SOW FDIO FS changes 9.21.23 draft.pdf

FAA-F-1369-3 (Reviewed 4-25-2023) Superseding

FAAD-F-1369-1&2

9/21/2023

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

FAA LOGISTICS CENTER ACQUISITION SPECIFICATION

THERMAL FLIGHT STRIPS

MANUFACTURING AND PACKAGING

SPECIFICATIONS

Thermal Flight Full Terminal Strips

NSN: 7530-01-682-7616

IFS PN 100026060

Thermal Flight Terminal 1/2 Strips

NSN: 7530-01-682-6809

IFS PN 100026061

Thermal Flight ARTCC ENROUTE Strips

NSN: 7530-01-682-6811

IFS PN 100026062

Written by:

Cynthia H. Vuong Electronics Engineer

Approved by

Changes:

Paragraph 3.4: The product shall have a shelf life of five (5) years when stored under the following conditions:

Revised 09/21/2023

Table of Contents:

1.0 Scope ---------------------------------------------------------------------- 3

1.1 General -------------------------------------------------------------------- 3

2.0 Applicable Documents -------------------------------------------------- 3

2.1 Documents ---------------------------------------------------------------- 3

2.1.1 Standards ----------------------------------------------------------------- 3

2.1.2 Specifications, Federal ------------------------------------------------- 3

2.1.3 TAPPI Specifications---------------------------------------------------- 4

2.1.4 ASTM Specification ---------------------------------------------------- 4

3.0 Common Specifications ------------------------------------------------ 4

3.1 Writing Attributes ------------------------------------------------------ 4

3.2 Paper ---------------------------------------------------------------------- 4

3.2.1 Material ------------------------------------------------------------------- 4

3.2.2 Color ---------------------------------------------------------------------- 5

3.2.3 Feed Direction Arrow -------------------------------------------------- 5

3.2.4 Sizes and Dimensions --------------------------------------------------- 5

3.2.5 Registration Mark ------------------------------------------------------- 5 3.2.6-Fold Perforation ---------------------------------------------------------- 5

3.3 Paper Performance Specification ------------------------------------- 5

3.4 Application Information Shelf Life( revised)-------------------------- 7

3.5 Approval for Production ------------------------------------------------ 7

3.6 Government Furnished Equipment (GFE)---------------------------- 7

4.0 Quality Assurance ------------------------------------------------------- 7

4.1 Method of Inspection ---------------------------------------------------- 7

4.2 Location of Inspection -------------------------------------------------- 8

4.3 Quality Assurance-------------------------------------------------------- 8

4.4 Contractor Quality Control Program Requirement------------------ 8

4.5 Attributes Inspected ----------------------------------------------------- 8

4.6 Critical Defects ---------------------------------------------------------- 8

4.6.1 Critical Defects-Details ------------------------------------------------- 8

4.7 Major Defects ------------------------------------------------------------ 9

4.7.1 Major Defects-Details --------------------------------------------------- 9

5.0 Packaging Requirement ------------------------------------------------- 9

5.1 Materials ------------------------------------------------------------------ 9

5.2 Boxes ---------------------------------------------------------------------- 9

5.2.1 Boxes-Requirements ---------------------------------------------------- 9

5.3 Grade Size ---------------------------------------------------------------- 9

5.4 Pallets --------------------------------------------------------------------- 9

5.4.1 Palletized Size Limits --------------------------------------------------- 9

5.5 Palletizing-General ----------------------------------------------------- 9

5.6 Product Identification Label ------------------------------------------- 10

5.7 Pallet Labeling ---------------------------------------------------------- 10

6.0 Delivery ------------------------------------------------------------------ 10

6.1 Delivery Requirements-All Thermal Flight Strips ----------------- 10

6.2 Freight Destination-All Flight Strips --------------------------------- 10

6.3 Mailing Address-Correspondence ------------------------------------ 10

APPLICABLE DRAWINGS

DWG# DE-A-4779-1, FDIO Thermal Flight Strips- Strip Dimensions DWG# DE-A-4779-2, FDIO Thermal Flight Strips- Paper Box Construction DWG# DE-A-4779-3, FDIO Thermal Flight Strips- Shipping Carton Construction

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

FAA LOGISTICS CENTER ACQUISITION SPECIFICATION

FLIGHT DATA INPUT/OUTPUT SYSTEM (FDIO)

THERMAL FLIGHT STRIPS

MANUFACTURING AND PACKAGING

1.0 SCOPE.

1.1 General: This specification defines the common attributes, physical characteristics, and packaging of thermal flight strips used by the Federal Aviation Administration (FAA) for the control of air traffic. The contractor shall provide thermal flight strips manufactured, packaged, and labeled in strict accordance with this specification.

