SOW ACES Seat Sequencer Program Phase 3 14 Jan 2025.pdf

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

STATEMENT OF WORK (SOW)

ACES Seat Sequencer Program Phase 3

AIR FORCE LIFE CYCLE MANAGEMENT CENTER (AFLCMC)

MUNITIONS SUSTAINMENT DIVISION

HILL AIR FORCE BASE, UTAH 84056-5609

14 January 2025

Prepared By:

Avery Johnson

AFLCMC/EBHJ

801-777-7326

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

ACES Seat Sequencer Program Phase 3

1.0 SCOPE

The ACES Seat Sequencer Program purpose is to design, develop, manufacture, qualify and support fielding of a sequencer for the ACES II and ACES 5 Ejection Seats. This includes the associated programmatic reviews and tasks necessary to support the effort.

The primary aspect of ACES Seat Sequencer Program Phase 3 will be a continuation of Phase 2 and progression into qualification testing. Activities will include close out of development with the appropriate programmatic steps through the Test Readiness Reviews (TRRs), remaining Phase 3 required hardware procurement, the LRU (Line Replaceable Unit) testing and System integration Qualification Sled Testing.

1.1 Background

The sequencer is a Time Change Item (TCI) and is utilized on all ACES II Ejections Seats and will be used on ACES 5 Ejections Seats. The current configuration is reaching the end of possible production due to obsolescence of several components. Other selected updates from Phase 1 will also be incorporated.

2.0 APPLICABLE DOCUMENTS

The following documents are applicable to the extent stated within this SOW. In the event of a conflict between the text of this SOW and other documentation such as test plans, drawings, specifications, or any documents cited herein, the Government will provide written guidance as to what shall take precedence. In addition, any conflict within the applicable specifications shall use the most stringent requirements. Final approval from the Government.

Document Number Document Title IEEE 15288.2 Systems Engineering Technical Reviews

A114520

MIL-C-83124

1847-208

18483(01) FCR

MIL-HDBK-516C

McDonnell Douglas Specification

CAD General Specifications

Specification – Electronic Module, Modernized ACES Seat Sequencer Assembly

Firmware Change Requirements for the Modernized ACES Seat Sequencer

Airworthiness Certification Criteria

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

MIL-STD-810H Environmental Engineer Considerations and Laboratory Tests

MIL-STD-461

MIL-STD-464

MIL-STD-881F

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

Electromagnetic Environmental Effects Requirements for Systems

Work Breakdown Structures for Defense Material Items

3.0 REQUIREMENTS

In Phase 3 the Contractor shall execute the LRU and System integration qualification testing on the sequencer designed during Phase 2. Phase 3 shall include remaining hardware procurements necessary for testing, utilize applicable Systems Engineering processes and include associated documentation.

Requirements and capabilities include but not limited to:

Collins Specification 1847-208

An updated specification approved through the appropriate government change process and Technical Reviews will be provided

Increase LRU environmental testing quantity to 22ea minimum.

Phase 1 Design Decisions

Software certification level to meet current Airworthiness and specification, reliability, and safety requirements

1000Hz minimum Sample Rate of Sensors Roll Rate Sensors

Update ACES II pressure transmission system (PTS) design to align with the ACES 5 rubber hosing and barbed fittings

Removable P-Leads to support sequencer removal without seat disassembly Ability for Government to download post ejection events Field level testing capability Backup functionality if there is only one participating channel. Proposal to include with and without backup functionality. Final decision to be made by Government.

LRU level testing capability to input egress pressure profiles for simulated ejections Anti-Tamper Requirements for Computer Hardware, Software, and Firmware

Implement safeguards to deter, detect, prevent, and respond to computer hardware, software, and firmware tampering. Design shall be such that active protection activities are not required.

