QASP - HANKOOK LATHE REPAIR.pdf

QUALITY ASSURANCE SURVEILLANCE PLAN AND MATRIX

1.0 PURPOSE

This Quality Assurance Surveillance Plan (QASP) is a Government developed and applied document used to make sure that systematic quality assurance methods are used in the administration of the

Performance Based Service Contract (PBSC) standards included in this contract. The intent is to ensure that the Contractor performs in accordance with performance metrics set forth in the contract documents, that the Government receives the quality of services called for in the contract and that the Government only pays for the acceptable level of services received.

2.0 AUTHORITY

Authority for issuance of this QASP is provided under FAR 52-212-4(a), Inspection/Acceptance, which provides for inspections and acceptance of the articles, services, and documentation called for in the contract to be accomplished by the Contracting Officer or their duly authorized representative.

3.0 SCOPE

The Contractor, and not the Government, is responsible for management and quality control actions necessary to meet quality standards set forth by the contract. The QASP is put in place to provide

Government surveillance oversight of the Contractor’s quality control efforts to assure that they are timely, effective and are delivering the results specified in the contract. The QASP is not a part of the contract nor is it intended to duplicate the Contractor’s Management Plan. The Government may provide the Contractor an information copy of the QASP as an Attachment to the solicitation to support the

Contractor’s efforts in developing its plan for maintaining the levels of quality anticipated to be delivered under the terms of the contract.

4.0 RESPONSIBILITIES

The Government resources shall have responsibilities for the implementation of this QASP as follows:

Contracting Officer – The Contracting Officer ensures performance of all necessary actions for effective contracting, ensures compliance with the terms of the contract and safeguards the interests of the United States in the contractual relationship. It is the Contracting Officer that assures the Contractor receives impartial, fair and equitable treatment under the contract. The

Contracting Officer is ultimately responsible for the final determination of the adequacy of the

Contractor’s performance.

Contracting Officer’s Representative (COR) – An individual designated in writing by the

Contracting Officer to act as his authorized representative to assist in administering a contract.

The source and authority for the COR is the Contracting Officer. COR limitations are contained in the written letter of appointment.

5.0 METHODS OF QA SURVEILLANCE

The below listed methods of surveillance shall be used in the administration of this QASP. The QASP

Matrix (Attachment 1) describes the methods of surveillance that may be used to monitor the services and deliverables to be provided under the contract.

Customer Feedback – Customer feedback may be obtained either from the results of formal customer satisfaction surveys or from random customer complaints. Customer complaints, to be considered valid, must set forth clearly and in writing the detailed nature of the complaint, must be signed and must be forwarded to the Contractor. The Contractor shall maintain a summary log of all formally received customer complaints as well as a copy of each complaint in a documentation file.

Random Monitoring – Random monitoring shall be conducted if and when deemed necessary to ensure compliance with the terms of the contract. The COR will conduct the random monitoring.

Random Checks/Inspections – Random checks will be conducted to ensure compliance with the terms of the contract. The COR will conduct the random monitoring.

6.0 IDENTIFIED QA SURVEILLANCE ITEMS

The PBSC items that have been identified for surveillance are identified in the Statement of Work

(SOW).

7.0 DOCUMENTATION

The COR will maintain a complete Quality Assurance Surveillance file. The file shall contain such documents as copies of all receiving reports, evaluations, recommendations, and any other actions related to the Government’s performance of the quality assurance function. All such records will be retained for the life of this contract.

8.0 ANALYSIS OF CONTRACTOR PERFORMANCE

The analysis of contractor performance shall be conducted at the end of each month and serves to provide a summary of the Contractor’s performance to the Contracting Officer and the Contractor. Overall performance is important in determining whether to increase, decrease or maintain the current level of surveillance and/or whether to initiate corrective action to bring the Contractor’s work up to the standards of the specification.

Quality Assurance Surveillance Plan (QASP) Matrix Project: Hankook R80W Shaft Lathe Repairs

Place of Performance: Norfolk Naval Shipyard, Building 171, Portsmouth Virginia 23709

Performance

Element Performance Requirement Surveillance Method Frequency Acceptable Quality Level

Procedures to be taken when performance standards are not met

Service

PWS Task 2.1.1

The contractor shall provide an open and inspection service to identify deficiencies and determine corrective actions required to return NNSY’s Hankook R80W CNC Shaft Lathe to fully operational status, In

Accordance With (IAW) the performance work statement (PWS) and all of its listed contract objectives and deliverables.