Thermal flight strips shall have consistent dimensions and physical characteristics in order to be functional in equipment used for the control of air traffic. Noncompliance with any of the COMMON SPECIFICATIONS will constitute sufficient cause for rejection of thermal flight strips.

2.0 APPLICABLE DOCUMENTS.

2.1 Documents: The following documents form a part of this specification. Unless otherwise indicated, the document issue in effect on the date of issuance of the producing or converting order shall apply. If any conflict exists between referenced standards and this specification, this specification shall take precedence.

2.1.1 Standards: ANSI/ASQC Q9002-1994*, Quality Assurance in Production, Installation, and

Servicing:(supersedes Q91-1987)

2.1.2 Specifications, Federal:

ASTM-D-5118/5118M: Standard Practice for Fabrication of Fiberboard Shipping Container.

NN‑P‑71: Pallets, Material Handling, Wood, Stringer Construction, 2‑Way and 4‑Way (Partial).

2.1.3 Specifications, TAPPI- Technical Association of the Pulp and Paper Industry:

T 410 om-88 Grammage of paper and paperboard (Weight per unit area)

T 411 om-84 Thickness (caliper) of paper, paperboard and combined board

T 538 om-88 Smoothness of paper and paperboard (Sheffield method)

T 543 om-84 Stiffness of paper (Gurley type stiffness tester)

T 494 om-88 Tensile breaking properties of paper and paperboard (using constant rate of elongation apparatus) T 414 om-88 Internal tearing resistance of paper (Elmendorf type method)

T 530 pm-83 Size test for paper by ink resistance

T 425 om-86 Opacity of paper (15% diffuse illuminant A, 89% reflectance backing and paper backing) T 452 om-87 Brightness of pulp, paper, and paperboard (directional reflectance at 457 nm)

The FAA will require two (2) sheets of non-converted sample material with dimensions of twenty-five (25) inches by thirty-six (25) inches to be tested for the cited TAPPI specifications.

Note: The FAA, at its sole discretion, may waive testing for compliance with the above TAPPI specifications.

2.1.4. Specifications, ASTM- American Society for Testing and Material:

ASTM Designation F1405-93, Standard test method for determining the Dynamic Thermal response of direct thermal imaging products. (method). Note: The FAA, at its sole discretion, may waive testing for compliance with this ASTM specification.

3.0 COMMON SPECIFICATIONS.

3.1 Writing Attributes: All thermal flight strips will have a common writing quality requirement.

The thermal flight strips shall be suitable for use with, but not limited to, the common pencil, ball point pen, and pen and ink.

3.2 Paper: All thermal flight strips shall be produced from paper/stock conforming to the following specifications.

3.2.1 Material: Thermal Tag Stock – HS 7 (top coated)

3.2.2 Finish: Non-glare, non-reflective, uniform smoothness, and uniform color. The finish shall be of uniform contrast with no visible dirt specks. The splicing of strips, by adhesive tape or any other method, is not permissible.

3.2.3 Color Face

(Thermally active side): Tinted Light green, Pantone Matching System (PMS) #358 @ 20% Screen. The FAA will provide a sample of desired color.

Image Color: Black

Back: White

3.2.4 Feed Direction Arrow: Feed Direction Arrow, PMS# 032 RED, printed on back of the thermal strip in accordance with dimensions on drawing # DE-A-3379-1, -2, -3.

3.2.5 Sizes and Dimensions: Size of each thermal flight strip is specified in Drawing# DE-A-3379-1, -2, and -3. (Drawings attached).

3.2.6 Registration Mark: Black, PMS Black U. Black mark is positioned on the back of 3425-1.

Black mark shall have a minimum PCS of 90% in the infrared range. The background area in line with the black mark shall have a maximum PCS of 20% in the infrared range.

