Attachment_A,_WFIRST-IC-SOW-0001-.pdf

Effective Date: July 9, 2019

National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

WFIRST-IC-SOW-0001, Revision-

Wide Field Infrared Survey Telescope (WFIRST), Code 448

Instrument Carrier (IC)

Flight Structure Fabrication

Statement of Work (SOW)

GSFC WFIRST CMO

July 11, 2019

Released

Instrument Carrier (IC) Flight Structure Fabrication Statement of Work WFIRST-IC-SOW-0001, Revision-ii

Instrument Carrier (IC)

Flight Structure Fabrication

Statement of Work (SOW)

Review/Signature/Approval Page

Prepared by:

Wes Alexander

Approved by:

Roman Kilgore iii

Preface

This document is a Wide Field Infrared Survey Telescope (WFIRST)

Configuration Management (CM)-controlled document. Changes to this document require prior approval of the applicable Configuration Control Board (CCB) Chairperson or designee.

Proposed changes shall be submitted to the WFIRST CM Office (CMO), along with supportive material justifying the proposed change.

In this document, a requirement is identified by “shall,” a good practice by “should,” permission by “may” or “can,” expectation by “will,” and descriptive material by “is.”

Questions or comments concerning this document should be addressed to:

WFIRST Configuration Management Office

Mail Stop 448

Goddard Space Flight Center

Greenbelt, Maryland 20771 iv

Change History Log

Revision Effective Date Description of Changes

(Reference the CCR & CCB/ERB Approval Date)

Rev- July 9, 2019 Initial Release per WFIRST-CCR-0049 v

Table of TBDs/TBRs/TBSs [optional]

Item No. Location Summary Individual/

Organization

Actionee

Due Date vi

Table of Contents

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Background

1.4 Related Documentation

1.4.1 Applicable Documents and Drawings

1.4.2 Reference Documents

1.4.3 Document Requirements Flow Down for reference

2 PROGRAM MANAGMENT

2.1 Project Management

2.1.1 Project Manager

2.1.2 Resource Management

2.1.3 Schedule

2.1.4 Subcontract Management

2.1.5 Configuration Management

2.1.6 Information, Data, Records, and Storage

2.1.7 Export Control and Technology Transfer

2.1.8 Government Insight

2.1.9 Internal Proprietary Documents

2.2 Communications

2.2.1 Weekly Meetings

2.2.2 Kick-off Meeting

2.2.3 Technical Interchange Meetings

2.2.4 Reviews

2.2.5 Site Access

2.2.6 Reports

2.3 Risk Management

3 ENGINEERING

3.1 System Design and Support Activities

3.1.1 Systems Engineering

3.1.2 Systems Management and Engineering

3.1.3 System Analysis and Allocations

3.1.4 Contamination Control and Analysis

3.2 Design and Development Engineering and Analysis

3.2.1 Design and Process Development

3.2.2 Design and Analysis of GSE and Subscale Test Articles

3.2.3 Spares, Redundancy, and Long Lead Procurement

3.3 Ground Support Equipment

4 SAFETY AND MISSION ASSURANCE

5 ASSEMBLY, INTEGRATION AND TEST

5.1 Tube Fabrication Process Development

5.2 IC Development Test Assemblies

5.3 IC Flight Assembly and Integration

vii

5.4 Performance Verification and Design Qualification

5.5 Final Flight Instrument Carrier Inspection

5.6 Logistics

5.7 Post Delivery Support

5.8 Mechanical Ground Support Equipment

6 DELIVERY INSTRUCTIONS

6.1 GSFC Responsibilities

6.2 Hardware Deliverables

APPENDIX A ABBREVIATIONS AND ACRONYMS

List of Figures

Figure 1. Document Requirements Flow Down

List of Tables

Table 1 WFIRST Instrument Carrier Flight Fabrication Review Summary

1 INTRODUCTION

1.1 Purpose

This Statement of Work (SOW) defines those tasks necessary to develop fabrication processes, fabricate, and integrate the Instrument Carrier (IC) flight structure. This SOW also defines the test articles to verify the processes and analysis as defined in the Instrument Carrier Development Test Assemblies and Flight Structure Specification WFIRST-IC-SPEC-0057.

This SOW also defines the tasks necessary to support the subsequent integration, development article fabrication and testing, evaluation, and validation of the IC flight structure at NASA

GSFC, including post-delivery support to payload and observatory integration and test.

In this document, a requirement is identified by “shall,” a good practice by “should,” permission by “may” or “can,” expectation by “will” and descriptive material by “is”.

1.2 Scope

This Statement of Work (SOW) defines

a. Requirements that govern the development and delivery of the WFIRST Instrument

Carrier flight structure, associated test hardware, and associated ground support equipment to NASA’s Goddard Space Flight Center.

b. Tasks necessary to develop test articles and test them in support of the WFIRST engineering design effort at NASA’s GSFC.

c. Tasks necessary to support the testing, evaluation, validation, and qualification of the IC flight structure at NASA’s GSFC.

d. Tasks necessary to support the WFIRST Payload and Observatory integration and test.

