CSS_Statement_of_Work.pdf

NAVAIR LAKEHURST

PMA260C2

ENGINEERING AND LOGISTICS

STATEMENT OF WORK

(SOW)

for

CRYOGENIC SERVICE SYSTEM

(CSS)

1678AS100-1 (Oxygen)

1678AS100-2 (Nitrogen)

17 April 2019

Version 1

Naval Air Systems Team

Naval Air Warfare Center Aircraft Division

SE and ALRE Department

SE and ALRE Systems Engineering Division

Lakehurst, New Jersey 08733-5109

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS

UNLIMITED.

Table of Contents

1. Scope

1.1 Purpose

1.2 Background

1.3 Critical Safety Items

2. Requirements

2.1 Program Management

2.1.1 Post Award Orientation (PAO)

2.1.2 Technical Interchange Meeting (TIM) 1

2.1.3 Technical Interchange Meeting (TIM) 2

2.1.4 Technical Interchange Meeting (TIM) 3

2.1.5 Test Readiness Review (TRR)

2.1.6 Technical Interchange Meeting (TIM) 4

2.1.7 Technical Interchange Meeting (TIM) 5

2.1.8 Physical Configuration Audit (PCA)

3. Testing

3.1 First Article Testing (FAT)

3.1.1 First Article Test (FAT) Procedures

3.1.2 First Article Test (FAT) Report

3.2 Production Acceptance Test (PAT)

3.2.1 Production Acceptance Test (PAT) Procedures

3.2.2 Production Acceptance Test (PAT) Report

3.3 Failure Analysis and Corrective Action Report (FACAR)

3.4 Physical Configuration Audit (PCA)

4. Integrated Logistics Support (ILS)

4.1 Purpose

4.2 Integrated Logistics Support Requirements

4.3 Logistics Program Management Planning and Control

4.3.1 Sub-contractor (s)

4.4 Configuration & Obsolescence Management

4.4.1 Configuration Management

4.4.2 Obsolescence Management During Production

4.5 Calibration Requirements

4.5.1 Background

4.5.2 Initial Calibration of Deliverable Assets

4.6 Maintenance Planning Requirements

4.6.1 Logistics Product Data (LPD) Elements Input Data

4.7 Technical Manuals

4.7.1 Technical Data

4.7.2 Technical Manual (TM) Mark-up

4.8 Supply Support

4.8.1 Interim Support Item List (ISIL)

4.9 Item Unique Identification

4.9.1 Item Unique Identification (IUID) Marking of US Military Property

4.9.2 Construct and Method

4.9.3 IUID Location and Marking

4.9.4 Permanency and Legibility

4.9.5 UID Registration

4.9.6 UID Records

1. Scope

1.1 Purpose

This SOW is for the procurement of a Cryogenic Service System (CSS), part number (P/N)

1678AS100-1/-2. The CSS is an existing DoD system with over 40 fielded units supporting the

Navy and Marine Corps. This document defines the requirements for the contractor to manufacture, assemble, test and deliver the CSS units.

1.2 Background

The CSS stores and supplies liquid and gaseous oxygen/nitrogen to service naval aviation support equipment and aircraft systems. The CSS shall replace existing 1000 gallon and 2000 gallon CSS currently in use throughout the Navy and Marine Corps.

1.3 Critical Safety Items

The CSS drawing package contains components that have been determined to be critical safety items (CSI) due to the critical characteristics of oxygen cleaning.

1.4 Description of CSS Assembly

The CSS provides bulk storage of cryogenic fluids as well as a means of delivering oxygen/nitrogen in liquid and in high pressure gaseous form. The CSS assembly consists of a cryogenic storage tank with a nominal capacity of 2000 gallons. The storage tank is a vertical tank mounted on four legs. The tank assembly is comprised of a stainless steel inner storage tank surrounded by a carbon steel shell separated by an annular vacuum space. The lower structure is situated under the tank and consists of the following major components: converter assembly, cryogenic pump, electric vaporizer and various controls and indicators. The converter assembly, cryogenic pump, and electric vaporizer are mounted to a removable skid for ease of maintenance.

The CSS assembly is defined by the drawing 1678AS100, titled: Final System Assembly 2000

Gallon Nitrogen/Oxygen. The part number 1678AS100-1 refers to the CSS assembly for liquid oxygen, and the part number 1678AS100-2 refers to the CSS assembly for liquid nitrogen.

1.5 References

Document Number Date Purpose Document Title

1678AS100 Rev C Per Individual

Drawings Required

Final System Assembly 2000 Gallon

Nitrogen/Oxygen and associated

Data List DL1678AS100 Rev C.

