SF1 SOW_20260129.pdf

STATEMENT OF WORK

SMALL-FORM-FACTOR WEAPON ATTRITABLE RADIO

MULTI-MODE (SWARMM) FAMILY 1 (SF1) RADIO

PRODUCTION

Revision 0 January 2026

Distribution Statement A: Approved for public release: distribution is unlimited. 29JAN26

1.0 SCOPE

This Statement of Work (SOW) defines the contractor tasks required for the production and delivery of the Small Form-Factor Weapon Attritable Radio Multi-Mode (SWARMM) Family 1 (SF1) radio. The SOW includes the associated program management, engineering support, configuration and data management, logistics support and manufacturing requirements.

The data to be delivered as a result of performing the tasks prescribed by this SOW are specified in the Contract Data Requirements List (CDRL).

2.0 APPLICABLE DOCUMENTS

The following documents of the exact issue shown form a part of this SOW to the extent specified herein. In the event of conflict between the documents referenced herein and the contents of this SOW, the SOW is the overarching document. For the specifications and references shown below without a release date or version number, this SOW assumes the latest issue at the time of this Request For Proposal (RFP) is issued form a part of this SOW to the extent specified herein.

2.1 Specifications

The contractor shall use the Top Level Requirements (TLR) 1.5 as a starting point to meet the requirements of this contract.

2.2 Standards

ANSI Z400.1-2004

31 March 2004

Hazardous Industrial Chemicals – Material Safety Data Sheets

ANSI/EIA-632-1999

January 1999

Processes for Engineering a System

ANSI EIA-649C

407 February 2019

Configuration Management Standard

ANSI/J-STD-001

Revision D February 2005

Requirements for Soldered Electrical and Electronic Assemblies

FED-STD-313D

3 April 1996 Notice 1 21 March 2000

Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities

GEIA-STD-0005-1

15 June 2006

Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-free Solder

GEIA-STD-0005-2

1 June 2006

Standard for Mitigating the Effects of Tin Whiskers in Aerospace and High Performance Electronic Systems

IEEE/EIA 12207-2008

1 Feb 2008

Systems and Software Engineering – Software Life Cycle Processes

IPC-A-600

Revision H April 2010

Acceptability of Printed Circuit Boards (PCBs)

IPC-A-610

Revision E April 2010

Acceptability of Electronic Assemblies

IPC-7711/7721

Revision B November 2007

Rework, Modification and Repair of Electronic Assemblies

ISO 9001-2008

15 November 2008

Quality Systems – Model for Quality Assurance in Design/Development, Production, Installation and Servicing

ISO/IEC 90003:2004

11 February 2004

Software Engineering - Guidelines for the Application of ISO 9001:2000 to Computer Software

ISO 10012:2003

14 April 2003

Measurement management systems – Requirements for measurement processes and measuring equipment

MIL-STD-196F

11 September 2013

Joint Electronics Type Designation Automated System

MIL-STD-461E

20 August 1999

Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-1686C

25 October 1995

Electrostatic Discharge Control Program for Production of Electrical and Electronic Parts, Assemblies, and Equipment

2.3 Handbooks

GEI-HB-649A

November 2015

Configuration Management Standard Implementation Guide

MIL-HDBK-217F

2 December 1991 Notice 1 10 July 1992 Notice 2 28 February 1995

Reliability Prediction of Electronic Equipment

MIL-HDBK-263B

31 July 1994

Electrostatic Discharge, Control Handbook for Protection of Electrical and Electronic Parts Assemblies and Equipment

MIL-HDBK-472

24 May 1966 Notice 1 12 January 1984

Maintainability Prediction

2.4 Other Documents

TBD Configuration and Data Management Plan for SF1

3.0 REQUIREMENTS

3.1 General

Responsibilities

The contractor shall build, test and deliver the SF1 radio in accordance with (IAW) the SF1 Top Level Requirements document version 1.6 located on the JWICS IntelDocs SF1 share.

Security The work to be performed includes access up to TOP SECRET for data, information, and spaces. The contractor will be required to attend meetings classified up to the TOP SECRET level. The contractor shall perform all work in accordance with DoD and Navy Operations Security (OPSEC) requirements and in accordance with the OPSEC attachment to the DD254.

3.2 Program Management

Program Manager The contractor shall designate a single program manager, who shall have overall responsibility for control and coordination of all work performed. This manager shall act as the single focal point within the contractor’s activity for all program status information.

Program Planning and Control The contractor shall identify, plan, organize, direct, coordinate and control the activities necessary to accomplish all contract requirements. In the performance of this task, the contractor shall establish, maintain, and use a management control system that provides for the planning and control of cost, measurement of performance (value for completed tasks), and generation of timely and reliable information for reporting requirements established herein. The contractor shall establish a formal organization responsible for accomplishing the tasks established in this SOW. The contractor shall ensure that all requirements of this SOW and the CDRL are adhered to by the contractor and its subcontractors. A clear line of project authority shall exist between all organizational elements and the program manager. The contractor shall identify one or more positions or elements within the contractor’s and subcontractors’ organizations against each SOW task that will perform the corresponding work. The contractor shall identify and maintain a list of key personnel who have management and task accomplishment responsibility, including the key personnel of the major subcontractors. The contractor shall ensure expeditious transfer of appropriate technical data among subcontractors, the other contractor and any associate contractors.

