste:

(CDRL A016)

1. Hazardous material item or substance name

1. Technical documentation and/or specification that requires the use of the hazardous material, if applicable

1. Name and Part Number of the component/part that contains the hazardous material or is associated with the use/generation of the hazardous material

1. Process associated with the use or generation of the hazardous material

1. Safety related information for each hazardous material (e.g. Material Safety Data Sheets (MSDS), Safety Data Sheet (SDS), or special control, training handling, and Personal Protective Equipment (PPE) required)

1. Chemical name(s) of hazardous component (sometimes found on MSDS)

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

1. Waste and disposal codes/regulations for the hazardous material, when appropriate

1. Quantity of hazardous material (as Parts Per Million (PPM) or per system/component as appropriate using best engineering judgment)

1. If the hazardous material is or contains a Targeted chemical, as defined in the SS, a trade-off analysis shall be prepared documenting the technical and financial costs of alternative materials compared to the selected hazardous material in accordance with NAS 411, paragraph 4.3.3.

Reliability and Maintainability (R&M) Program The Contractor shall maintain a comprehensive R&M program to ensure that the PCPLT meets the R&M standards set forth in the PCPLT SS. 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 PCPLT SS. The Contractor shall be responsible for flowing R&M quantitative requirements, analyses, and test tasks down to all subcontractors and suppliers, as necessary.

The Reliability Program shall be planned and accomplished in accordance with SAE JA1000; SAE JA1000-1; MIL-HDBK-781; and Section 4 of the PCPLT SS. The Maintainability Program shall be planned and accomplished in accordance with SAE JA1010, MIL-HDBK-470A, Section 4 of the PCPLT SS, and this SOW.

Reliability Analysis and Predictions Report Reliability predictions shall be performed in accordance with SAE JA1000-1 Reliability Method A.32 to evaluate the PCPLT system design and provide inputs into logistics support analyses. The reliability prediction shall provide a prediction of Mean Time Between Failure (MTBF) for the PCPLT. The prediction shall be based on failure rates in the mission environment identified in the SS for all components or assemblies. The reliability prediction shall be addressed at each design review.

Mechanical component reliability predictions shall be based on (1) engineering design calculations (i.e. fatigue), (2) 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. The report shall also address the following topics.

(CDRL A017)

Reliability Critical Items The Contractor shall identify and control those items which require "special attention" because of complexity, life limit, application of advanced state of the art techniques, and the impact of potential failure on safety, readiness, mission success, or the demand for maintenance/logistics support.

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 all major subassemblies. From this block diagram, a mission reliability prediction shall be developed providing a prediction of MTBF.

Maintainability Predictions Maintainability predictions shall be performed in accordance with SAE JA1010-1 Method C.19 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. Design and failure analyses 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 PCPLT SS. A Maintainability Predictions Report shall be submitted.

(CDRL A018)

Quality Management 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 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.

Testing The Contractor’s test effort shall include a logical sequence of tests that shall demonstrate compliance with the SS and supportability requirements of the PCPLT. The Contractor shall document, via test plans/procedures, the tests required in this section. The Contractor shall provide all test equipment necessary to simulate all significant modes of operation and provide sufficient information to determine suitable test modes and operating environments. The Contractor is responsible for maintaining calibration of all test and measurement equipment and/or ensuring test subcontractor certification. The results of the tests shall be documented and submitted in the appropriate test reports. The Government shall reserve the right to witness any and all testing performed on the PCPLT hardware. The Contractor will notify the Government when a test is scheduled to commence at least 21 days prior to the test.

Master Test Plan The Contractor shall submit a Master Test Plan that describes the testing and checkout of the PCPLT hardware. The test plan shall address all development testing by the Contractor and all testing up to and including PAT of the PCPLT. The plan shall identify the groups/individuals responsible for the implementation of the test program and describe the testing equipment, manuals, and other resources required. The Master Test Plan shall also include a master schedule of all tests required by this SOW.

(CDRL T001)

Failure Reporting, Analysis And Corrective Action System (FRACAS) The Contractor shall utilize a FRACAS Plan in accordance with SAE JA1000-1 Method A.11 and MIL-HDBK-2155 to track, evaluate, and correct failures that occur during the test program. The FRACAS Plan shall identify responsibilities within the IPT for identifying, analyzing, reporting, and scoring failures and potential failures. Each failure or potential failure experienced during testing of the PCPLT shall have a preliminary Failure Analysis and Corrective Action (FACA) Report prepared and submitted within 24 hours of the discovery of the failure or potential failure. A final FACA Report shall be submitted within 30 days of the preliminary report.

(CDRLs T002 & T003) Pilot Production Test (PPT) Program The Contractor shall produce a maximum of five PPUs for use during PPT and the PPUs shall be calibrated by the Contractor prior to PPT I. Additionally, any follow-on calibration required during the testing phase PPAT, PPT I, PPT II, Independent Government Testing, and PAT shall also be performed by the Contractor. All PPUs shall undergo all PPT I which encompasses PPAT. A number of PPUs specified by the Government will be shipped to Naval Air Warfare Center Aircraft Division, 22763 Saufley Rd, Building 1405, Patuxent River, MD 20670, 360 DACA for Independent Government Testing while PPT II is ongoing. The Contractor is required to complete CTR prior to shipment of these units.