ASME Boiler and Pressure

Vessel (BPV) Code Section VIII 7/1/2017 Required

ASME Boiler and Pressure Vessel

(BPV) Code Section VIII

ANSI/ASQC Q9001 2015 Reference Quality Management Systems -

Requirements

Document Number Date Purpose Document Title

National Aerospace Standard

(NAS) 411-1

10/31/2016 Reference

Hazardous Materials Target List

NA 19-5-502

11/1/2016 Required

2000 Gallon Oxygen Cryogenic

Service System (CSS), Technical

Manual (TM)

NA 19-600-262-6-1

7/1/2012

2000 Gallon Oxygen Cryogenic

Service System (CSS), Pre-

Operational Checklist, (Pre-OP)

19-600-262-6-2

3/1/2016

2000 Gallon Oxygen Cryogenic

Service System (CSS), Periodic

Maintenance Requirement Manuals

(PMRM)

2. Requirements

2.1 Program Management

The contractor shall be responsible for management of the overall program. The contractor shall develop, maintain, and deliver an Integrated Master Schedule (IMS) in accordance with the milestones set in this SOW, the contract and CDRL A001. For the period of performance of this contract, the contractor shall provide a Program Manager (PM). The PM shall have the full responsibility and a clear line of authority to the contractor’s executive management for carrying out the specific requirements of this SOW. The PM shall manage this effort holding schedule reviews; tracking to detailed schedules and milestones and implementing and managing a risk mitigation process. The PM shall also authorize, oversee and manage budgets. The PM has responsibility and authority for overall compliance to this SOW, including the Management, Engineering, Logistics, Test and Quality Assurance activities. The PM shall provide visibility to the USN identified Point of Contact (POC) on the status of activities covered by this SOW and shall disclose existing or potential problems and a plan for problem resolution. The PM shall serve as a direct POC for program management concerns and shall maintain communication with

USN identified POC personnel for matters relating to program performance and integration. All references to “days” in the SOW refer to calendar days. At a minimum, the contractor shall be prepared to participate in the following meetings described in the SOW and summarized in the table below (Summary of Required Meetings is listed in table below):

Type Periodicity Location

Minimum Content /

Deliverables

Required

Recommended Attendees

Post-Award

Orientation (PAO) Once

Contractors’ site See SOW Para 2.1.1

Contractor’s Program management team, Technical team, and Logistics team

Technical Interchange

Meeting (TIM) 1 Once Lakehurst, NJ See SOW Para 2.1.2

Contractor’s Technical team

Technical Interchange

Meeting (TIM) 2 Once Teleconference See SOW Para 2.1.3

Contractor’s Program management team, Technical team, and Logistics team

Type Periodicity Location

Minimum Content /

Deliverables

Required

Recommended Attendees

Technical Interchange

Meeting (TIM) 3 Once Teleconference See SOW Para 2.1.4

Contractor’s Program management team, Technical team, and Logistics team

Test Readiness

Review (TRR) Once Teleconference See SOW Para 2.1.5

Contractor’s Program management team, Technical team, and Logistics team

Technical Interchange

Meeting (TIM) 4 Once Teleconference See SOW Para 2.1.6

Contractor’s Program management team, Technical team, and Logistics team

Technical Interchange

Meeting (TIM) 5 Once

Contractors’ site See SOW Para 2.1.7

Contractor’s Program management team, Technical team, and Logistics team

Physical

Configuration Audit

(PCA)

Once Contractors’ site See SOW Para 2.1.8

Contractor’s Technical team

2.1.1 Post Award Orientation (PAO) (CLINs 0001, 0005)

The Post Award Orientation (PAO) shall be held at the contractor’s site within 30 days after contract award. The purpose of the PAO is to introduce the Government team members, review the IMS (CDRL A001), discuss expectations and clarify any questions. The PAO shall also address any questions regarding the logistic requirements of the SOW. The contractor shall host this meeting of approximately 5 Government attendees. The contractor shall be responsible for preparing and delivering any materials for review prior to the PAO in accordance with CDRL

A002. The contractor shall be responsible for recording and delivering the minutes and any action items of the PAO in accordance with CDRL A003. Completion of all action items shall constitute closure of the PAO.

2.1.2 Technical Interchange Meeting (TIM) 1 (CLINs 0001, 0005)

Technical Interchange Meeting (TIM) 1 shall be held at NAVAIR Lakehurst, NJ within 45 days after contract award. The purpose of this meeting is to complete the following tasks: (1) familiarize the contractor’s technical team with the CSS through the Governments’ demonstration of the 1000 gallon CSS units in use at Lakehurst, (2) discuss the contractor’s findings from the drawing package review with the NAVAIR technical team, and (3) discuss contractor’s findings in terms of logistics requirements of this SOW. The contractor shall be responsible for preparing and delivering any materials for review prior to TIM 1 in accordance with CDRL A002. The length of the meeting is anticipated to be 3 days. The contractor shall be responsible for recording and delivering the minutes and any action items of the meeting in accordance with CDRL A003. Completion of all action items shall constitute the closure of TIM

1.