Program Schedule The contractor shall prepare and maintain a master schedule of program events. Back-up schedules detailing the sub-events required to achieve milestones in the master schedule shall also be prepared and maintained. Schedules shall be updated weekly and augmented with an explanation addressing all updates. The contractor shall address the effect on interrelated milestones. The status of program schedules shall be presented during each Program Management Review (PMR) and each Program Management Status Teleconference.

Risk Assessment and Management The MIDS Program Office has selected the U.S. Navy’s Naval Air Warfare Center (NAWC) Aircraft Division to lead Manufacturing Readiness Assessments (MRAs) for the SF1 radio. The contractor shall support annual site risk assessments of the contractor and its subcontractors, as determined by the Government, to update the Manufacturing Readiness Level (MRL) of the SF1 production program. The contractor shall provide the Government with an analysis of the potential effects on cost and schedule, as well as proposed mitigation plans of all high and medium risks and shall close all resulting action items within sixty (60) days of each assessment. The contractor shall prepare a Risk Assessment in accordance with the Risk Management Plan for the SF1 Production Program. The contractor’s risk assessment shall be presented at each PMR.

Program Management Reviews

The contractor shall conduct and administratively support PMRs every four (4) months.

All PMRs shall be held at the contractor’s or a subcontractor’s facility unless the Government directs an alternate location for efficiency of schedule or travel cost. The contractor shall provide wireless Internet connectivity to the attendees.

3.2.5.1 Content

The contractor shall host and coordinate the PMR agendas shall include the PMR items identified in Appendix A, at a minimum. The Government shall have the option to modify or add items to the PMR agenda. At the PMRs, the contractor shall report detailed program status information, linked to the SOW and the CDRL, including subcontractor work.

(CDRL B001, B002, B003)

Program Management Status Teleconferences The contractor shall support and participate in weekly Program Management Status Teleconferences. The contractor shall provide a slide by Close of Business (COB) on the first working day prior to each teleconference that includes the current status of all radio production and depot repairs (warranty and non-warranty), schedules and metrics (to include failure reports, investigation reports and Engineering Change Proposal (ECP) status) for all related activities during these teleconferences. These teleconferences shall be no more than two (2) hours in duration each week.

Cost and Software Data Reporting The Contractor shall use a documented standard Cost and Software Data Reporting (CSDR) process that satisfies the guidelines contained in the DoD 5000.04–M–1, CSDR Manual.

3.2.7.1 Contractor Cost Data Reporting (CCDR)

The Contractor shall:

a. Use the Government-approved Contract Cost and Software Data Reporting (CSDR) Plan, DD Form 2794, and the related Resource Distribution Table (RDT) as the baseline for reporting (see contract attachment);

b. Prepare and deliver to the Government a Cost and Hour Report (FlexFile) (CDRL B004) for every indicated data element (Data Group B) within the Government-approved Contract CSDR Plan;

c. Provide a Work Breakdown Structure (WBS) Dictionary and Remarks as a part of the FlexFile format (Data Group C) for every data element identified within the approved Contract CSDR Plan.

d. Prepare and deliver to the Government a Quantity Data Report (CDRL B005) for every indicated data element (Data Group B) within the Government-approved Contract CSDR Plan;

e. Prepare and deliver to the Government DD Form 1921-3 (CDRL B006);

f. Provide updates to the Government-approved Contract CSDR Plan and related RDT for Government approval. Updates include: aligning reporting Subcontractor effort to a single WBS element and updating the RDT as new Subcontracts are awarded;

g. Hold a post award meeting after contract award to include a discussion of the Contractor’s standard cost and software data reporting process that satisfies the guidelines contained in the DoD 5000.04-M-1 (CSDR Manual) and the requirements in the Government-approved Contract CSDR Plan and related

RDT.

3.2.7.2 Subcontractor Cost Data Reporting

The Contractor shall:

a. Flow-down Contractor Cost and Software Data Reporting (CSDR) requirements to any Subcontracts valued over $50 million or any Subcontracts valued between $20 million and $50 million that are designated by the Cost Working Integrated Product Team (CWIPT) as high risk, high value, or high technical interest;

b. Notify the Government of any subcontractor changes or new subcontracts awarded for subcontracts that exceeds $50 million;

c. Flow-down DD Form 1921-3 (CDRL B006) to any Subcontractors required to submit Cost and Software Data Reporting.

(CDRL B004, B005, B006)

3.3 Engineering Support

Systems Engineering

3.3.1.1 Systems Engineering Management

The contractor shall perform systems engineering management activities in accordance with the Government approved Systems Engineering Management Plan

(SEMP) for the SF1 and shall conduct analysis to identify the engineering support functions and requirements needed to produce, accept, operate, and maintain the SF1 radio. The contractor shall adhere to those portions of the SEMP that apply to a production effort.