1.3 Background

The IC structure design concept consists of a bonded frame assembly, incorporating square

Graphite Fiber Reinforced Plastic (GFRP) tubes, fingerplate gussets, very large highly loaded titanium forged and machined plug joints, and titanium clips. The material baseline is Hexcel’s

M55J/954-6 and T300/954-6 pre-preg. The IC structure requires predictable and repeatable thermal distortion from room temperature to 170 degrees Kelvin.

1.4 Related Documentation

The latest versions of all documents below should be used. WFIRST documents can be obtained from URL: https://ipdtdms.gsfc.nasa.gov.

1.4.1 Applicable Documents and Drawings

The documents listed below are applicable to this SOW to the extent specified herein, and apply directly to the performance of the IC Flight Structure contract. These documents establish detailed specifications, requirements, and interface information necessary for the performance of the contract.

In the event of conflicting requirements between this SOW and the Applicable Documents, the

Contractor shall follow the following precedence:

GSFC drawings

Flight Structure Fabrication Specification https://ipdtdms.gsfc.nasa.gov/

Statement of Work

Other WFIRST documentation

GSFC approved Contractor documents

Other Government approved documents

Industry standard documents

Document Number Title

NASA-STD-5005 Standard for the Design and Fabrication of Ground Support

Equipment

NASA NPR 6000.1 Requirements for Packaging, Handling and Transportation for

Aeronautical and Space Systems, Equipment and Associated

Components

540-PG-8700.2.1 Design and Certification of Dollies, Stands, and Shipping

Containers

WFIRST-IC-LIST-0023 IC Flight Structure Deliverable Items List and Schedule (DILS)

WFIRST-SYS-PLAN-0051 WFIRST Contamination Control Plan

WFIRST-SMA-REQ-0032 WFIRST Mission Assurance Requirements Document (MAR)

WFIRST-IC-SPEC-0046 Instrument Carrier, Flight Structure Fabrication Specification

WFIRST-IC-SPEC-0017 Material Specification, 954-6 pre-impregnated tape

WFIRST-IC-SPEC-0067 Process requirement for adhesive bonding

WFIRST-IC-SPEC-0068 Process r specification for Composite Laminate Fabrication

WFIRST-IC-SPEC-0035 Requirements for Machining, Drilling and Trimming of

Composite Structures

WFIRST-IC-SPEC-0032 Non Destructive Examination Specification and Defect

Acceptance Criteria for Non- Metallics

WFIRST-IC-SPEC-0062 Process Requirements for Application of Br127 Primer, Instrument

Carrier

2242498 Raw Diamond Tube Stock (“Blank”)

2242499 Raw square Tube Stock (“Blank”)

2250600 Raw Gusset panel Stock (“Blank”)

2250602 Development Test Specimen, Plug Joint assembly

2250603 Development Test Specimen, T joint assembly

2250604 Development Test Specimen, Diagonal Assembly

2250608 Flight structure assembly with critical dimensions

2250578 Large titanium Node

540-PG-8719.1.1- Lift Sling Design

1.4.2 Reference Documents

The following documents shall be considered supplemental information to this SOW in so far as they are applicable to this type of engineering effort.

Document Number Title

NPR 7123.1 NASA Systems Engineering Processes and Requirements

GPR 8700.6 Engineering Peer Reviews

1.4.3 Document Requirements Flow Down for reference

Figure 1. Document Requirements Flow Down

2 PROGRAM MANAGMENT

2.1 Project Management

A. The Contractor shall establish, implement and maintain a management system that effectively and efficiently plans, organizes, controls, and reports on the contract objectives, as well as provide the necessary leadership and technical coordination of the activities to ensure schedules and technical progress are consistent with the contract objectives.

B. As part of this effort, the Contractor shall provide traceability of cost, schedule and technical progress data for work being performed by the Contractor and all of its suppliers and sub-Contractors in support of this contract.

C. The Contractor shall provide a verification matrix for the Specification WFIRST-IC-

SPEC-0046 (DILS-PM-1).

D. The Contractor shall provide a verification matrix for this SOW (DILS-PM-2).

E. The Contractor shall provide a verification matrix for the DILS WFIRST-IC-LIST-0023

(DILS-PM-3).

2.1.1 Project Manager

A. The Contractor shall designate, by name, an IC Flight Structure Project Manager (PM).

B. The PM shall be responsible for leading the IC flight structure team per the requirements and tasks laid out in this document.

C. The PM is the primary point of contact and shall provide full visibility to NASA/GSFC on all aspects of performance covered by this SOW.

D. The PM shall provide full visibility including the immediate disclosure of existing or potential problems along with their planned resolutions.