3.2.7-Fold Perforation: The perforation shall be made from the face of the flight strips.

The perforation shall end at a distance of .03 inches or 0.75 millimeter from each side.

See drawing # DE-A-3379-1, -2, -3.

Configuration: 8 TPI (teeth per inch)/.039 inch tie

Cut/tie Ratio: 2.2 : 1

3.3 Paper Performance Specifications:

* Applies to NSN 7530-01-682-6716, and IFS PN 100026060, Full Terminal Strip ** Applies to NSN 7530-01-682-6809, and IFS PN 100026061, ½ Terminal Strip *** Applies to NSN 7530-01-682-6811, and IFS PN 100026062, ARTCC ENROUTE Strip

Target Range Basis weight: (24X36-500 sheets) g/m² 173 158-188

TAPPI T-410

Caliper (thickness): Mils 7.2 6.9-7.5

TAPPI T-411

Length: Inch 8.0 +/-.005

*Width: Inch 1.000 +/-.002 **Width: Inch 1.000 +/-.002 ***Width: Inch 1.317 +/-.002

Paper, continuous strips per Stack: 1,000 950-1,050

*Paper, continuous strips per shipping carton: 10,000 12,950-13,050 **Paper, continuous strips per shipping carton: 13,000 12,950-13,050 ***Paper, continuous strips per shipping carton: 10,000 9,950-10,100

Smoothness (Sheffield Units, Coated side) 10 0-30

TAPPI T-538

Stiffness (Gurley units) TAPPI T-543 MD (Machine Direction) 1,360(Typical) CD (Cross Direction) 611(Typical)

Tensile (lbs force) TAPPI T-494 MD 63.2 lb/in (Minimum)

CD 38.1 lb/in (Minimum)

Tear (grams force) TAPPI T-414 MD 113 (Minimum) CD 110 (Minimum)

Absorption rate (second) TAPPI T-530 Face: 2005.3 (Typical)

Back: 390.4 (Typical)

Opacity (Ratio) TAPPI T-425 98.4 (Typical)

Light reflection (Ratio) TAPPI T-452 82 (Typical)

Dust TAPPI T-437 SEE CHART

Static Thermal Response Temperature:

0.2 ODU 179 degree F +/-40 F or 77 degree C +/-5 C

1.0 ODU 180 degree F +/-40 F or 82 degree C +/-5 C

Maximum Density 1.33 odu 1.3-1.4 Temperature required 230 degree F +/-40 F or 110 degree C +/-5 C

Dynamic Thermal Response Temperature:

(Atlantek 300 - 12 volts: millijoules per sq.mm.)

0.2 ODU 13.37

1.0ODU 21/55

Maximum Density 1.40 odu Energy Required: 37.69

3.4 Application Information:

The product shall have a shelf life of five (5) years when stored under the following conditions:

1. Product shall be kept dry and out of direct sunlight

2. The storage temperature is maintained at an optimum condition of 80-degree Fahrenheit plus or minus 20-degree Fahrenheit.

3. The humidity range is maintained at 45% to 65% HR

Higher storage temperatures and/or relative humidity will affect product performance. The product can be exposed to temperature up to 125-degree Fahrenheit for short periods of time without affecting product performance.

3.5 Approval for Production.

Where changes are made to the specifications or drawings pursuant to the Changes clause of the contract, the FAA will require a pre-production conference. This pre-production conference will be conducted by the Contracting Officer’s Representative (COR) and attended by the FAA, at the production plant, prior to start of production. The FAA will require testing of pre-production samples prior to approval for production. Pre-production samples will be tested to demonstrate conformance to this specification. Documentation of test results shall be provided to the Contracting Officer and COR.

3.6 Government Furnished Equipment (GFE).

The FAA will provide the successful bidder a Flight Data Input/Output (FDIO) thermal printer used by the National Airspace System (NAS), and instructions for running test patterns to verify the thermal paper meets the performance requirements as defined in this specification.

The printer shall be returned to the FAA upon completion of the contract.