3.3.1.2 System Engineering Responsibilities

The contractor shall perform the following systems engineering tasks:

a. Maintenance of the common Product Baseline (PBL),

b. Designation of Hardware Configuration Items (HWCIs) and CSCIs, and

c. Technical evaluation of Engineering Change Proposals (ECPs)

3.3.1.2.1 Maintenance of the PBL

The contractor shall maintain the PBL for the SF1 radio only by incorporation of Engineering Change Orders (ECOs). These ECOs shall be (a) to incorporate Government approved Class I ECPs into the design of the Radio configuration or

(b) to incorporate Class II ECPs as agreed to by the contractor and the Government for classification. The contractor shall ensure that the incorporated ECOs and the associated common PBL result in the SF1 radio configuration being in compliance with the current Functional Baseline (FBL) and Allocated Baseline (ABL) requirements, and all other requirements applicable to the SF1 radio, as specified elsewhere in the contract.

3.3.1.2.2 Designation of HWCIs and CSCIs

The contractor shall maintain the HWCIs and CSCIs designations.

3.3.1.2.3 Technical Evaluation of ECPs

The contractor shall evaluate all Class I and Class II ECPs for impacts to the safety, reliability, maintainability, Built-In-Test (BIT), Electromagnetic Interference/Electromagnetic Compatibility (EMI/EMC), environmental factors, telecommunications security, Software Communications Architecture (SCA) compliance, TEMPEST, and computer resource reserve capacity of the SF1 Radio configurations, and for impacts to the Specialized Test Equipment (STE) and Acceptance Test Procedures (ATPs) used for the production and acceptance testing of the SF1 Radio configurations. ECPs shall be designated Class I or Class II in accordance with Section 3.4.1.1 of this SOW and shall be processed accordingly. The contractor shall submit the results of these evaluations to the Government as part of the ECP approval process for Class I ECPs. The contractor shall incorporate into each ECP a regression test analysis section that provides the justification and details of the required regression testing.

3.3.1.2.3.1 Safety Evaluation

The contractor shall evaluate all proposed changes for any impacts to Radio safety due to the resulting changes to the design of the SF1 radio.

3.3.1.2.3.1.1 Hazardous Materials

Any additional hazardous material as defined in FED-STD-313 and not previously approved by the Government which may be used in, supplied with, or required in support of the SF1 radio configuration as a result of approving any ECP shall be approved by the Government. Prior to approval, the contractor shall update their Hazardous Material Summary Report and resubmit the updated report to the Government. This updated report shall identify all additional hazardous material and include justification for its use. Additionally, it shall include the necessity for the type, container size, and quantity of additional hazardous material (or material that results in additional hazardous waste) together with a listing of less hazardous potential substitutes that were considered and the reasons why these substitutes cannot be used. The order of precedence for acceptance shall be:

a. Non-hazardous material

b. Material that is recyclable

c. Material that results in hazardous waste that can be treated to reduce it to a non-hazardous state.

The contractor shall submit updated Hazardous Material Summary Reports to the Government for review and approval as part of the ECP approval process. The submittal shall include a Material Safety Data sheet (MSDS) (ANSI Z400.1) for all additional material listed in the report.

(CDRL B008)

3.3.1.2.3.2 Reliability Evaluation

The contractor shall evaluate all proposed changes for any impacts to Radio reliability due to the resulting changes to the design of the SF1 Radio configuration. The contractor with the other contractor, shall evaluate the reliability impacts to predict the Mean Time Between Failure (MTBF) of the SF1 radio configuration. The contractor may use the operating environments as defined in table 3.2 of MIL-HDBK-217 to predict the reliability impacts that would result from approving the proposed changes. The contractor may use the procedures of MIL-HDBK-217, parts stress analysis method, to predict the reliability impacts that would result from approving the proposed changes. If the contractor elects to use MIL-HDBK-217 and, in the contractors’ judgment, the data in MIL-HDBK-217 is determined to be dated, incomplete, or otherwise inadequate, the contractor shall use additional sources, of the contractors’ choosing, that, in the contractors’ judgment, provide more accurate data for the prediction of reliability. The contractor shall identify these additional sources, which shall be approved by the

Government. All trade studies shall consider reliability as an equally weighted performance parameter.

3.3.1.2.3.3 Maintainability Evaluation

The contractor shall evaluate all proposed changes for any impacts to Radio maintainability due to the resulting changes to the design of the SF1 radio configuration. The contractor shall evaluate the maintainability impacts to predict the Mean Time to Repair (MTTR) of the SF1 radio configuration. The contractor may use the procedures delineated in procedure V of MIL-HDBK- 472 to predict the maintainability impacts that would result from approving the proposed changes.