Inspection by the

Contract Officer Representative (COR) and Technical Point of

Contact (TPOC)

Continuous until 100% inspection of all contract objective deliverables.

Zero deviation of requested service and performed

IAW the PWS to identify and provide corrective actions for all Contract

Objectives.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.1.

(Report)

The contractor shall provide condition assessment and deficiency report with findings, corrective actions and cost estimates to repair all reported problems with the

Hankook R80W CNC Shaft Lathe, not covered by the PWS contract objectives.

The Government shall have a minimum of 5 working days to review the deliverable and concur with the suggested corrective actions.

Continuous until 100% inspection of all contract objective deliverables.

Contractor format

Zero deviation of requested deliverables and submitted in a timely manner with minimal rework.

Service

PWS Task 2.1.2.

The contractor shall perform a full machine level and alignment service on the Hankook R80W CNC shaft lathe to achieve OEM Level and Alignment Standards IAW the PWS.

Inspection by the COR with TPOC.

Continuous until OEM

Alignment Standard is achieved and verified by the COR and

Technical Point of

Contact (TPOC).

Rework shall be required if the contractor disassembles any part of the machine that affect the level and alignment.

Within OEM Alignment

Standards or an acceptable deviation of 10% from this standard if, it does not require farther rework.

PWS 2.1.2.

(Material)

The contractor shall provide all material for service objective PWS 2.1.2.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than

OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.2.

(Report)

The contractor shall provide complete machine alignment report after completing the alignment service, that includes the initial and final alignment values of all requested components and assemblies

IAW the PWS 2.1.2. and PWS 2.1.8. (Tool changer)

The Government shall have a minimum of 5 working days to review the deliverable and concur with the corrective actions.

Once after the completion of the alignment service PWS

2.1.2. and repeated if rework of the alignment service is performed.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

Performance Requirement Surveillance Method Frequency Acceptable Quality Level

Procedures to be taken when performance standards are not met

Service

PWS 2.1.3.

The contractor shall perform a repair service on the

Hankook R80W CNC shaft lathe’s multi-axis drive systems in order to remedy drive/servo overload problems identified by the open and inspection service

PWS 2.1.1. and IAW PWS 2.1.3 to achieve normal operational drive loading.

Inspection by the COR with TPOC.

Continuous until the satisfactory inspection by COR of normal machine operational loading of the servo drive system.

Zero deviation from OEM specification for normal operational drive loading for traversing the machine

PWS 2.1.3.

(Report)

The contractor shall report the discovered root causes, a list of damaged components which caused the axis drive overloads, corrective actions taken, and recommended future actions to be taken to prevent future problems.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions.

Once after the satisfactory inspection by COR of normal machine operational loading of the servo drive system IAW

Service objective 2.1.3.

Contractor format with zero deviation of requested deliverables and submitted

PWS 2.1.4.

The contractor shall perform a repair service for the issues identified during open and inspection service

PWS 2.1.1. causing the X-Axis to back out when the Z-

Axis engages IAW PWS 2.1.4.

Inspection by the COR with TPOC.

Continuous until the

COR and TPOC inspect and verify the contractor has achieved normal operational performance in accuracy, precision and repeatability of all axis.

OEM accuracy, precision and repeatability specifications of all machine axis.

Zero deviation of requested service and completed with no farther rework required.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.4.

(Report)

The contractor shall report the corrective actions taken to repair the drive engagement issues between the X- Axis and Z Axis and shall suggest future actions to be taken by NNSY to prevent future problems.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions.

Once after the satisfactory inspection by COR of Contract

Service Objective 2.1.4.

Contractor format with zero deviation of requested deliverables and submitted

PWS 2.1.5.

The contractor shall provide a service to inspect, refurbish or replace, and adjust all machine gibbs to

OEM specifications and IAW PWS 2.1.5.

Inspection by the COR with TPOC.