4.0 QUALITY ASSURANCE.

4.1 Method of Inspection: The critical application of thermal flight strips and the necessity of their functioning in FAA owned equipment dictate that all physical attributes specified herein for the manufacturing, packaging, and transportation of thermal flight strips are subject to inspection. Acceptance inspection of all flight strips shall be done in accordance with

ANSI/ASQC Z1.4-1993.

In brief, ANSI/ASQC Z1.4-1993 is an established method for sampling inspection by attributes of incoming lots of material. Lot size determines the sample size to be selected from the lot and inspected. Results of the sample inspection determine if the lot is accepted or rejected.

The Acceptable Quality Level (AQL) will be one percent (1 %) defective as defined by ANSI/ASQC Z1.4-1993 for all flight strips. (Reference attached TDR data sheet). The FAA, at their sole discretion, may elect to accept portions of lots found defective.

4.2 Location of Inspection. Final acceptance of all thermal flight strips is at destination with acceptance inspection as specified by the contract. The FAA reserves the right to make in‑ plant inspection during the contract period as designated by the Contracting Officer.

A pre-production conference at the contractor’s plant is required for the first two production runs ordered pursuant to terms of the contract. FAA representatives and contractor personnel shall attend with the conference scheduled no more than two (2) calendar days prior to production. The FAA shall be notified a minimum of seven (7) workdays in advance of the meeting date.

When an in-plant inspection is requested by the FAA, it shall always follow the pre-production conference. The Contracting Officer’s Representative at the pre-production conference shall define the inspection authority delegated to the FAA at the conference. The presence of the Contracting Officer’s Representative during all or part of the inspection process is at the sole discretion of the Contracting Officer. The FAA in‑plant inspection process shall follow all requirements of section 3.0 in its entirety.

4.3 QUALITY ASSURANCE

The contractor shall furnish the FAA inspectors floor space, material handling assistance and complete product for inspection. The FAA recognizes that lot inspection can be accomplished by random sampling of the continuous process and will have adequate personnel to perform on that basis if a method is agreed to by the FAA, the Contracting Officer, and the contractor.

When in-plant inspection is performed, final destination acceptance of the material inspected in-plant will be limited to verification of quantity and physical integrity of the material. All other material produced under the contract shall be destination inspected, as defined in this specification.

4.4 Contractor Quality Control Program Requirement. The contractor shall provide and maintain a quality control program that fulfills the requirements of this specification and compliance with the specification of ANSI/ASQC Q9002/1994, Inspection Systems Requirements. The contractor's quality control program shall be a scheduled and controlled plan of events integrating all necessary inspections and tests required to substantiate product quality during purchasing, subcontracting, manufacturing, fabrication, processing, assembly, packaging, and shipping. The contractor shall perform, or have performed, all inspections and tests required to substantiate product configuration and conformance to drawings and specifications.

4.5 Attributes Inspected. As stated in section 1.1, all defined attributes are subject to inspection and are in themselves, cause for rejection if out of tolerance in quantities defined by ANSI/ASQC Z1.4/1993. A list of these attributes will include Critical Defects: Thermal top coat; paper thickness; perforation strength; black register mark, basic size dimensions, thermal coat, paper color, single stack fanfold contiguous of 1000 (+/-0.5%) strips, and directional arrow on first strip of each stack. Major Defects: labeling, packaging, and label code of box.

4.6 Critical Defects. A part whose failure to meet specified requirements results in the failure of the product to serve its intended purpose.

4.6.1 Critical Defects-Details: Paper thickness, perforation strength, black registration mark, basic size dimensions, thermal coat, quality of thermal printing, paper color and contrast, overall visual impression, and single stack fanfold contiguous of 1,000 (+/-50) strips.

4.7 Major Defects. A defect that could result in failure or significantly reduces the usability of a unit for its intended purpose.

4.7.1 Major Defects-Details: Labeling, packaging, and label code on box.

5.0 PACKAGING REQUIREMENTS.

5.1 Materials. The contractor shall furnish all boxes, cartons, labels, pallets, and other miscellaneous items required to package flight strips as specified herein.

5.2 Boxes. Box is defined as the smallest container/package of flight strips. A box of thermal paper flight strips shall contain one (1) individual stack of 1,000 contiguous fanfold strips (folded singularly) with each strip separated by a perforation. The splicing of strips, by adhesive tape or any other method, is not permissible. Construction and Labeling of boxes shall be in accordance with Drawing # DE-A-3379-1, -2, -3.