3.3.1.2.3.4 EMI/EMC Evaluation

The contractor shall evaluate all proposed changes for any impacts to Radio EMI/EMC performance due to the resulting changes to the design of the SF1 radio configuration.

3.3.1.2.3.5 Telecommunications Security Evaluation

The contractor shall evaluate all proposed changes to the design of the SF1 radio configuration for any impacts that affect compliance with the Radio telecommunications security requirements. The contractor shall ensure that the implementation of all approved changes shall comply with the telecommunication security requirements for the SF1 radio configuration.

The contractor shall prepare and submit the National Security Agency (NSA) Questionnaire for ECPs (see contract attachment), and the TEMPEST Assessment Form for ECPs (see contract attachment), for each ECP and shall submit them with each ECP.

3.3.1.2.3.6 Computer Resource Reserve Capacity Evaluation

The contractor shall evaluate all proposed changes for any impacts to Radio computer resource reserve capacity due to the resulting changes to the design of the SF1 radio configuration. The contractor shall ensure that the implementation of all approved changes shall not degrade the computer resource reserve capacity of the SF1 radio configuration beyond the reduction of computer resource reserve capacity approved by the Government.

3.3.1.2.3.7 Special Test Equipment (STE) Evaluation

The contractor shall ensure all necessary STE is available to manufacture and deliver a NSA signed and encrypted SF1 radio. The contractor shall ensure that any necessary changes to the STE/factory test equipment resulting from the implementation of all approved changes to the SF1 radio configuration are implemented in the STE/factory test equipment.

Contractor Verifications The contractor shall perform the necessary tasks to maintain the following verifications:

3.3.2.1 EMI Qualification Verification

The contractor shall conduct EMI regression verification to verify compliance of the EMI requirements of the SF1 radio. The EMI regression verifications shall be conducted by a laboratory accredited to conduct MIL-STD-461 compliance verifications by the National Voluntary Laboratory Accreditation Program (NVLAP).

All EMI regression verifications shall be under the guidance of National Association of Radio and Telecommunication Engineers (NARTE).

Contractor Approvals The contractor shall perform the necessary tasks to maintain the following approvals:

3.3.3.1 Telecommunications Security Approval for Use

The contractor shall take all the actions and provide all the information required to comply with JTRS-UPA-022-06, TSRD No. 04-10 and C-M(55)15 and maintain Telecommunications Security Approval for Use. As part of this effort, the contractor shall plan and conduct regression verifications of the telecommunication functions of the SF1 radio configuration as required by the TSRD No. 04-10. The contractor shall coordinate the requirements for these telecommunications security regression verifications with the applicable security authority. The contractor shall update documentation as directed by the NSA to achieve and maintain approval for use.

3.3.3.2 Air Worthiness Certification

The Contractor shall certify that the delivered radios are safe for intended use. The certificate shall be based on successful completion of Contractor testing and analysis.

Safe-For-Intended Use (SFIU) tests shall consist of (1) Crash Safety, (2) Random Vibration, (3) RE102 radiated emissions, electrical field, 10 kHz to 18 GHz, (4) CE102 conducted emissions, power leads, 10 kHz to 10 MHz, (5) RS103 radiated susceptibility, electric field, 2 MHz to 40 GHz, and (6) Explosive Atmosphere.

The Contractor shall provide a completed AFMC Form 3, Component Airworthiness Certificate, prior to First Article Approval. The AFMC Form 3 is considered "completed" once the contractor has completed the necessary testing and analysis and the responsible contractor system safety engineer/officer/ manager has signed the form. The Government expects to review the test data and analyses upon which the Contractor based the airworthiness certificate.

The Contractor shall maintain the SF1 radio airworthiness certificate until the period of performance for the entire contract is completed.

3.3.3.3 Stage 4 DD-1494 Certification

The Contractor shall provide the necessary Stage 4 Terminal measured data and information required for incorporation into the DD-1494. The required data shall be submitted to the Program Office via the DoD Certification Authority, currently designated as the Program Executive Office (PEO) Command, Control, Communications, Computers and Information (C4I).

3.4 Configuration and Data Management

Configuration Management The contractor shall identify a single Point of Contact (POC) within its organization who shall be responsible and have authority for all configuration management and control.

Configuration management shall be in accordance with the SF1 radio Configuration and Data Management Plan (CDMP) and the Government approved Joint Contractor Configuration Management Plan (CMP).

The Government reserves the right to require the Contractor to re-qualify his product if either of the following occurs:

(1) The Contractor has modified its product, or changed the material or its manufacturing processes such that, in the opinion of the Government, the validity of the previous qualification is questionable. Any expenses incurred by the Contractor associated with re-qualification in these instances (including but not limited to regressive testing) shall be borne by the Contractor.

(2) It is otherwise necessary to determine that the quality of the product is maintained in conformance with the specification. Any costs incurred by the Contractor associated with re-qualification in this instance (including but not limited to regressive testing) shall be negotiated between the Government and the Contractor.