2.1.3 Technical Interchange Meeting (TIM) 2 (CLINs 0001, 0005)

Technical Interchange Meeting (TIM) 2 shall be held via teleconference in accordance with the

IMS (CDRL A001). The purpose of this meeting is to review the first draft of the Bill of

Materials which shall be developed and delivered in accordance with CDRL A005. The contractor shall be prepared to discuss deliveries against CDRLs LC01, LM01, LL01, LN01, and

LP01 as well as any open actions from TIM 1. The contractor will be responsible for preparing and delivering materials for review prior to TIM 2 in accordance with CDRL A002. The contractor shall provide review materials that address applicable CDRLs to be discussed. The contractor will be responsible for recording and delivering the minutes and any action items of the meeting in accordance with CDRL A003. Completion of all action items shall constitute closure of TIM 2.

2.1.4 Technical Interchange Meeting (TIM) 3 (CLINs 0001, 0005)

Technical Interchange Meeting (TIM) 3 shall be held via teleconference in accordance with the

IMS (CDRL A001). The contractor will be responsible for preparing and delivering any materials for review prior to TIM 3 in accordance with CDRL A002. The purpose of this meeting is to facilitate the preliminary approval of the second draft of the Bill of Materials which shall be delivered in accordance with CDRL A005 prior to the manufacture of the First Article

(FA) unit. The contractor shall also be prepared to discuss the logistics requirements of this SOW as well as any open actions from TIM 2. The contractor shall be responsible for recording and delivering the minutes and any action items of the meeting in accordance with CDRL A003. The contractor must receive written Government approval of the second draft Bill of Materials before the release for production of the FA unit. Completion of all action items shall constitute closure of TIM 3.

2.1.5 Test Readiness Review (TRR) (CLINs 0001, 0005)

The contractor shall hold a Test Readiness Review (TRR) via teleconference in accordance with the IMS (CDRL A001). The contractor shall be prepared to discuss the testing of the CSS units in accordance with Section 3 of this SOW. The contractor shall prepare and deliver a Test Plan in accordance with CDRL A004 and shall deliver TRR review materials in accordance with

CDRL A002. The contractor shall be responsible for recording and delivering the minutes and any action items of the meeting in accordance with CDRL A003. Completion of all action items shall constitute closure of the TRR.

2.1.6 Technical Interchange Meeting (TIM) 4 (CLINs 0003, 0005)

Technical Interchange Meeting (TIM) 4 shall be held via teleconference in accordance with the

IMS, (CDRL A001), to discuss the delivered First Article Test (FAT) Report, CDRL A008, open actions from TIM 3 and to discuss any issues discovered during FAT of the FA. (See Failure

Reports CDRL A013). The contractor shall address any potential logistics impact due to test failure at TIM 4. The contractor shall be responsible for preparing and delivering any review materials prior to TIM 4 in accordance with CDRL A002. The contractor shall be responsible for recording and delivering the minutes and any action items of the meeting in accordance with

CDRL A003. Completion of all action items shall constitute closure of the TIM 4.

2.1.7 Technical Interchange Meeting (TIM) (CLIN 0005, 0006)

The contractor shall hold Technical Interchange Meeting (TIM) 5 at the contractor’s facility in accordance with the IMS (CDRL A001) to facilitate the approval of the Final Bill of Materials

CDRL A005, and to discuss any changes to the Government Technical Manual (TM). The

Government will ensure that the Source Data delivered by the contractor matches the updates that are being captured in the TM. Any issues that arise during the Government’s update of the

TM will be discussed at this meeting. The contractor shall provide final drafts of logistics

CDRLs LC01, LM01, LL01, LN01, and LP01 at this meeting. The contractor shall host this meeting of approximately 5 Government attendees. The contractor shall delivery review material that addresses applicable CDRLs to be discussed as outlined in this paragraph. The contractor shall be responsible for preparing and delivering any review materials prior to TIM 5 in accordance with CDRL A002. The contractor shall be responsible for recording and delivering the minutes and any action items of the meeting in accordance with CDRL A003. The contractor shall receive written Government approval of the Final Bill of Materials (CDRL

A005) prior to release for production of the Production Units. Completion of all action items shall constitute closure of the TIM 5.

2.1.8 Physical Configuration Audit (PCA) (CLIN 0004)

The Physical Configuration Audit (PCA) shall be held at the contractor’s facility 15 months after release for production and shall be conducted on the Second Pre-Production unit PN

1678AS100-1. The PCA shall be in accordance with paragraph 3.4 of the SOW.

2.2. Drawing Package (CLIN 0005)

The CSS Baseline Configuration is defined by the existing drawing package 1678AS100, and its corresponding data list DL 1678AS100. The drawing package reflects the 1989 design of the

CSS currently in use by the Navy and Marine Corps. Section 4 of this SOW describes the required documentation and approval process required for any configuration changes of the CSS

Baseline Configuration. In accordance with Section 4, only Government approved changes to the

CSS Baseline Configuration shall be incorporated into the Production Baseline Configuration of the CSS.