E. The PM will utilize the COR as the primary point of contact with the GSFC team.

F. The PM shall coordinate the Contractor efforts with that of its sub-Contractors, the

Government Furnished Property (GFP) providers if outside of NASA/GSFC, and

NASA/GSFC.

2.1.2 Resource Management

A. Contractor shall provide the necessary resources for monitoring, controlling, executing, and administering the IC flight structure development test assembly’s contract and subcontracts to ensure compliance with all contractual requirements.

B. The Contractor shall provide a detailed Work Breakdown Structure (WBS) Diagram and dictionary plus all updates and revisions in accordance with the IC flight Structure development test assemblies Work Breakdown structure Diagram and Dictionary (DILS

PM-4).

C. The Contractor shall provide visibility into cost and schedule performance at a frequency identified in the DILs WFIRST-IC-LIST-0023

D. The Contractor shall provide monthly and quarterly financial management reports in the form of 533’s (DILS PM-5).

E. The Contractor shall provide all necessary facilities, tools, test equipment, materials, and processes required for the execution of this statement of work. That list would include, but is not limited to: clean rooms, thermal vacuum chambers, thermal cycle chambers, and inspection facilities.

2.1.3 Schedule

A. The Contractor shall establish, implement, and maintain an integrated scheduling system consistent with their corporate procedures and approved by GSFC.

B. This Integrated Master Schedule (IMS) shall be provided for planning, controlling, modeling and specifying work activities throughout the project life cycle in accordance with the IMS (DILS PM-6).

C. The Contractor shall use Microsoft Project to maintain compatibility with the WFIRST project team.

2.1.4 Subcontract Management

A. The Contractor shall provide quality, technical and programmatic oversight over all subcontracts.

B. The Contractor shall report their sub-Contractor progress and performance to GSFC in the weekly reports.

C. The Contractor shall conduct surveillance of all subcontracts to ensure satisfactory performance.

D. The Contractor shall report the results of this surveillance to GSFC.

E. The Contractor shall deliver component and subassembly inspection reports for all subcontracted items, in accordance with (DILS PM-7).

F. The Contractor shall provide a description of the methods used to flow down requirements and manage sub-tier suppliers. The Contractor shall identify critical processes related to sub-Contractors and the methods for ensuring the process requirements are met. Sub-tier supplier management shall use established processes, practices and procedures to reduce risk to the program and increase sub-tier performance.

Sub-tier supplier performance measures shall be used to provide the Contractor and

WFIRST with visibility to sub-tier supplier performance and overall program status.

2.1.5 Configuration Management

A. The Contractor shall use a Configuration Management (CM) system to configuration control all documentation and hardware related to this SOW at all times.

B. The Contractor shall deliver a Configuration Management Plan in accordance with (DILS

PM-8).

C. The Contractor shall maintain configuration of all documents and drawings verifying the correct version is used throughout all phases of the contract.

D. Configuration verification shall be performed and documented as assemblies are incorporated into higher-level assemblies and at major project milestones (i.e. pre-environmental cycling and testing, pre-ship, etc.).

E. The Contractor shall provide a list once every 2 weeks and at each review with all revision level documents and drawings that are being used for fabrication. (DILS- PM-

9).

F. The Contractor shall have in place a Configuration Control Board (CCB) to review and approve changes to the configuration of deliverable items.

G. The CM system shall have a change classification and impact assessment process that results in all changes being forwarded to the GSFC COR. These changes are defined as any change that affects requirements, levied on the Contractor by GSFC.

H. The Contractor shall provide photo documentation of all tasks associated with the fabrication, assembly, integration, and test of all hardware governed by this SOW.

I. Photo documentation shall be in accordance with the Digital Image and Video Records

Document (DILS PM-10).

2.1.6 Information, Data, Records, and Storage

A. The Contractor shall establish a method to provide access by Internet to authorized

WFIRST Project personnel for working data products. A GSFC or Contractor electronic database system or combination of both can be used.

B. If a Contractor database is used, the Contractor shall maintain access protection for the system, including an access control list for all authorized WFIRST Project personnel.

C. The Contractor shall store all data relating to testing governed by this SOW in a database that is accessible to WFIRST personnel through the life of the contract.

D. The Contractor shall ensure accessibility of Electronic and Information Technology (EIT) in compliance with the Workforce Investment Act of 1998 amended section 508 of the

Rehabilitation Act of 1973. This accessibility shall be in developing, procuring, maintaining or using EIT as required by this Statement of Work.

2.1.7 Export Control and Technology Transfer

A. The Contractor and all sub-Contractors shall work with GSFC to determine and identify whether information, data and records that it produces is designated International Traffic in Arms Regulations (ITAR), Export Administration Regulation (EAR), proprietary, before releasing in the public domain.

B. The Contractor and all sub-Contractors shall prepare, submit, and update as necessary any ITAR and Export Control Administration (EAR) licensing documentation required.

C. The Contractor and all sub-Contractors shall prepare, submit, and update as necessary any EAR licensing documentation required.