3.4.1.1 Engineering Change Proposals

The contractor shall prepare proposed changes as ECPs in accordance with section

5.3 of SAE EIA-649C and using GEIA-HB-649A for guidance.

(CDRL B009)

3.4.1.2 Notices of Revision

The contractor shall submit NORs for all proposed changes to FBL and ABL documents under Government configuration control with the ECP that proposes the change. The NORs shall delineate the “From:” and “To:” content for each document.

For clarity purposes, an additional markup shall be required using strikethrough for removing text and bold text for additions. The contractor shall use GEIA-HB-649A for guidance on NOR preparation.

(CDRL B00A)

3.4.1.3 Regression Verification

For all Class I PBL ECPs, the contractor shall determine the impact on its system qualification requirements and shall develop a Regression Verification Procedure (RVP) to define the necessary analysis and testing to ensure the new configuration meets all qualification requirements. Requirements in Temperature/Altitude, Random Vibration (endurance), Gunfire Vibration, Crash Safety, Explosive Atmosphere, EMI, and Electrical Power are Safety of Flight requirements and their verification is mandatory. Requirements in interchangeability, including vendor-to-vendor interchangeability and their verification, are also mandatory. Verification may be accomplished either by test, analysis or a combination of both methods. The RVP shall include the detailed procedures for any testing required and the details of any analyses to be performed, and the details for any combination thereof. The contractor shall submit the RVP to the Government for approval concurrently with the Class I PBL ECP. The contractor’s analysis of the required regression testing shall follow the guidance used in qualifying the radio. The contractor shall not proceed with regression verification without prior approval from the Government. The contractor shall submit a Regression Verification Report (RVR) to the Government, upon completion of regression verification conducted in accordance with the Government approved RVP. The RVR shall include the results of all tests conducted and analyses performed. Any failures shall require corrective action and retesting by the contractor. All regression testing and analyses, based on a Government approved RVP, shall be successfully completed before delivering an RVR to the Government.

(CDRL B00B, B00C)

3.4.1.4 Requests for Deviation (RFD)

The contractor shall submit RFDs that fully document all non-compliances with the FBL and ABL for all Configuration Items (CIs) delivered to and approved by the Government. Each non-compliance shall be submitted as a separate RFD. For RFDs that the Government does not approve, the contractor shall correct the non-compliance. All non-compliances with the approved common PBL, for CIs delivered to the Government, shall be submitted to and approved by any participating SF1 contractor, and shall further be submitted to the Government for concurrence of classification. The contractor shall use GEIA-HB-649A for guidance on RFD classification and content.

(CDRL B00D)

3.4.1.5 Interface Control

The contractor shall comply with the requirements of SAE EIA-649C for identifying and defining the functional and physical external, internal, and installation interfaces.

3.4.1.6 Configuration Status Accounting

3.4.1.6.1 Configuration Management Accounting Report (CMAR)

The contractor shall develop a CMAR that meets the requirements of section 5.4 of SAE EIA-649C and using GEIA-HB-649A for guidance. The contractor’s CMAR shall include such items as ECPs, deviations, conditional acceptance terms, and software definition for the as-built configurations. Additionally, the contractor shall include an equipment tree drawing that documents all approved part number changes to a configuration item and that lists the version numbers for all CSCIs and the changes thereto. The initial delivery of the CMAR shall include top-level assembly drawings and associated parts lists for each HWCI.

Subsequent deliveries of the CMAR shall include updated top-level assembly drawings and associated parts lists for each HWCI for which these drawings or parts lists have changed since their prior submittal.

(CDRL B00E)

3.4.1.6.2 Configuration Data Information

The contractor shall document the as-built configuration of each HWCI delivered to the Government. The documentation shall include hardware, software, and firmware and shall accompany each HWCI delivery.

(CDRL B00F)

Data Management The contractor’s Data Management team shall possess a thorough understanding of current data management techniques. The contractor shall work with the Government to resolve all computer related compatibility issues. The contractor shall be responsible for obtaining and maintaining any Public Key Infrastructure (PKI) certificates necessary to access the Government maintained data management systems.

3.4.2.1 Contract Data Requirements

The contractor shall provide electronic copies of all data deliverables. Data deliverables shall not include embedded files. The contractor shall utilize the Government maintained data management systems for delivery of all CDRL items.

All data shall additionally be submitted in a universal viewer format (e.g. html, pdf, tif). The contractor shall provide the native format data (preferably Microsoft Office Suite) to the Government upon request at no additional cost and as required by the

CDRL.

3.4.2.2 Data Accession List

All documentation produced or prepared by the contractor or its subcontractors under this contract shall be accessible to the Government. The Data Accession List is a complete listing of all data, computer software and documentation generated by the contractor for use during the course of performing or fulfilling the contract requirements herein. The contractor shall prepare and update quarterly a Data Accession List for all data, software and documentation generated. This list shall be provided to the Government. At all times, throughout the life of the contract, the contractor shall provide Government personnel full access to this documentation including providing copies to the Government, as requested.