2.2.1 Drawing Package Review

2.2.1.1 The contractor shall complete a detailed review of the existing Government drawing package to ensure compliance with the ASME Boiler and Pressure Vessel (BPV) Code Section

VIII in effect as of date of contract award. If updates are required for compliance, the contractor shall be expected to recommend updates to align the existing Government drawing package with current ASME BPV Code Section VIII requirements. The contractor shall provide this information to the Government during TIM 1.

2.2.1.2 The contractor’s drawing package review shall, at a minimum, address the following areas:

(1) Issues due to current ASME BPV Section VIII Code requirements

(2) Part obsolescence issues

(3) Part long lead-time issues

(4) Issues due to improved manufacturing processes and best commercial practices

2.2.1.3 The contractor shall identify the issues found during the drawing package review and be prepared to discuss proposed issue resolutions during TIM 1.

2.2.2 Drawing Package Revisions

The contractor shall not make drawing package revisions contractor without prior approval of the

Government in accordance with Section 4 of this SOW.

2.3 Manufacture

2.3.1 Bill of Materials (CLIN 0006)

2.3.1.1 The contractor shall be responsible to deliver a Bill of Material for the manufacture of the

CSS. The Bill of Materials shall be representative of the drawing package. The Bill of Materials shall list the drawing numbers, part numbers and vendors for all purchased parts as listed on the drawings. Any changes to the parts listed on the Bill of materials throughout the production of the CSS units shall follow the requirements of Section 4 of this SOW for documentation and configuration management.

2.3.1.2 Submission of the Bill of Materials shall be a minimum of three submissions in accordance with CDRL A005. The Bill of Materials submissions shall be identified as follows:

(1) First draft Bill of Materials: The contractor shall deliver a first draft Bill of Materials based upon the Government drawing package. It shall be representative of the CSS Baseline

Configuration. The contractor shall prepare the first draft Bill of Materials and the contractor shall deliver the first draft Bill of Materials to the Government prior to TIM 2, in accordance with CDRL A005.

(2) Second draft Bill of Materials: The contractor shall deliver a second draft Bill of Materials which will include any approved changes or updates in accordance with Section 4 of the SOW.

The second draft Bill of Materials shall be prepared by the contractor and delivered to the

Government prior to TIM 3, in accordance with CDRL A005. The FA unit shall be manufactured to the Government approved second draft Bill of Materials.

(3) Final draft Bill of Materials: The contractor shall deliver a final draft Bill of Materials representative of the Production Units. The final draft Bill of Material shall be prepared by the contractor and delivered to the Government prior to TIM 5, in accordance with CDRL A005.

2.3.1.3 The contractor shall require as part of its purchasing agreements with component sub-vendors, that these sub-vendors submit product specification data (i.e. part number, Original

Equipment Manufacturer (OEM) info etc..). The contractor shall provide required data upon request of the Government.

2.3.2 Safety (CLINs 0002, 0004, 1001, 2001, 3001, 400X, 500X)

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 and all provisions set forth in the contract. 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 and all applicable provisions of this contract.

2.3.3 Quality Assurance (CLINs 0002, 0004, 0005, 1001, 2001, 3001, 400X, 500X)

2.3.3.1 The contractor shall establish and maintain Quality Assurance (QA) in accordance with

ANSI/ASQC Q9001 or equivalent. The QA program shall insure that all hardware and documentation developed, tested, and delivered meets the requirements of the contract.

2.3.3.2 The contractor shall establish and maintain a QA program specifically for welding to ensure the consistent quality of welding and brazing used during the manufacture of the CSS. In accordance with the ASME BPV Code Section VIII and the American Welding Society (AWS), the contractor shall have only certified welders perform welding or brazing per the drawings.

The contractor shall deliver copies of the welders’ certifications at the Government’s request.

The contractor shall deliver welding reports and certifications according to the ASME code per

CDRL A009.

2.3.3.3 The contractor shall establish and maintain a QA program to manage the Critical Safety

Items (CSI) unique to the CSS. The CSI items are items which require specialized cleaning for oxygen service per the drawings. Information about the handling of CSI items shall be delivered to the Government at the Government’s request. The contractor shall delivery Oxygen clean certifications per CDRL A009.

2.3.4 Hazardous Materials Management Program (CLINs 0002, 0004, 1001, 2001, 3001, 400X, 500X)

Hazardous Materials shall be eliminated or reduced from the CSS and associated manufacturing, operation and maintenance processes wherever practical. Hazardous materials that cannot be eliminated and any hazardous wastes generated during the CSS’s production shall be properly controlled so as to minimize risk to the environment and personnel safety. The NAVAIR

Chemicals of Concern List (CoCL) and NAS 411-1 shall be used as guidance in identifying

Prohibited, Targeted and Tracked Chemicals. NAVAIR CoCL restrictions will take precedence over NAS 411-1.