Phase 3 Inclusion of Phase 2 testing and design decisions

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

LRU Qualification Testing Environmental Testing-In accordance with approved specifications and test plans Software Testing - In accordance with approved specification and test plan HERO, EMI Testing - In accordance with approved specification and test plan Utilize simulated ejection testing with historical pressure profile inputs 14ea ACES II system integration sled test ejections Sled testing scope to be limited to verification of sequencer integration attributes

Seat configurations including dual/single sled configurations to be included in a detailed a System Integration Test Plan

Sequencer support for 8ea ACES 5 system integration sled tests ejections

Alternate seat program sled testing to be supported with hardware and programming necessary to utilize the update sequencer

Airworthiness Certification Support Sequencer development documentation for airworthiness certification of software and hardware after completion of Phase 3 qualification.

3.1 Program Management

The Contractor shall provide program management support to the ACES Seat Sequencer Program. Program management tasks include, but are not limited to, hosting and/or participating in meetings, reviews, and events; providing insight into subcontractor management and performance; cost reporting; risk management; and access to Contractor facilities. The Contractor shall provide input for the ACES Seat Sequencer Program as required to plan for follow on sequencer Qualification and fielding. The Contractor is responsible for meeting program performance/technical, cost, and schedule requirements. The Contractor shall develop and deliver Integrated Master Schedule and Integrated Program Plan. The Contractor shall monitor, maintain, project, and present program information including that contained in these documents, through weekly interchange meetings, and as required, in response to Government inquiries. [CDRL A004 Integrated Master Schedule (IMS), DI-MGMT-81861C/T;

CDRL A005 Work Breakdown Structure (WBS)/Integrated Master Plan (IMP), DI-MGMT- 81861C/T]

3.1.1 Program Management Reviews (PMRs)

The Contractor shall conduct, participate in, and host quarterly Program Management Reviews. These reviews shall address, at a minimum, the program status, testing activities, schedule information, risk management, system safety, financial and cost data, and any special interest items requiring management attention. Meeting timing may be altered as programmatically needed with government concurrence. The Contractor shall conduct Technical Interchange Meetings (TIMs) in conjunction with each PMR. The material from each PMR and TIM shall include content since the preceding Technical Review, PMR or TIM event. The Contractor shall prepare an agenda and presentation materials in advance and record the minutes during the PMRs and TIMs. [CDRL A001 Meeting Agenda, DI- ADMN-81249C; CDRL A002 Presentation Materials, DI-ADMN-81373; CDRL A003 Conference Minutes, DI-ADMN-81250C]

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

3.1.2 Progress Reports

The Contractor shall submit progress reports documenting program status of milestones, schedule cost objectives and technical performance requirements. The report will be delivered every quarter. [CDRL A006 Contractor’s Progress and Status Report DI-MGMT- 81928]

3.1.3 Risk Analysis and Management

The Contractor shall have a focused risk management strategy and deliver its Risk Management Plan in support of Risk Assessment, Risk Analysis, and Risk Resolution. The Contractor shall prepare and execute an internal risk process to ensure risks are identified, reviewed, and resolved. The Contractor shall utilize the initial assessment developed in Phase 2 and continue to update this risk assessment during Phase 3 to include potential risk issues that are specific to the Contractor design and testing approach. The Contractor shall manage program risks (e.g. performance, cost, schedule, qualification, and manufacturing risks) using an integrated management approach of risk planning, risk assessment, risk handling, and risk monitoring. The Contractor shall track, monitor, and maintain risk status for reporting via delivery of a Risk Management Status Report, and in response to Government inquiries. [CDRL A007 Risk Management Status Report, DI-MGMT-81809]

3.1.4 Financial Management

The Contractor shall implement Contractor Cost Data Reporting (CCDR) in accordance with DoD 5000.4M-1 to accumulate actual Contractor costs to analyze costs efficiently and effectively in support of future cost estimate efforts. The Contractor shall track costs to applicable CWBS elements on monthly invoices. The Contractor shall deliver Contract Funds Status Reports monthly. [CDRL A008 Contract Funds Status Report (CFSR), DI-

MGMT-81468A]