(CDRL B00G)

3.5 Manufacturing and Acceptance Verification

Manufacturing

The contractor shall fabricate SF1 radios. The contractor shall fabricate all SF1 radios using qualified production and quality assurance processes, and environments in accordance with the IPC and ISO standards noted in Section 2.1. All SF1 radios shall be fabricated in accordance with Class three (3) workmanship standards per the ANSI/J and IPC standards provided in Section 2.1. The contractor shall have documented subcontractor control processes. The contractor shall notify the Government of any subcontractor or supplier base changes prior to implementation of any such changes.

Should such a change be processed, the Government may require the contractor to perform. All the requirements of 3.5.1 shall be flowed to subcontractors.

3.5.1.1 Part Control Program

The contractor shall have a parts qualification system to ensure the reliability and quality of basic system piece parts entering the manufacturing process. The intent is to start the manufacturing process with reliable piece parts by both validating vendor assessments of part reliability and quality. The contractor shall obtain Government approval for the use of all up-screened parts. Any part operated outside the standard manufacturer’s published data sheet shall be considered up-screened. In addition, the contractor shall control and prohibit use of counterfeit parts and material. The contractor shall at a minimum:

a. Flow down requirements to subcontractors;

b. Address application and derating criteria during component selection;

c. Conduct receiving inspection;

d. Maintain yield records on suppliers; and,

e. Screen all custom components that are determined to be critical (e.g.

Application Specific Integrated Circuit (ASIC)), and provide the list of critical parts to the MPO.

3.5.1.2 Production Controls

The contractor shall employ robust production controls to ensure repeatability and product producibility, reliability, and maintainability. The contractor shall ensure production controls include the following, at a minimum:

a. Manufacturing drawings do not contain redlines;

b. In-process inspections throughout the manufacturing and rework cycle;

c. Processes and materials are fully documented with the design captured in the

Material Requirements Planning (MRP) system and released to production;

d. Assembly documentation and instructions are complete and released to the production floor;

e. The workforce has all appropriate certifications to perform their jobs (e.g., soldering, etc.);

f. A qualified design, including software;

g. Baking of Ball Grid Array (BGAs) and printed wiring boards to remove moisture;

h. X-Raying all BGAs;

i. Use of parts with a Moisture Sensitivity Level (MSL) of > 5;

j. Having manufacturing facilities to control moisture levels;

k. Prohibiting the use of lead free solder and pure tin finishes on any part (except as per a Government approved tin whiskers mitigation plan);

l. Use of Rosin Mildly Activated (RMA) flux and cleaning for all board repairs;

m. Having zero “dead bugs” on all production circuit boards;

n. Established best manufacturing practices in regards to “white wires” on all production circuit boards;

o. Conformance with ANSI/J-STD-001;

p. Conformance with IPC-A-600;

q. Conformance with IPC-A-610;

r. Conformance with IPC-7711-21B;

s. One hundred percent (100%) visual inspection of all Circuit Card Assemblies

(CCAs); and,

t. Conduct acceptance testing in accordance with approved Government procedures.

3.5.1.3 Manufacturing Program Planning

The contractor shall perform manufacturing planning throughout the program to assure early risk identification and resolution.

3.5.1.4 Manufacturing Surveillance

The contractor shall maintain an effective, timely, and responsive manufacturing surveillance operation. As part of the manufacturing surveillance operation, the contractor shall collect data (metrics) sufficient to track the following metrics as applicable to the individual contractor’s production line:

a. Radio work in inventory;

b. Radio first time test yields;

c. Radio ATP and ESS:

d. Failure types e.g., component, workmanship, equipment;

e. Failure cycle;

f. Total ESS cycles or test attempts to pass by serial number;

g. Percent parts defect free;

h. Average number of failures during ESS and ATP per radio;

i. Radio delivery schedule line of balance; and

j. Number of reworks by classification and department.

The contractor shall report the status and results of the manufacturing surveillance operation including the above listed metrics monthly. The contractor shall make recommendations, to the Government for approval, for metrics tracked to better meet overall program needs. The contractor shall prepare and submit the report of the status and results of the manufacturing surveillance operation.

(CDRL B00H)

3.5.1.5 Tin Whisker Mitigation

As part of the manufacturing program, the contractor shall incorporate a government approved tin whisker mitigation plan to avoid associated manufacturing issues.

3.5.1.6 Manufacturing Operations Management

3.5.1.6.1 Work Management System

The contractor shall provide the Government with access to the documentation, data, and reports generated by any existing work measurement system applied to production.

3.5.1.6.2 Telecommunications Security Production Assurance

The contractor shall maintain a Security Production Assurance (SPA) program to ensure the security integrity as required by the TSRD No. 4-10. The contractor shall coordinate the requirements for the SPA program with the NSA.