A hazardous material is any material that due to its chemical, physical, or biological nature may cause safety, public health, or environmental concerns.

2.3.4.1 Prohibited Chemicals

The following hazardous materials are identified as prohibited by the NAVAIR Chemicals of

Concerned List (CoCL): Asbestos, Class I ODS, Class II ODS, Hexavalent Chromium, and

Polychlorinated Biphenyls (PCBs). No exemptions shall apply to prohibited materials.

2.3.4.2 Targeted Chemicals

The following hazardous materials are identified as targeted by the CoCL: Arsenic & Arsenic

Compounds , Benzene, Beryllium & Beryllium Compounds , Cadmium & Cadmium

Compounds, Chloroform, Chromium & Non-Hexavalent Chromium Compounds, Cyclotrimethylenetrinitramine (RDX), Cyanide Compounds, Ethylene Glycol, Formaldehyde, Glycol Ethers, Hydrazine, Hydrofluoric Acid, Isocyanates, Lead & Lead Compounds, Mercury

& Mercury Compounds, Methyl Ethyl Ketone (MEK), Methyl Isobutyl Ketone (MIBK), Methylene Chloride, Methylene Dianiline (MDA), Naphthalene, Nickel & Nickel Compounds, Perchlorates, Perchloroethylene, Perfluorooctanoic Acid (PFOA), Phenol, Polybrominated

Diphenyl Ethers (PBDEs), Radioactive Materials, Toluene, Trichloroethylene (TCE), and

Xylene & Xylene Isomers. Targeted chemicals shall be used only when there is no viable technically feasible alternative and will require Government approval.

2.3.4.3 Exceptions

a. Chromium and nickel as a constituent of metal alloys are exempt from Targeted

Chemicals restrictions.

b. Lead as a constituent of lead solder is exempt from Targeted Chemicals restrictions.

3.0 Testing (CLINs 0004, 0005, 1001, 2001, 3001, 3002, 4001, 4002)

The contractor shall perform First Article Testing (FAT) of PN 1678AS100-1 CSS (oxygen) in accordance with the drawing requirements (CLIN 0002). The contractor shall perform

Production Acceptance Testing (PAT) of the CSS in accordance with the drawing number

1678AS300 requirements.

The contractor shall develop and deliver a test plan in accordance with CDRL A004 which shall specify the test equipment required, the location of testing and the proposed test schedule.

The contractor shall receive written Government approval of the test plan (CDRL A004) and

First Article Test Procedures (CDRL A006) prior to FAT of the First Article (FA) unit. The FA unit produced by the contractor shall be made in accordance with the technical data package and shall be identical to the Production Units. The contractor shall perform FAT on the FA unit in accordance with the contract. The contractor shall perform PAT on all Production Units

(1678AS100-1 for oxygen and 1678AS100-2 for nitrogen) in accordance with the contract. The contractor shall notify the Government at least 15 days prior to the start of FAT. The contractor shall not begin manufacturing Production Units until successful completion of FAT and

Government approval of the FAT Report (CDRL A008). The contractor shall allow the

Government to witness all testing. Upon approval of the FAT report, the contractor shall refurbish the FA unit to production level standards and shall be delivered to the Government in accordance with the delivery schedule or within 6 months of FAT completion, whichever comes first.

3.1 First Article Test (FAT) (CLIN 0002)

3.1.1 First Article Testing Procedures (CLINs 0001, 0005)

The contractor shall deliver FAT procedures for Government approval. The contractor shall compile FAT procedures based on the FAT requirements identified in Table 1 of drawing number 1678AS300. Procedures shall be in contractor format and shall include a summary description of all tests and detailed test procedures. The FAT shall not begin until Government approval of the FAT procedures. The Government may ask for a demonstration of any or all of the FAT procedures. The contractor shall submit the FAT procedures in accordance with CDRL

A006.

3.1.2 First Article Test (FAT) Report (CLINs 0003, 0005)

The contractor shall track all FAT testing and deliver verification that each requirement is met.

Any measured values or accumulated data obtained from separately prepared documents/reports shall be incorporated where applicable. The contractor shall document any failure during testing and the Government shall be notified of the failure within 24 hours of occurrence (CDRL A013).

The contractor shall be responsible for identifying the cause of the failure and recommending failure resolutions to the Government. The contractor shall not continue testing until failures are resolved. The contractor shall be the responsibility for retesting. The FAT Report shall include all test data including any failure resolution and retesting data and shall be submitted in accordance with CDRL A008.

3.2. Production Acceptance Test (PAT)

3.2.1 Production Acceptance Test (PAT) Procedures (CLINs 0001, 0005)

The contractor shall deliver PAT procedures for Government approval. The contractor shall compile procedures based on the PAT requirements identified in Table 1 of drawing number

1678AS300. The procedures shall be in contractor format and include a summary description of all tests; test data sheets and detailed test procedures. The PAT procedures shall be submitted in accordance with CDRL A007. The contractor shall not begin production acceptance testing until

Government approval of procedures and the successful completion of the FAT.