Continuous until the contractor finalizes the service work IAW PWS 2.1.2. (including all rework) and 100% inspection by COR of

PWS 2.1.5.

OEM Gibb adjustment

Specifications with zero deviation of requested service and completed with no farther rework required.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.5.

(Material)

The contractor shall provide all material for service objective PWS 2.1.5.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than OEM specifications.

Performance Requirement Surveillance Method Frequency Acceptable Quality Level

Procedures to be taken when performance standards are not met

Contract Deliverable

PWS 2.1.5.

(Report)

The contractor shall report the final condition of all machine gibbs, identify deficiencies, and suggest future actions on any identified deficiencies not corrected during PWS 2.1.5. service.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions.

Once after the satisfactory inspection by COR of Contract

Service Objective

2.1.5.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.6.

The contractor shall provide a service to inspect, refurbish or replace, and adjust all machine wipers to

OEM/Industry specifications and IAW PWS 2.1.6.

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of requested service at acceptable quality level

OEM/Industry wiper alignment standard.

Zero deviation of requested service and completed with no farther rework required.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.6.

(Material)

The contractor shall provide all material for service objective PWS 2.1.6.

Inspection by the COR Satisfactory inspection by COR

All material shall be of equal or better quality than

OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.6.

(Report)

The contractor shall report the final condition of all machine wipers, identify deficiencies, and suggest future actions on any identified deficiencies not corrected during PWS 2.1.6. service.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract Service Objective

2.1.6.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.7.

The contractor shall perform a service to the Hankook

R80W CNC shaft lathe’s machine carriage to repair problems identified during the service PWS 2.1.1 for service objectives listed IAW PWS 2.1.7.

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of requested service at acceptable quality level

Services listed IAW PWS

2.1.7 have been completed and the hydrostatic system operates within OEM parameters/specifications

(Flowrate and pressure).

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.7.

(Material)

The contractor shall provide all material for service objective PWS 2.1.7.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than

OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.7.

(Report)

The contractor shall report the final condition of the machine carriage hydrostatic system, identify deficiencies and suggest future actions to be taken by

NNSY to prevent future problems.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective 2.1.7.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without

Performance Requirement Surveillance Method Frequency Acceptable Quality Level

Procedures to be taken when performance standards are not met

Service

PWS 2.1.8.

The contractor shall perform a service IAW PWS 2.1.8.

to inspect, repair and align the automatic tool/pallet change turret, drive, and assemblies

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of requested service at acceptable quality level

OEM Level and Alignment specifications and smooth automatic tool changes with zero allowable deviation.

PWS 2.1.8.

(Material)

The contractor shall provide all material for service objective PWS 2.1.8.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than

OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.8.

(Report)

The contractor shall report the final condition of the automatic tool/pallet changer after performing the service objective PWS 2.1.8. The contactor shall also report identified problems, repaired deficiencies and shall suggest future corrective actions to be taken to prevent or remedy the problems from reoccurring.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective 2.1.8.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.9.

The contractor shall perform a service IAW PWS 2.1.9.

to repair or replace the B-Axis Cable.

Inspection by the COR

Continuous until 100% inspection by COR of

OSHA 1910.305, NFPA

79, and NEC code and with zero deviation from national standards for acceptable quality.

PWS 2.1.9.

(Material)

The contractor shall provide all material for service objective PWS 2.1.9.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than

OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.9.

(Report)

The contractor shall report the final status of the B-Axis

Cable repair for service objective PWS 2.1.9.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective

2.1.9.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.10.

The contractor shall perform a service IAW PWS

2.1.10. to install replacement AC assemblies on the

Hankook R80W CNC shaft lathe’s electrical cabinets.

Inspection by the COR

Continuous until 100% inspection by COR of

OSHA 1910.305, NFPA

79, and NEC code and with zero deviation from national standards for acceptable quality.

Performance Requirement Surveillance Method Frequency Acceptable Quality Level

Procedures to be taken when performance standards are not met

Contract Deliverable

PWS 2.1.10.

(Report)

The contractor shall report the final status of the AC assembly installation for service objective PWS 2.1.10.

and any discovered deficiencies with suggested repair or resolution.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective

2.1.10.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.11.

The contractor shall perform a service IAW PWS

2.1.11. to restore axis compensation functionality within OEM specifications.