3.5.1.6.3 Failure Reporting and Corrective Action System (FRACAS) The contractor shall implement a disciplined FRACAS. The system shall be maintained for reporting and analysis of all failures and faults for both hardware and software. The system shall do this to the extent necessary that failure causes are understood, and positive corrective actions are identified, implemented and verified to prevent further recurrence of the failures. Records shall be maintained for all reported failures, failure investigations and analyses, assignable failure causes, corrective actions taken, and effectiveness of corrective actions for all receiving inspections, in process manufacturing, acceptance tests (including ESS), qualification tests, and field failures returned to the factory. Failure records shall be maintained in the Contractor Database and reported during PMRs.

(CDRL B00J)

3.5.1.6.3.1 Failure Review Board (FRB)

The contractor shall establish an FRB to review failure trends, corrective action status, and to assure adequate corrective actions are taken. The personnel appointed by the contractor to act on the FRB and the scope or extent of their authority shall be documented in the FRACAS procedures. The FRB shall meet on a regular basis to review failure data from appropriate inspections and tests. The contractor shall brief to the Government on a monthly basis the results of the FRBs.

3.5.1.6.4 COMSEC Inventory Report

For SF1 radios produced or repaired for U.S. requirements, the Contractor shall ensure that all COMSEC portions of the radio are manufactured, integrated and delivered in the U.S. only by a U.S. contractor holding a U.S. COMSEC account.

Once the COMSEC portions of the SF1 radio are integrated, the SF1 radio shall not leave the custody of that U.S. contractor prior to delivery.

The COMSEC Manager shall provide a monthly COMSEC Inventory Report for their account. At a minimum, the report shall document all SF1 radio products by Short Title (RT-1957, RT-2031, Z-BAS, etc.), Serial Number, Accountability Legend Code, and physical location and/or sub-custody holder.

(CDRL B00N)

Acceptance Tests The contractor shall conduct acceptance tests on all SF1 radios to be delivered to the

Government, in accordance with Government approved ATPs. Acceptance tests shall include both functional and ESS tests with the version of software to be delivered. If the software component requires encryption and NSA signature to meet TSRD No. 04-10 requirements, the contractor shall perform the acceptance tests with the encrypted and NSA-signed executable software files installed. The contractor shall use the ESS environmental profile as specified in SS-J-10001. Functional test requirements shall be derived from the requirements established in the FBL and ABL specifications. The contractor shall update the SF1 radio, as necessary, when these requirements change as a result of a Government approved ECP. Updated ATPs shall be submitted to the Government for approval and shall be approved by the Government prior to their use to conduct acceptance testing. The contractor shall maintain all results from each acceptance test conducted in an Acceptance Test Report (ATR). ATRs shall be submitted as a part of the As-Built Configuration List (ABCL) package.

(CDRL B00K, B00F)

3.5.2.1 Electromagnetic Interference Periodic Verification

Once every quarter, the contractor shall conduct the RS103 test method in accordance with MIL-STD-461 on one Radio to be delivered to the Government in order to verify compliance with EMI requirements. The contractor shall provide a notification to the Government at least two (2) weeks prior to the actual test event to allow the Government sufficient time to make arrangements to witness the test, at the discretion of the Government. The contractor shall record and provide the results of the test as a part of the ATR for each radio tested.

3.6 Quality Assurance (QA)

Quality Assurance Program The contractor shall implement a quality assurance program to monitor manufacturing and procurement processes (e.g. material change, technology insertion, redesign, etc.), including acceptance testing in accordance with International Standards Organization (ISO) 9001 as supplemented by AQAP-2110, AQAP-2120, AQAP-2130 and AQAP 2210. Quality manufacturing and procurement assurance processes shall be maintained in such a way as to assure that quality components and products are being produced in a consistent manner. As part of the quality manufacturing process, the contractor shall identify and resolve potential product failure modes caused by manufacturing or assembly process deficiencies. The goal is to continuously improve first-pass yields.

The quality assurance program shall:

a. Achieve and maintain high repeatability in the production and depot repair lines;

b. Achieve and maintain low variability in the production and depot repair lines;

and,

c. Ensure that best commercial practices and policies are in place and there is capability to audit that these practices and policies are being followed.

3.6.1.1 Stipulations

The following stipulations apply:

a. The contractor shall apply the quality standards and specifications to the following:

i. All internal management processes;

ii. All manufacturing processes;

iii. All procurement processes;

iv. Process improvement practices;

v. Product development;

vi. Acceptance testing, procedures and reporting; and,

vii. Radio specifications compliance and related requests for deviation.

b. The contractor shall make available for review, and retention if required by the Government, all records associated with the establishment, implementation, and operation of a quality system compliant with the documents listed above;

c. The contractor shall monitor the preparation, maintenance, and compliance with work and inspection instructions as a function of the quality program;

d. The contractor shall make available for review and retain all records associated with the establishment, implementation and operation of its quality program. The quality trends data maintained and briefed by the contractor during program reviews shall include, at a minimum, the number of scraps, number of re-work dispositions, hours of re-work, number of repair dispositions, hours of repair, contractor benchmarks and quality metrics; and,

e. The contractor shall demonstrate, in detail, at each PMR how:

i. Benchmarks and metrics are established and controlled to ensure repeatable results;

ii. At regular intervals, that processes used will produce or are producing radios with low variability; and,

iii. Internal QA processes meet all applicable Government requirements stated elsewhere in this contract.