3.2 Qualification

3.2.1 Technical Interchange Meetings (TIMs)

The Contractor shall conduct Technical Interchange Meetings (TIMs) in conjunction with quarterly PMRs. The material from each PMR and TIM shall include content since the preceding TRR, PMR, TIM or test event. The TIMs shall be technically focused and support configuration management, data management, requirements traceability, reliability/maintainability engineering, test engineering, manufacturing engineering, and planning for supportability, sustainability, safety engineering. Additionally, the TIMs shall support creation and/or maintenance of technical data as applicable. This includes but is not limited to any updates from Phase 2 baseline documents such as Requirements Traceability Verification Matrix, Cyber Security Risk Management, Supply Chain Risk Management, T.O. Updates, FMECA, Technical Drawing Package and software qualification documentation. The TIMs will also serve as a support meeting in determining scope, entrance and exit criteria and other associated activities in connection with follow on TRRs, test events and TIMs.

3.2.1.1 Configuration Control

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

Following CDR approval, all Engineering Change Proposals (ECPs) or Request for Variances (RFVs) affecting the approved product baseline configuration, acceptance test procedures or manufacturing process shall be in accordance with EIA-649B.

[CDRL A011, Engineering Change Proposals (ECP), DI-SESS-80639E; CDRL A012, Request for Variance (RFV) DI-SESS-80640E]

3.2.2 Test Readiness Reviews (TRR)

The contractor shall conduct a Master TRR that will cover the planned Phase 3 test events.

The Master TRR shall be conducted prior to proceeding into formal Qualification or Integration Phase 3 test events and will include but is not limited to a review of Test Assets, Test Fixtures, Approved Test Plans, Test Schedule, Testing Facilities and expected Test Reports. Individual TRRs will be held for each individual test event. Agendas are not required for TRRs.

Unless otherwise stated each TRR will be conducted in accordance with the standards found in IEEE 15288.2 and include Presentation Material, and meeting minutes.

Presentation Material to be provided 7 calendar days prior to the review and Meeting Minutes to be delivered within 7 calendar day after the review [CDRL A002, Presentation materials, DI-ADMN-81373; CDRL A003, Conference Minutes, DI-ADMN-81250C]

3.2.3 Qualification Testing

The primary Phase 3 Qualification Testing activities will include LRU Qualification Testing, and System Integration Testing. LRU Qualification will focus on the component level testing and System Integration will consisting of the required sled testing. Phase 2 test hardware procurement efforts will continue into Phase 3 with any remaining Phase 3 required hardware to be procured as part of early Phase 3 activities.

As applicable Hardware acceptance documentation shall be created or updated in Phase 3.

This includes but is not limited to Acceptance Test Plan and Report (ATP/ATR), Hardware Accelerated Life Test Plan and Report (HALT), and Environmental Stress Screening Plan and Report (ESS); The Government reserves the right to determine test asset disposition plans as part of the test planning process.

Approval of CDR, applicable qualification production documentation/reports, Master Test Plan and Master TRR shall be completed before the start of LRU Qualification or System Integration testing. Qualification associated draft plans were include in Phase 2 with final versions required as part of Phase 3.

Following the completion of LRU and System Integration testing a comprehensive ACES Seat Sequencer Program Qualification Test Report shall be submitted 14 days after the conclusion of test activities. The Qualification Test Report shall include but not be limited to software qualification from Phase 2, LRU Qualification and System Integration, with a summary of all qualification associated activities, data, and conclusions for the updated sequencer. In the event of a test failure(s), a Failure Analysis and Corrective Action Report with proposed corrective actions/recommendations is required.

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

[CDRL A009 Test Plan, DI-NDTI-80566A; CDRL A010 Test Report, DI-NDTI-80809B;

CDRL A013, Failure Summary and Analysis Report, DI-SESS-80255B]

3.2.3.1 LRU Qualification Testing

As part of the Phase 3 the contractor shall conduct LRU qualification testing in accordance with contractual requirements, approved specifications, and approved test plans. Individual TRRs shall be conducted before each major test event or test series. Testing shall include simulated ejections which utilize Power Module representative input profiles, ejection representative pressure profiles inputs through pressure ports and start switch application.