3.2.2 Production Acceptance Test (PAT) Report (CLINs 0005, 1001, 2001, 3001, 400X, 500X)

The contractor shall deliver a PAT Report detailing the results of each production unit tested.

The PAT Report (CDRL A009) shall display successful passing, failure, and failure resolution of all acceptance testing procedures for each unit tested. Any failure during testing shall be documented and the Government shall be notified of the failure within 24 hours of occurrence

(CDRL A013). The contractor shall be responsible for identifying the cause of the failure and recommending failure resolutions to the Government. The contractor shall not continue manufacturing of Production Units until failures are resolved. The contractor shall be responsible for retesting. Upon completion of all retesting and resolution of all failures, the contractor shall produce and deliver Production Units PN 1678AS100-1 or PN 1678AS100-2 as required by the Contract. If no failures, the units shall be delivered as Production Units PN

1678AS100-1 or PN 1678AS100-2 as required by the contract.

3.3 Failure Analysis and Corrective Action Report (FACAR) (CLINs 0002, 0005)

3.3.1 The contractor shall submit a Failure Analysis and Corrective Action Report (FACAR) in accordance with CDRL A013 in the event of a failure during First Article testing of the FA unit or any failures during Production Acceptance testing.

3.3.2 The contractor shall notify the Government within 24 hours of occurrence of a failure. The contractor shall be responsible for identifying the cause of the failure and recommending failure resolution to the Government.

3.3.3 The contractor shall make no changes to approved test procedures to resolve the failure without the Government’s approval of the changes.

3.4 Physical Configuration Audit (PCA) (CLINs 0004, 0005)

The contractor shall hold a Physical Configuration Audit (PCA) to compare the Second Pre-

Production Unit to the drawing package. The contractor shall use Section 8.2.2 of MIL-HDBK-

61 for guidance. The contractor shall conduct the PCA and will be witnessed by the Government in accordance with the PCA Plan (CDRL A012). 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 (CDRL A012) that fully describes the procedures and methodologies used to conduct the PCA. The contractor shall submit a PCA Report after completion of the PCA in accordance with CDRL A014 that fully describes all discrepancies in the drawing package and gives results of the PCA. The contractor shall describe all corrective actions to the CSS and/or drawings in this report. The contractor shall include raw data and worksheets in the report. Upon

Government approval of the PCA Report (CDRL A014), the contractor shall incorporate all CSS discrepancies identified in the PCA Report into the Second Pre-Production Unit and deliver the

Second Pre-Production Unit in accordance with the contract.

4. Integrated Logistics Support Requirements (ILS)

4.1. Purpose

This section defines the requirements and services that are to be furnished by the contractor in order to establish Integrated Logistics Support (ILS) for the CSS. The following sections define the approach, tasks, activities and requirements necessary to satisfy the Government’s overall objective of timely delivery of quality logistics support.

4.2 Integrated Logistics Support Requirements

All logistics requirements defined with this SOW, unless otherwise stated, shall be in support of the end item, the CSS, P/N 1678AS100-1/-2.

4.3 Logistics Program Management Planning and Control (CLINs 0002, 0004, 1001-500X, and 0011)

The contractor shall establish a management system to monitor the execution of the ILS portion of the contract requirements. The ILS management system shall provide for control of the development of a logistics support system for any CSS ECPs. The contractor shall ensure detailed integrated timelines for each ILS requirement are contained in the IMS (CDRL A001).

4.4 Configuration & Obsolescence Management

4.4.1 Configuration Management (CLINs 0002, 0004, 0011 and 1001-500X)

The contractor shall manage the configuration of the CSS beginning with the initial configuration identified through the end of the contract. Any changes made to the CSS shall be identified by the contractor, shall be presented to the Government in accordance with the

Configuration Management (CM) Plan (CDRL LL01) and shall be approved by the Government before changes are made to the drawings or, if after production, to the physical unit. Any changes made to the configuration management shall be executed by the contractor in accordance with PMA 260 Configuration Management Plan for Aviation Support Equipment dated 18 April 2013 (Appendix B) for guidance. Configuration changes are defined as additions, deletions, supersedes, or modification of the unit or any part of the unit during the performance of the contract. Configuration changes will be approved in writing, prior to any design change implementation. If and when parts become obsolete, the contractor shall submit an Engineering

Change Proposal. Any changes to the CSS configuration will require Government approval via

Request for Deviation and/or Engineering Change Proposals (ECPs) Class I/Class II in accordance with the PMA 260 Configuration Management Plan. The contractor shall identify any changes required to technical manuals, logistics product data, drawings, specifications, calibration in the ECP. The ECP shall include, but is not limited to, the following: acquiring replacement parts, investigating parts availability, interchangeability and substitutability, engineering efforts in regards to hardware and software, testing requirements, and changes to internal documents, Government drawings and subsequent Bill of Materials.