2.1.8 Government Insight

A. Contractor shall be open to Government attendance, all Contractor and sub-Contractor internal data, reviews, audits, meetings and other activities within the scope of the contract. For access and insight activity, “Government” includes Government personnel and Government Contractor personnel.

B. The Contractor shall allow and enable the use of Non-Disclosure Agreements (NDA) with Government Contractors where appropriate.

C. For meetings not called out in the DILS document, the Contractor shall notify the

Contracting Officer and the COR of meetings, reviews or tests in sufficient time

(nominally five working days) to permit meaningful Government participation. All major meetings shall follow the DILs document WFIRST-IC-LIST-0023

2.1.9 Internal Proprietary Documents

A. The Contractor shall inform the government of such documents if they need to be used in the execution of this statement of work.

B. The Contractor and the Government shall, on a case by case basis, determine if and how the proprietary documents can be applied to the execution of the work governed by this SOW.

C. The Contractor cannot withhold information related to the output or result of a methodology or procedure.

D. The Contractor cannot withhold methodology or procedural information from a failure review board.

2.2 Communications

A. Contractor shall provide regular communications and meetings with WFIRST project to discuss programmatic, financial, contracts, technical, and mission assurance status and issues.

2.2.1 Weekly Meetings

A. Contractor shall report technical and programmatic progress in weekly telecom meetings with the COR. In-person attendance is encouraged if Contractor personnel are on site at

Goddard.

B. The Contractor shall generate a brief email status to the COR to be used in reporting IC flight structure weekly status to the WFIRST Project.

2.2.2 Kick-off Meeting

A. The Contractor shall organize and hold a Kick-off Meeting at the Contractor’s facility prior to any activity identified in this SOW. Kick off meeting shall be held no later than

25 calendar days after contract award. The Contractor shall provide to the NASA/GSFC

COR a Kick-off Presentation Package and all other required deliverables. (DILS PM -11)

The Kick-off Meeting shall address program management and quality assurance activities outlined in this SOW, as well as the performance and environmental requirements outlined in the WFIRST-IC-SPEC-0046 specification in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

Program Management organization Chart.

Review of flow-down documentation (SOW, MAR, Spec, DILS, applicable documents etc).

Review of key baseline assumptions.

Quality Assurance including non- conformance processing.

Design description review of technical approach.

Flight heritage, including review of applicable Lessons Learned.

Review of critical processes.

Facilities.

Review of potential risks and risk mitigation plan.

Review of key technical areas, confirmation of plans for Technical

Interchange Meetings TIMs.

Schedule Review including critical path, margin, and review of deliverable items.

2.2.3 Technical Interchange Meetings

A. Contractor shall provide a minimum of two Technical interchange meetings (TIM). One

TIM shall be held prior to the fabrication of the development tubes and lamina/laminate material testing. The second TIM shall be held prior to the flight Structure assembly.

Additional TIM’s will be conducted as needed to resolve and work out detailed technical issues (e.g. interfaces). As much as possible, these TIMs will be held remotely, but in some cases, there will be technical matters where it will be more effective to conduct the

TIM via face-to-face meetings.

B. Whenever possible, the location of these TIMs will alternate between GSFC and the

Contractor location. As a planning guide, the number of TIMs to be held at GSFC per

Contract will be one, and the number to be held at the Contractor facility would be one, each for duration of 2 days. Attendance to these TIMs will depend on the topic to be discussed and should be limited to the appropriate personnel. Some examples of specific

TIMs include, but are not limited to:

Review of the mandrels and material before manufacturing.

Table Top reviews.

IC Working Groups.

2.2.4 Reviews

A. Contractor and the Government shall coordinate to finalize the review dates during regular weekly meetings, as outlined in above weekly meeting Section.

B. The Contractor shall organize and hold two MRR’s at the Contractor’s facility prior to

Fabrication of flight articles.

a) The first (DILS PM-12) shall be before fabrication of flight tubes and gussets, meeting the following requirements as a minimum:

Fabrication and inspection flow;

Key individuals working on the fabrication;

Facilities;

Quality/Verification plan;

Contamination control plan;

Material certifications and test reports;

Mandrel evaluation or overall Ground Support Equipment

(GSE);

Thermal cycle details; and

Schedule;

b) The Second (DILS PM-13) would be before flight assembly begins and after all tubes, gussets, and clips are completed, covering Titanium nodes may not be 100% complete but should be far enough along to understand the assemble process:

Fabrication and inspection flow;

Assembly flow;

Key individuals working on the fabrication;

Facilities;

Quality/Verification plan;

Contamination control plan;

Piece part inspection and test reports;

Mandrel evaluation or overall GSE;

Schedule;

C. The Contractor shall conduct Test Readiness Reviews (TRRs) prior to the start of each sub-scale test as described in the specification WFIRST-IC-SPEC-0046. A TRR for each planned test or series of tests ensures that the test article (hardware/software), test facility, support personnel, and test procedures are ready for testing and data acquisition, data reduction, and procedure and data control including configuration management and data storing and archiving. There shall be a minimum of 2 TRR’s (DILS PM-14) one before any joint testing article such as double lap shear and one at the start of the joint development test articles. This could be one TRR that covers the three or more development test articles such as the plug joint. If only one TRR is performed for the joint development test articles then all the documentation required shall be presented for all test configurations.