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of

OEM/FANUC Axis Compensation

Specifications and OEM accuracy, precision and repeatability specifications of all machine axis.

PWS 2.1.12.

The contractor shall perform a service IAW PWS

2.1.12. to restore, repair or replace cutter compensation functionality within OEM specifications and Industrial

Standards.

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of

OEM/FANUC Cutter

Compensation Specifications with zero deviation.

PWS 2.1.11. & 2.1.12.

(Material)

The contractor shall provide all material for service objective PWS 2.1.12.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.11. & 2.1.12.

(Report)

The contractor shall report the final status of the all of the Hankook R80W Operational Control features and functions (this includes all computer numerical control codes and features: for example cutter compensation and axis compensation) after the repairs for service objectives PWS 2.1.11. and 2.1.12 are complete.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective

2.1.11. and 2.1.12.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.13.

The contractor shall perform a service IAW PWS

2.1.13. to repair or replace post processor for Siemens

NX10 in order to get functional code output for production and manufacturing needs.

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of

Satisfactory turning and milling code output to include complex machining function and features (for example: turning and milling contours with cutter compensation) with zero deviation of functional and operational code output.

Performance Requirement Surveillance Method Frequency Acceptable Quality Level

Procedures to be taken when performance standards are not met

Contract Deliverable

PWS 2.1.13.

(Material)

The contractor shall provide all material for service objective PWS 2.1.13.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than

OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.13.

(Report)

The contractor shall report the corrective actions taken to complete service objective PWS 2.1.13.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective

2.1.13.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.14.

The contractor shall perform a service IAW PWS

2.1.14. to repair inherent OEM design fault with the C-

Axis control and drive system.

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of

OEM electrical specification and design change IAW OSHA

1910.305, NFPA 79, and NEC code.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.14.

(Material)

The contractor shall provide all material for service objective PWS 2.1.14.

Inspection by the COR

Satisfactory inspection by COR

All material shall be of equal or better quality than OEM specifications.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.14.

(Report)

The contractor shall report the corrective actions taken to complete service objective PWS 2.1.14.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective

2.1.13.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without rework required.

FAR Clause 52.212-4

Service

PWS 2.1.15.

The contractor shall perform a service IAW PWS

2.1.15, 3.1, 3.2, 3.3, 3.4, and 3.5 to test the operation, performance, accuracy, precision, and available machining power of the Hankook R80W.

Inspection by the COR with TPOC.

Continuous until 100% inspection by COR of

OEM Machine specifications for operational abilities, accuracy, precision, repeatability and machining horsepower.

FAR Clause 52.212-4

Contract Deliverable

PWS 2.1.15.

(Report)

The contractor shall develop a final report to include all other contract deliverable reports including the results of service objective PWS 2.1.15. The contractor shall also include all discovered deficiencies, repairs performed, and suggested recoveries or repairs to fix identified problems.

The Government shall have a minimum of 5 working days to review and concur with the suggested corrective actions

Once after the satisfactory inspection by COR of Contract

Service Objective 2.1.15.

Contractor format with zero deviation of requested deliverables and submitted in a timely manner without

Performance Requirement Surveillance Method Frequency Acceptable Quality Level

Procedures to be taken when performance standards are not met

Invoicing Monthly invoices per contract procedures are timely and accurate.

Review & acceptance of the invoice

Monthly 95% accuracy FAR Clause 52.212-4

Overall Contract

Performance

Overall contract performance of sufficient quality to earn a Satisfactory (or higher) rating in the COR’s annual report on Contractor Performance

Assessment by the

COR

Annual

All performance elements rated Satisfactory (or higher)

-If performance is within acceptable levels, it will be considered to be satisfactory. If not, overall performance may be considered unsatisfactory.

INCENTIVES/DISINCENTIVES:

For each item that does not meet acceptable levels, the Government may issue a Contract Discrepancy Report (CDR). CDRs will be forwarded to the Contracting Officer with a copy sent to the contractor. The contractor must reply in writing within 5 days of receipt identifying how future occurrences of the problem will be prevented. Based upon the contractor’s past performance and plan to solve the problem, the Contracting Officer will determine if any further action will be taken.