Calibration Systems The contractor shall maintain a calibration system in accordance with ISO 10012-1 and shall develop and maintain a written description of its calibration system covering measuring and test equipment standards.

Corrective Action and Disposition System The contractor shall maintain a corrective action and disposition system for nonconforming material in accordance with ISO 9001 as supplemented by AQAP-2110, AQAP-2120, AQAP-2130 and AQAP-2210.

Subcontractor Quality The contractor shall ensure all QA requirements herein are passed to its subcontractors.

Internal QA Audits The contractor shall conduct periodic internal QA audits on critical manufacturing processes that include, at a minimum, process improvements and process efficiency.

Results shall be reported at each PMR.

3.7 Government Furnished Property

Government Furnished Property (GFP) Reporting The contractor shall conduct monthly audits of all GFP on contract and submit updates (see contract attachment) as new GFP is received from the Government.

(CDRL B00L)

4.0 DATA DELIVERABLES

CDRL Title Frequency

B001 Conference Agenda Draft due NLT than 15 working days prior to start of each meeting. Final due

NLT 5 DARGC.

B002 Presentation Materials

Hard copies of all materials presented at each meeting shall be provided for 10 Government attendees. 20 soft copies of all materials shall be provided at each meeting. Presentation shall be posted to MIDSvue 5 days prior to meeting.

B003 Conference Minutes One time per meeting.

B004 Cost and Hour Report (FlexFile) Submission due to DCARC in accordance with CSDR Plan B005 Quantity Data Report Submission due to DCARC in accordance with CSDR Plan

B006 Contractor Business Data Report (DD Form 1921-3)

Submission due to DCARC in accordance with CSDR Plan

B008 Hazardous Material Summary Report As required. Draft report shall be submitted for all hazardous materials within 15 days from when they are identified. Government comments within 45 days. Final due 30 DARGC.

B009 Engineering Change Proposal As required. Final is due within 30 DARGC.

B00A Notice of Revision Submitted in conjunction with each ECP (CDRL B009)

B00B Regression Verification Procedure Draft is due at least 60 days prior to start of verification along with the applicable ECP. Final is due within 15 DARGC.

B00C Regression Verification Report Due NLT 30 days after completion of each regression verification conducted.

B00D Request for Deviation As required for each non-conformance, final is due within 30 DARGC.

B00E Configuration Management Accounting Report Due at end of first full calendar year ARO. Subsequent submission due within 10 days of update.

B00F As-Built Configuration List Due NLT 10 days after acceptance of each HWCI delivered to the Government.

B00G Data Accession List Due at end of first full calendar year ARO. Subsequent submission due within 10 days of update.

B00H Metrics Report Due monthly.

B00J Failure Reporting and Corrective Action Report Due bi-monthly.

B00K Acceptance Test Procedure As required. Government comments within 45 days. Final due 30 DARGC.

B00L GFP Monthly Status Report Updates are required as new GFP is provided by the Government B00N COMSEC Inventory Report Due monthly, within 5 business days of beginning of month

APPENDIX A

PROGRAM MANAGEMENT REVIEWS

1.0 Scope

This appendix defines the program status information to be reported at the PMRs.

2.0 General

Each PMR shall be a formal management review of the contractor’s overall SF1 radio production efforts.

3.0 Items to be Reviewed

The contractor shall present the following for review:

3.1 Program Status:

a. Program Overview

b. Summary of action items from all formal meetings and reviews;

c. The contractor’s risk assessment;

d. The contractor’s schedule and status;

e. Contract status and actions;

f. Proposal status;

g. Letter response status; and,

h. Production delivery status.

3.2 Engineering Support Status:

a. Systems Engineering Status,

b. SPR status; and,

c. Verifications and Approvals status.

3.3 Configuration and Data Management Status:

a. ECP status;

b. RFD status;

c. RVP/RVR status;

d. CDRL status; and,

e. Data Accession List

3.4 Logistics Status:

a. TAT status;

b. Material inventory status;

c. Material failure status and analysis;

d. Radio depot repair Work In Process;

e. Corrective action status;

f. Cataloging status, and,

g. Maintenance planning;

h. Parts Obsolescence;

i. Configuration, availability, maintainability and reliability of SF1 radios.

3.5 Manufacturing and QA Status:

a. Part control status;

b. Production controls status and effectiveness;

c. Defect controls status, results and analysis;

d. Manufacturing program planning status and metrics;

e. Manufacturing surveillance;

f. Manufacturing operations management status;

g. FRACAS status;

h. ATP status;

i. EMI periodic verification status and analysis;

j. ESS Effectiveness;

k. Acceptance and factory test equipment status and reporting;

l. STE; and,

m. QA audit reporting.

3.5.1.6.4 COMSEC Inventory Report