D. The Contractor shall hold a Pre-Ship Review (PSR)/ Acceptance Review at the

Contractor's facility at the completion of verification tests and prior to the shipment of the flight instrument carrier to NASA/GSFC. This presentation shall demonstrate completion of all activities required for delivery of any hardware deliverable item to

NASA/GSFC, and note any activities that are incomplete. In particular, the Contractor shall present the completed verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses from subscale test articles and complete materials testing package) where applicable (DILS PM-15). Any requirements that are not met shall be identified in the Deviations/Waivers etc. list and discussed with

NASA/GSFC during the review.

E. An End Item Data Package (EIDP) shall be made available for review during Pre-Ship

Reviews for each of the different hardware deliverables (DILS PM-16). This package shall be delivered with each end item with the level of detail required of that item.

F. The Contractor shall implement a system for tracking the status and resolution of Action

Items initiated during peer and formal reviews whose status shall be reported at the formal reviews.

The following table summarizes the current reviews. Please note that the dates shown here are to be used as a guide for planning and cost estimating. These dates are subject to change during the course of the development effort.

Table 1 WFIRST Instrument Carrier Flight Fabrication Review Summary

Reviews Tentative Date Days Location/Comments

Kickoff Meeting 15 days ACA 2 Contractor

IC CDR 4/20 2 GSFC

MRR Tube Fabrication 2/20 1 Contractor

MRR Flight

Fabrication

5/20 2 Contractor

TRR for Double lap shears

2/20 2 Contractor

TRR for development test assemblies

4/20 1 Contractor

PSR/Acceptance for

Flight units and spares

1/21 1 Contractor

2.2.5 Site Access

A. NASA shall be granted access to the Contractor’s and sub-Contractor facilities. Procedures for visit requests, contacts and authorizations will be coordinated with the IC flight structure PM.

2.2.6 Reports

A. Contractor shall provide programmatic reports as outlined in the Instrument Carrier Flight structure development and test assemblies DILS (WFIRST-IC-LIST-0023).

B. The Contractor shall provide a Monthly Status Report identifying the technical and schedule progress made by the Contractor compared to the goals established for the

Program (DILS-PM-17). This report shall include but is not limited to:

a. Description of work performed, including updated milestone plan.

b. Cumulative action item list showing open and closed action items with

Estimated Completion Date (ECD) and assigned responsibility, as well as status of any open action items.

c. Description of significant problems and proposed solutions.

d. Risk and Opportunity management listing and status.

e. Status of all changes.

f. Material Review Board status.

g. Part and material status including sub tier supplier status.

h. DILS delivery status.

i. Other items as defined in applicable sections of the MAR.

C. The Contractor shall provide electronically to the WFIRST project, when requested, within five business days, any IC flight structure and development test assemblies related plans, reports, technical memoranda, procedures, and analyses that are Contractor or sub-

Contractor generated under this contract for the WFIRST mission, but not listed in the

DILS.

2.3 Risk Management

Contractor shall present for approval a Risk Management Plan in support of the IC flight structure.

3 ENGINEERING

3.1 System Design and Support Activities

3.1.1 Systems Engineering

A. Contractor shall establish and maintain a Systems Engineering Program for directing, specifying and overseeing the technical process development of the IC flight structure and IC flight structure GSE.

B. The Contractor shall efforts to manage and verify requirements, perform risk assessment, conduct systems analyses and trade studies, sponsor peer reviews, manage interface control documentation, manage systems budgets, and guide an integrated design and test process.

C. The Contractor shall develop and maintain a requirements traceability tool or utilize an existing tool and use that tool to demonstrate that the IC flight structures design meets all requirements.

D. For all IC flight structure activities, the Contractor shall use the International System of

Units (SI) with the following exceptions:

a) SI units with parenthetical English units are permitted for engineering and manufacturing drawings.

b) Angular measurement may be expressed in degree of arc or in an appropriate subdivision of degree of arc such as minute or second of arc

(arc-min or arc-sec).

c) Hardware that has been previously built, or of similar design heritage, may be specified in English units where use of metric equivalents would lead to additional risk and cost to the program.

3.1.2 Systems Management and Engineering

A. Contractor shall document the plan, method, and artifacts of verifying all controlled technical requirements including inspection, analysis, demonstration, and test.

B. The Contractor shall provide or maintain, if supplied by GSFC, a Drawing Tree that includes all IC flight structure and IC flight structure GSE drawings, plus updates and revisions, in accordance with (DILS SE-1).