LRU Qualification Testing focused deliverable documents shall include but not be limited to the following: Environmental Test Procedure (ENV); Environmental Test Report (ETR); Electromagnetics Test Procedure and Report (EMI/HERO);

Individual Test Event Plans as applicable; Individual Test Event Reports as applicable.

Test plans shall be delivered 30 days before the beginning of testing or applicable TRR. Test Reports shall be delivered within 14 days of completion of testing and include all associated test documentation to include any sub vendor reports and raw data files. In the event of a test failure(s), a Failure Analysis and Corrective Action Report with proposed corrective actions/recommendations is required.

[CDRL A009 Test Plan, DI-NDTI-80566A; CDRL A010 Test Report, DI-NDTI- 80809B; CDRL A013, Failure Summary and Analysis Report, DI-SESS-80255B]

3.2.3.2 System Integration Testing

System Integration Testing shall consist of 22ea sled test ejections and take place following LRU qualification testing. System integration testing will serve as fit checks for each seat configuration and updated T.O. validation. Each individual test event is considered a “success” if the test plan was properly executed, and the system met the performance requirements outlined in the individual test plan with correct sequencer operation as defined within the approved specification with full functionality retained.

System Integration Testing focused deliverable documents shall include but not be limited to the following: Individual Test Event Plans; Individual Test Event Reports;

Quick Look Reports.

Individual Test Event Plans for each of the ACES II sled test events must be approved before the test event TRR. Quick Look Test Reports and sled test data shall be delivered within 2 day of test completion. This includes sequencer download data. Test Report to be delivered within 14 days of test completion.

A sequencer specific report shall be prepared for any ACES 5 integration sled test ejections events. This will be completed as part of an alternate program’s sled testing series but utilizing the updated sequencer.

PR FD2020-25-50609 ACES Seat Sequencer Phase 3

In the event of a test failure(s), a Failure Analysis and Corrective Action Report with proposed corrective actions/recommendations is required. [CDRL A009 Test Plan, DI-NDTI-80566A; CDRL A010 Test Report, DI-NDTI-80809B; CDRL A013, Failure Summary and Analysis Report, DI-SESS-80255B]

3.2.3.2.1 ACES II Sled Tests

As part of Phase 3 the contractor shall conduct 14ea ACES II sled test ejections. A combination of dual seat, single seat, and stationary sled tests with various ACES II configurations to be utilized and defined in the Master Test Plan. Individual test plans, quick reports, test event data, sequencer download data and test reports will be delivered for each sled test event. An individual TRR will be held before each sled test event. The scope of this testing is to verify compliant sequencer functionality within the system without increasing test complexity, cost, or schedule impacts. Seat hardware and other CAD/PAD will be provided by government.

3.2.3.2.2 ACES 5 Sled Tests

As part of Phase 3 the contractor shall provide updated sequencer integration support for 8ea sled test ejections during an alternate ACES 5 program qualification series.

Updated sequencer hardware, program specific mode boundary programming and sequencer download shall be included for each test event. The sequencer download, sequencer specific quick look report and sequencer specific sled test report shall be delivered for each test event. This report shall not include protected information from the alternate ACES 5 program but must be sufficient to support the updated sequencer qualification.

3.2.3.2.3 Sled Test Option

In the event that Phase 3 System Integration Testing with ACES 5 sled tests ejections are not able to be completed due to ACES 5 program delays or cancelation an Option may be exercised. The Option will be to change from support of 8ea ACES 5 sled tests as defined in 3.2.3.2.2 to performing and additional 8ea ACES II sled test ejections as defined in 3.2.3.2.1.

4.0 QUALITY CONTROL

4.1 Quality Control Program

The contractor shall be responsible for their own Quality Control Program to ensure the requirements of this contract are provided as specified.