4.4.2 Obsolescence Management During Production (CLINs 0002, 0004, 1001, 2001, 3001, 400X, 500X)

The contractor shall manage obsolescence issues throughout the life of contract. This includes ongoing review and identification of actual and potential obsolescence problems for all components, assemblies, sub-assemblies, piece parts and materials of CSS. The contractor shall submit a plan identifying obsolescence risks and mitigation. Any configuration change due to obsolesce shall be through the approved program configuration management plan. The contractor shall submit the obsolescence management plan in accordance with CDRL LC01.

4.5 Calibration Requirements

4.5.1 Background

Calibration of support/test equipment is essential to ensuring that prime systems/end items meet specification requirements and their intended performance level. Calibration ensures the readiness of Support Equipment (SE) to perform accurate measurements, provide valid test data, limit erroneous test decision, and maintain measurement integrity and traceability. Any data referenced as guidance will be provided as Government Furnish Material (GFM) upon request.

4.5.2 Initial Calibration of Deliverable Assets (CLINs 0002, 0004, 1001, 2001, 3001, 400X, 500X)

The contractor is responsible for the initial calibration of any component or assembly delivered to the Government and affected by the ECP. The initial calibration shall be performed such that it can be verified in accordance with NAVAIR instruction 17-35QAC-01 (Series) Joint Navy and

Marine Corps Calibration Laboratory Audit/Certification Manual. The contractor’s calibration sticker shall be affixed where it is viewable by the operator. Each sticker shall identify who performed the calibration, the serial number of the item being calibrated, when the calibration was completed and when the next calibration is due. A letter or “Certificate of Calibration” in contractor format shall also be delivered with each unit stating date calibration was performed, procedures, standards used and date recalibration is due and shall be delivered in accordance with CDRL LC02.

4.6 Maintenance Planning Requirements

4.6.1 Logistics Product Data (LPD) Elements Input Data (CLIN 0008)

The contractor shall deliver the required data elements (refer to Appendix C, Table 1) which are defined in GEIA-STD-0007B, for all parts identified in support of the CSS. The contractor shall deliver minimum data elements for all legacy items, and deliver all elements for any new items.

Refer to Appendix C, Table 2 to determine minimum elements required. The contractor shall deliver data for contractor manufactured component/assemblies as well as sub-vendor data for components/assemblies from the contractor’s suppliers. The contractor shall deliver this information in an excel document using the column headings and format provided in Appendix

C, Table 2. This LPD Element Data shall be submitted for all components within the system and shall be updated in accordance with CDRL LM01. The contractor shall identify changes and additions within each LPD Element Input data by highlighting that amended portion of the Excel document. The data elements listed in the Appendix C Table 2 shall be submitted and shall be accompanied by top down breakdown of the End Item to its lowest indentured part in accordance with CDRL LM01.

4.7 Technical Manuals

4.7.1 Technical Data (CLIN 0011, CDRL LN01)

This section specifies the requirements for delivery of all source data provided by the contractor, in order for the Government to update the 2000 Gallon Oxygen CSS, Technical Manual (TM)

NA 19-5-502; Pre-Operational Checklist, (Pre-OP) NA 19-600-262-6-1; and Periodic

Maintenance Requirement Manuals (PMRM) 19-600-262-6-2. The three (3) technical manuals listed will be updated by the Government in accordance with the latest version of the specifications in effect at the time of initial preparation of the manuals. Source data delivered must meet the requirements outlined in these specifications listed below. If the source data does not meet the requirements of the specifications listed below the contractor shall take the necessary steps to correct or update the source data to meet the requirements. Digital specifications are available on the WEB at US DEPARTMENT OF DEFENSE ASSIST DOC

WEB SITE http://www.assistdocs.com .

The AL-855TM-GYD-000 Technical Manual Quality Assurance Program Guide is posted on the

NATEC web. The following table is provided as a guideline:

SPECIFICATION TITLE Date

MIL-STD-3001 DOD Standard Practice, Preparation of Digital

Technical Information for Multi-output presentation of

Technical Manuals.

1Dec2016

MIL-HBK-3001

(Series)

DOD Handbook, Guide to General Style & Format of

U.S. Navy

15May2015

AL-855TM-GYD-

Technical Manual Quality Assurance Program Guide

MIL-M-85337A Manual Technical: Quality Assurance Program Guide 19Jan2017

MIL-PRF 28001 Markup Requirements And Generic Style Specification

For Exchange of Text And Its Presentation

22Apr2010

The requirements established herein are designed to provide accurate, comprehensible, and usable TMs.