C. The Contractor shall provide and maintain, if supplied by GSFC, a Document Tree that includes all IC flight structure and IC flight structure GSE documents, plus updates and revisions, in accordance with (DILS SE-2).

3.1.3 System Analysis and Allocations

A. Contractor shall provide Computer Aided Design (CAD) models, Finite Element Models

(FEMs), and other supporting analyses to the WFIRST Project. These models would include but are not limited to models and analysis of the test articles, GSE, and the transport carrier. Contractor.

3.1.4 Contamination Control and Analysis

A. During all phases of the project, the Contractor shall comply with the contamination requirements documented in the WFIRST Contamination Control Plan (CCP) (WFIRST-

SYS-PLAN-0051).

B. The Contractor shall document compliance with the CCP (WFIRST-SYS-PLAN-0051) in accordance with the IC flight structure Contamination Control Implementation Plan

(DILS SE-3).

C. The Contractor shall provide suitable access-limited, clean room facilities as specified by the WFIRST CCP (WFIRST-SYS-PLAN-0051), D. The Contractor shall provide “contingency” capability of a temporary clean bench/tent if required for offline GFP processing/testing.

3.2 Design and Development Engineering and Analysis

3.2.1 Design and Process Development

A. The Contractor shall provide support for all process development including but not limited to Square and Diamond section tube fabrication, circular and damming of bond areas, repair and assembly procedures.

B. The Contractor shall provide documented procedures for the following:

a. Tube and flat part fabrication meeting the dimensional tolerances required on drawings. This could be in the form of a traveler with inspection documentation to support (DILS SE-4).

b. Development report on circular bonding and damming processes which includes taper bonds, any testing performed to identify process and inspection reports.

(DILS SE-5).

c. Non-Destructive Evaluation (NDE) procedures and any standards that were produced for inspection process. (DILS SE-6).

d. Inspection reports both dimensional and NDE documentation process that has been approved by WFIRST (DILS SE-7).

e. Repair Procedure (DILS-SE-8).

3.2.2 Design and Analysis of GSE and Subscale Test Articles

A. The Contractor shall provide all personnel, facilities, and support necessary to design and analyze a transportation unit and testing GSE that will maintain all thermal, mechanical, and structural requirements from the IC Flight Structure Fabrication Specification

(WFIRST- IC-SPEC-0046.

B. The Contractor shall provide design and analysis documentation showing the

GSE/transportation/handling equipment will not harm the flight structure or effect the testing of the development joints in an adverse way.

C. WFIRST shall review and approve the design of the shipping container for the flight structure.

3.2.3 Spares, Redundancy, and Long Lead Procurement

The following requirements apply to the IC flight structure.

A. Contractor shall qualify, test, and calibrate the spare parts to the same standards as the flight articles consistent with their spared level of assembly.

B. The Contractor shall provide a Spare Parts Plan and List plus all updates and revisions, in accordance with (DILS SE-9).

C. The Contractor shall identify critical procurements of long lead materials and items that must be procured in order to support the IC flight structure master schedule.

3.3 Ground Support Equipment

This section applies to Contractor-supplied GSE.

A. The Contractor shall design and certify Dollies, Stands, and shipping containers per 540-

PG-8700.2.1, Design and Certification of Dollies, Stands, and Shipping Containers.

B. The Contractor shall design and certify lifting slings per 540-PG-8719.1.1 “Lift Sling

Design”

C. GSE shall include deliverable items listed in the contract as well as equipment required for the Contractor’s own use.

D. The Contractor shall provide any certifications required such as proof tests and analysis performed on the GSE.

E. The Contractor shall provide the GSE for use by the Government as requested during IC flight structure integration and testing.

F. The Contractor shall design, test and certify GSE that interfaces directly to the flight hardware per the requirements in the IC Flight Structure Fabrication Specification

(WFIRST-IC-SPEC-0046) and the MAR.

G. The IC flight structure Contractor shall be responsible for Mechanical GSE (MGSE) required to integrate and move the IC flight structure in their facility. The functions include: assembly integration and test work-stands, lifting, transporting, and storing, as well as environmental fixtures for post curing.

4 SAFETY AND MISSION ASSURANCE

A. The Contractor shall comply with the applicable safety and mission assurance requirements and the corresponding Data Item Descriptions (DIDs) documented in subsections 3.1 through 3.6, 4.1, 4.2.1, 4.2.2, 6.5, 6.7, 6.8, 6.9, 6.11, 6.12, and sections 10 through 11, subsection 12.3, and sections 13 through 14 of the WFIRST Mission

Assurance Requirements (MAR WFIRST-SMA-REQ-0032).

B. All Close Calls and Mishaps per NPR 8621.1, major non-conformances, and test failures shall be reported to the COR and WFIRST Chief Safety and Mission Assurance Officer

(CSO) immediately and followed up with a written report within 24 hours of the occurrence.