5.2.1 Boxes-Requirements. Boxes shall be constructed of 24 point, C1S Kraft back. Do not use staples.

5.2.1.5 Shipping Cartons. Each Carton shall contain ten (10) boxes or thirteen (13) boxes of individual stacks of 1,000 contiguous fanfold strips, as applicable per Sect 3.3 herein. Each Shipping Carton shall also be individually shrink-wrapped to prevent absorption of moisture.

Construction and Labeling shall be in accordance with Drawing # DE-A-3379-1, -2, -3.

5.3 Grade Size. Cartons shall be constructed of material that meets or exceeds the thirty-two (32) pounds/inch carton Edge Crush Test (ECT), TAPPI 811 om-95, with reinforced tape applied over all outside closures. Do not use staples.

5.4 Pallets. Pallets shall not exceed forty-three (43) inches by fifty-two (52) inches, Type III pallets as defined by Federal Specification NN‑P‑71. Type III pallets are four‑way (partial), flush, assembled, non‑reversible made of untreated group II woods (medium density softwood) or better.

5.4.1 Palletized Size Limits. No portion or part of the contents of the pallet shall overhang or project beyond any edge of the pallet. The overall height of pallet and contents shall not exceed fifty-four (54) inches.

5.5 Palletizing- General. All palletized material produced under this specification shall be centered upon the pallet and tightly shrink- wrapped. The wrapping shall be multiple layers as required to maintain load centering when the pallet is subjected to a non-elastic stop (collision with a stationary object), while moving at two (2) miles per hour. All pallets for an order/contract shall contain the same number of boxes with the exception of the last pallet load required to complete the order. An identifying number shall be stamped or legibly handwritten on all boxes. This number will allow the supplier to identify the manufacturing date of the finished product. It will also allow the supplier to trace the finished product back to the raw material used. One such identifying number is, 123456.

Where positions 1 and 2 represent a two-digit month and position 3 and 4 represent the two-digit day. Position 5 represents a time of the day and position 6 identifies the raw material.

In addition to the label, each production order shall be labeled with a different color label using the following sequence of colors: 1. Yellow; 2. Red; 3. Green; 4. Pink; 5. Blue; 6. Orange, and

7. White.

5.6 Product Identification Label. Boxes shall also be labeled as followed:

TITLE: PAPER, TABULATING MACHINE, CONTINOUS FLAT

NSN: 7530-01-682-6716, and IFS PN 100026060, Full Terminal Strip (13,000)

Or NSN: 7530-01-682-6809, and IFS PN 100026061, ½ Terminal Strip (13.000) Or NSN: 7530-01-682-6811, and IFS PN 100026062, ARTCC ENROUTE Strip (10,000)

QUANTITY: 10,000-strips or 13,000 strips

PRODUCTION DATE: MM-DD-YY

EXPIRATION DATE: MM-DD-YY

5.7 Pallet Labeling. Palletized shipment is required. Any Commercial Order requirement to show addresses and complete address on each box is waived. The name and address of the consignee is required for each wrapped pallet. The consignee (“SHIP TO”) address is shown in 6.2 below. The purpose of the pallet label is to assure delivery to the original consignee.

Photocopied pallet labels are acceptable.

6.0 Delivery.

6.1 Delivery Requirements – All Thermal Flight Strips. Delivery shall be scheduled so that receipt at destination is on or before the date(s) shown on the accompanying delivery order. Shipment lot size and delivery dates will be agreed upon by the CO and Contractor for each order placed.

6.2 Freight Destinations ‑ All Flight Strips:

U.S. Department of Transportation FAA Mike Monroney Aeronautical Center Mark For: Operating Stock Attn: (Indicate delivery order number) 6500 S MacArthur Blvd.

Oklahoma City, OK 73169

Normal receiving hours at this address are 7:00am to 3:00pm. Freight carriers may call 405- 954-5471 to schedule delivery.

6.3 Mailing Address - Correspondence:

U.S Department of Transportation Federal Aviation Administration ATTN: AJW-L800, Automation/Communications Products Division, TSF Building 215 7100 S. MacArthur Blvd.

Oklahoma City, OK 73169