The contractor shall provide the below material to allow the Government and/or its’ contracted representative to update the above TMs in accordance with the above specifications:

For all portions affected by an ECP, the contractor shall deliver all required contractor source data, to include sub-vendor data, to include drawings, schematics, diagrams, specifications, or any other documentation as deemed necessary by the Government to allow the Government and/or its’ contracted representative to update the TMs in accordance with the above specifications. The contractor shall deliver written procedures for any changes to the operation of the system as well as supporting illustrations for updated operation and/or maintenance procedures. For parts supplied by the contractor’s sub-vendors, the contractor shall deliver the

Government and/or its’ contracted representative the source control drawings and/or http://www.assistdocs.com/ specifications. This Source Data Package (SDP) will be delivered pending Government approval of the ECP in accordance with CDRL LN01. The contractor shall provide engineers, technicians, and/or provisioning personnel with sufficient knowledge of the system at TIM 5 to ensure the integrity of the data provided in the SDP. The Government will be the decision authority to make the determination of what is deemed “necessary or required” to meet all of the specifications listed above throughout the TM update.

4.7.2 Technical Manual (TM) Revisions (CLIN 0011)

The contractor shall perform a review of the TM, provided by the Government, in order to improve troubleshooting, operation, and maintenance procedures. The contractor shall deliver back to the Government a list of the proposed changes, additions, and deletions to the tech manual. (Refer to CDRL LN01).

4.8 Supply Support (CLIN 0012)

The contractor shall use, to the maximum extent practical and cost effective, parts that are currently in the Government supply systems. This means that the preferred parts are those that have a National Stock Number (NSN).

4.8.1 Interim Support Item List (ISIL) (CLIN 0012)

The contractor shall propose an Iterim Support Item List (ISIL) that reflects the recommended contractor furnished (including vendor items) spares and high usage repair parts required to support the CSS for a period of 24 months (from IOC to MSD). Once the Government receives the contractor’s proposed ISIL, the suggested parts will be screened for approval in accordance with CDRL LP01.

4.9 Item Unique Identification (CLIN 0004, 0006, 1001, 2001, 3001, 400X, 500X)

4.9.1 Item Unique Identification (IUID) Marking Of Us Military Property

In accordance with DFARS Clause 252.211-7003 Item Identification and valuation, the contractor is required to mark and register all parts and assemblies, meeting the requirements called out in MIL-STD-130N. These include new parts and assemblies for which the

Government’s unit acquisition cost is $5,000 or greater, or any component, subassembly or embedded part that is serially managed, mission essential or a controlled inventory item. Refer to DFARS Clause 252.211-7003 for additional guidance.

4.9.2 Construct And Method

Details on creating the IUID and the marking method are contained in MIL-STD-130N. The

IUID may be either IUID Construct #1 or Construct #2 with Construct #2 being the preferred method.

4.9.3 IUID Location And Marking

The locations and marking methods selected should bear no impact on the performance of the part and minimal configuration change(s) to the part. The IUID (including 2D Matrix) should be incorporated onto the equipment data plate required under Engineering SOW para. X.X. If the

2D matrix cannot be incorporated onto the data plate, a 2D matrix sticker can be applied onto the main data plate provided it can be done without covering any critical data. When the 2D Data

Matrix is placed directly onto the data plate, human readable characters such as the Part Number, Serial Number and CAGE, are not required. If the above cannot be accomplished, a separate data plate can be attached which contains the 2D Matrix plus the human readable characters for the Part Number, Serial Number and CAGE. This added data plate should be attached in close proximity to the main data plate.

4.9.4 Permanency And Legibility

The IUID marking and identification plates, tags, or labels when used on equipment, parts, assemblies, subassemblies, units, sets, or groups shall be permanent during the normal life expectancy of the item and be capable of withstanding the environmental test and cleaning procedures specified for the item. Legibility shall be as required for ready readability as per

MIL-STD-130N.

4.9.5 UID Registration

The prime contractor has the responsibility to furnish IUID data to the IUID registry. Data submission of IUID data and acquisition cost should be submitted via Wide Area Work Flow

(WAWF), IUID XML file, IUID flat file or web entry. Additional information regarding data submission as well as the actual marking can be found at <http://www.acq.osd.mil/dpap/UID/>.

4.9.6 UID Records

The contractor shall maintain an accurate, current list of IUIDs for all manufactured items on this contract. This shall be supplied to the Government periodically and upon request. The list shall include Part Number, Serial #, CAGE, IUID Location, Construct used, how it was marked and the registration method used. If a third party is utilized they shall be identified.

4.9.7 IUID Plan (CLIN 0009)

The contractor shall develop a plan on how they intend on complying with the IUID requirement.

The IUID plan shall identify the components that require IUID marking, the method of marking, material used, and if a third party is planned to produce the IUID 2D image they shall be identified. The contractor shall verify that 100% of IUID’s have been produced correctly; the

IUID plan shall address how the IUID 2D images will be verified in accordance with CDRL

LL02.