C. The Contractor shall prepare and provide inputs to the WFIRST Project Safety Manager for the applicable System Safety requirements defined in section 5 of the MAR, to identify, evaluate, and eliminate or control hazards in support of MAR DIDs 5-1 through

5-6.

D. The Contractor shall plan for Government Mandatory Inspection Points (GMIPs) per

MAR section 3.8. The Contractor shall provide work instructions, procedures, drawings, etc. that are appropriate for the activities. The following are examples of activities that may be subject to GMIPs.

- Unit and component level assembly – witness final assembly;

- Mechanical – final assembly and acceptance test;

- Rework and repairs to flight hardware;

- Pre-Ship Inspection/Data Review, etc.

5 ASSEMBLY, INTEGRATION AND TEST

The Contractor shall assemble and integrate 1x flight IC structure and deliver it to GSFC for testing. The assembly and integration process shall be reviewed with the COR to verify that the loading is either enveloped by flight loads or is acceptable to the IC team.

The Contractor shall assemble and integrate all development test assemblies required per

WFIRST-IC-SPEC-0057 and this SOW

5.1 Tube Fabrication Process Development

The Contractor shall work with the COR and the WFIRST IC team to develop the tube fabrication process to be used on test assemblies and the flight hardware.

In order to verify the process is acceptable, the Contractor shall provide GSFC with the following for evaluation:

A. 3x square tubes per 2242499

B. 3x diagonal tubes per 2242498

Once the process is developed and concurred with by GSFC, the Contractor shall use the established process, the same GSE, and the same personnel to fabricate the test assembly tubes and the flight IC tubes used in support of sections 5.2 and 5.3

5.2 IC Development Test Assemblies

A. The Contractor shall develop and provide a component assembly, drawings, and

Procedures based on the WFIRST test plan for all joint development test assemblies

(DILS IT-1).

B. The Contractor shall generate work instructions for hardware assembly as part of the end item data package. These work instructions shall be available for review by GSFC at any time.

C. The Contractor shall assemble the development test assemblies’ hardware per the approved work instructions.

5.3 IC Flight Assembly and Integration

A. The Contractor shall develop and provide an assembly plan for the flight structure. This will be broken down into manageable timeframes taking into consideration pot life and out times of the materials being used. WFIRST will provide drawings based on the plan.

(DILS IT-2).

B. The Contractor shall accommodate the IC delivery schedule or identify any issues.

C. The Contractor shall provide appropriate space for hardware and associated GSE to minimize risk of damage to hardware and interface with other activities.

D. The Contractor shall integrate all flight hardware using approved procedures, tools and

GSE.

5.4 Performance Verification and Design Qualification

A. A Verification Plan shall be generated by the Contractor to describe the details of how the analyses, inspections, and verification tests identified in the WFIRST-IC-SPEC-0046

Specification will be performed (DILS IT-3). Verification tests shall demonstrate the item meets all of the specified performance requirements over the specified range of environments, measure performance parameters and reveal inadequacies in manufacturing and assembly such as workmanship or material problems. Any requirement that exceeds previous qualification test data shall be presented to the

NASA/GSFC COR as part of the planning process for evaluation and a possible delta qualification test.

a. The plan shall state the purpose of each test, state acceptance criteria, describe in detail the test method, set up, instrumentation, data analysis methods (if applicable), and give the test sequence. The plan shall include a verification matrix summarizing how all requirements are verified (analysis, inspection, test, per the definitions in the Spec.), and listing all tests that will be performed on the

IC flight Structure.

b. This plan shall be a Contractor controlled document and shall indicate all changes made after the initial approval by the NASA/GSFC COR. After Verification Plan approval, no changes shall be made without written NASA/GSFC COR approval.

B. The Contractor shall generate individual test plans including updates and revisions for each verification test performed on the development test assemblies, in accordance with the Individual Test Plans (DILS IT-4).

C. The Contractor shall provide a method whereby GSFC can review, comment on, and approve test plans.

D. The Contractor shall generate individual test procedures plus updates and revisions, in order to implement the test plans and to provide input to WFIRST Payload and

Observatory level test procedures, in accordance with the Test Procedures (DILS IT-5).

E. The Contractor shall provide a method whereby GSFC can review, comment on, and approve the test procedures.

F. The Contractor shall perform tests per the approved test procedures. These tests include but are not limited to:

a. Structural

b. Mechanical

c. Calibration

G. The Contractor shall hold a post-test review with GSFC prior to test disassembly. The criteria for test disassembly should be clearly defined in the test plan.

H. The Contractor shall generate Test Reports per (DILS IT-6).

5.5 Final Flight Instrument Carrier Inspection

The Contractor shall provide a set of metrology measurements that could be used to generate as-built surfaces in our mechanical and optical CAD and analysis programs (DILS-IT-7).

5.6 Logistics

A. The Contractor shall comply with NASA NPG 6000.1H, Requirements for Packaging, Handling and Transportation for Aeronautical and Space Systems, Equipment and

Associated Components when handling and transporting hardware, documentation, software and Ground Support Equipment among test facilities, (GSFC), and the launch site.

B. The Contractor shall provide an IC flight structure, and GSE Transportation Plan in accordance with the Transportation Handling Plan and Procedures (DILS IT-8).

C. The Contractor shall provide the shipping container and environmental monitoring equipment to demonstrate that no transportation design loads are exceeded.

D. The Contractor shall ensure that environmental requirements (per the IC Flight Structure

Fabrication Specification WFIRST- IC-SPEC-0046) and the Contamination Control Plan

(WFIRST-SYS-PLAN-0051)) are met while shipping.

E. The specific method of transportation (truck type carrier etc.) shall be reviewed and approved by WFIRST.

5.7 Post Delivery Support

The Contractor shall support receiving of the structure at GSFC. This shall include post-delivery NDE of all joints. Verification of bonded joint integrity using comparison of pre and post shipment data shall be performed on all bonded joints. Activities include, but are not limited to set up and instruction and support of technicians at GSFC for use of the

Contractor’s devices. For the purpose of this SOW the Contractor shall assume 160 hours of work.

5.8 Mechanical Ground Support Equipment

The IC flight structure Contractor shall be responsible for Mechanical GSE (MGSE) required to integrate and move the IC flight structure. The functions include: assembly integration and test work-stands, lifting, transporting, and storing, as well as environmental fixtures for post curing.

6 DELIVERY INSTRUCTIONS

A. Except as otherwise provided in this Contract, the point of inspection, acceptance and delivery of all DILS items deliverable under this Contract shall be the NASA Goddard

Space Flight Center, Greenbelt, Maryland 20771.

B. All such deliverables shall be packaged, packed, boxed or crated in such a manner to ensure safe delivery and shall be shipped prepaid and at the Contractor’s expense to the point of delivery.

C. The IC flight structure shall be shipped from the Contractor in a shipping container designed and tested by the Contractor. The point of delivery for the IC flight structure shall be at GSFC, Maryland.

D. Residual flight and non-flight hardware shall be identified and GSFC will recommend disposition.

6.1 GSFC Responsibilities

A. GSFC is responsible for the final designs of the items listed in section 6.2.

B. GSFC shall provide technical direction and shall be fully responsible for the final design of the Instrument Carrier Flight Structure.

C. GSFC shall provide all required documentation to the Contractor.

D. GSFC shall be responsible for documenting all changes.

E. GSFC provided documentation as needed and providing said changes to the Contractor.

6.2 Hardware Deliverables

The deliverables outlined in the Statement of Work are described in the Instrument Carrier

Development Test Assemblies and Flight Structure Deliverable Items List and Schedule (DILS) document (WFIRST-IC-LIST-0023).

A. 2242499 Three square development tubes (HW-1).

B. 2242498 Three diamond development tubes (HW-2).

C. Instrument Carrier Flight Structure (HW-3).

D. Shipping container (HW-4).

E. Spare tubes (HW-5).

F. Spare Gussets (HW-6).

G. Repair panels (HW-7).

H. Completed Test Articles (HW-8).

I. Trials for adhesive processing (HW-9).

a. These would include but not limited to Plexiglas trials, repair procedures and articles, all broken test articles, NDE Standards, and any other testing items.

Appendix A Abbreviations and Acronyms

Abbreviation/

Acronym

DEFINITION

ACA After Contract Award

AI&T Assembly, Integration, and Test

CAD Computer Aided Design

CCB Configuration Control Board

CCP Contamination Control Plan

CCR Configuration Change Request

CDR Critical Design Review

DILS Contract Deliverables Requirement List

CM Configuration Management

CMO Configuration Management Office

COR Contracting Officer’s Representative

DILS Deliverable Items List and Schedule

EAR Export Administration Regulation

EGSE Electrical Ground Support Equipment

EIT Electronic and Information Technology

EMC Electromagnetic Compatibility

EMI Electromagnetic Interference

ESD Electro-Static Discharge

FEM Finite Element Model

GFP Government Furnished Property

GSE Ground Support Equipment

GSFC Goddard Space Flight Center

I&T Integration and Test

IBR Integrated Baseline Review

IC Instrument Carrier

ICD Interface Control Document

IM Integrated Modeling

IMS Integrated Master Schedule

ITAR International Traffic in Arms Regulations

MAIP Mission Assurance Implementation Plan

MAR Mission Assurance Requirements

MGSE Mechanical Ground Support Equipment

MRB Material Review Board

PDR Preliminary Design Review

PM Project Manager

PSR Pre-Ship Review

SI International System of Units

SMA Safety and Mission Assurance

SOW Statement of Work

STOP Structural-Thermal-Optical

TGSE Thermal Ground Support Equipment

Abbreviation/

Acronym

DEFINITION

TIM Technical Interchange Meeting

TRR Test Readiness Review

WBS Work Breakdown Structure

WFIRST Wide Field Infrared Survey Telescope