M1028-SOW-10-23-2015.pdf

Section C - Descriptions and Specifications

STATEMENT OF WORK

SECTION C – STATEMENT OF WORK

C.1.0 Scope:

This Statement of Work (SOW) encompasses the effort to fabricate and deliver M1028, 120mm Canister

Cartridges for the U.S. Army. Overall responsibility for this effort rests with the contractor. Basic

Contract Delivery Order for the first ordering period (FY16) is anticipated to be approximately 12,000 cartridges. Subsequent quantities will vary. Delivery for each order will be eighteen (18) months from date of delivery order award. Each order will be produced in one lot.

C.2.0 Applicable Documents:

Unless otherwise specified, the most current revision at the time of contract shall apply.

C.2.1. Mandatory Documents

ASME Y14.5M-1994- Dimensioning and Tolerancing

ASME Y14.34M - Associated Lists

ASME Y14.100-2004 - Engineering Drawing Practices

FR- 6-23-97 Environmental Protection Agency Waste Minimization Master Plan

MIL-A-70625 - Automated Acceptance Inspection Equipment Design, Testing and Approval

MIL-STD-961 - Defense Specifications

MIL-STD-974 - Contractor Integrated Information Service (CITIS)

MIL-STD-1168 – Ammunition Lot Numbering and Ammunition Data Cards

MIL-STD-1916 - DoD Preferred methods for Acceptance of Product

ISO/IEC 17025 – General Requirements for the Competence of Testing and Calibration Laboratories ISO

9001:2008 – Quality Management Systems Requirements

PRF-14000044A – M1028 Performance Specification including the following:

1) ECP: R15T2003

NAS 411 – National Aerospace STD: Hazardous Materials Management Program

TACOM-TARDEC/ARDEC 3 - Dimensional Technical Data Package Solid Modeling Standard

Operating Procedures

TITLE 49 Code of Federal Regulations (CFR) parts 100-180

SAE EIA-649 (Configuration Management Standard)

SAE EIA-649-1 (Configuration Management Requirements for Defense Contracts)

C.2.2 Documents to be used for reference or guidance:

Technical Data Package List: TDPL 13006675, Combination of Adopted Items (COAI) for Cartridge, NSN# 1315-01-516-5248 (Army), 120MM, CANISTER, M1028 and ECPs: R11T2004, H15A3009, and

R15T5017

13011569 – PROPELLANT, JA2 7-PERF GRANULAR, CYLINDRICAL

12527480 – PROPELLANT, JA2 19-PERF

QAP 13011569 – Quality Assurance Provisions for PROPELLANT, JA2 7-PERF GRANULAR, CYLINDRICAL

QAP 12527480 - Quality Assurance Provisions for PROPELLANT, JA2 19-PERF GRANULAR, CYLINDRICAL

AMCR 385 – 100 – AMC Safety Manual

MIL-DTL-31000 – Technical Data Packages

MIL-HDBK-61 – Configuration Management Guidance

MIL-HDBK-1461 – Ammunition Manufactures and their Symbols

MIL-STD-882D – Standard Practice for System Safety

C.3.0 Requirements:

C.3.1 Production: During production, the contractor has complete responsibility for system engineering, quality, configuration management, and fabrication of the complete M1028 cartridge and meeting all requirements in the Performance Specification. The Government will conduct testing and evaluation per the Performance Specification, PRF-14000044A, and ECP R15T2003. In the event that an offeror proposes a design other than the qualified design, they are required to submit substantiating test data, reports, or other data as to verify to the Government that the proposed design meets all requirements of the Performance Specification. If such data is not provided or it does not verify the performance of the proposed design, the Offeror shall be ineligible for award. Offerors are further advised that the

Government shall not fund any qualification or performance verification testing and will not allow or provide delivery schedule relief to enable the Offeror to perform any such testing after contract award.

C.3.2 Propellant Surveillance Sample: The contractor shall deliver one 5 pound sample of propellant from each lot of propellant utilized in cartridge lot production. If de-milled propellant is used, the sample shall be comprised of the final blend across all lots used. The contractor shall deliver the sample concurrent with each Lot Acceptance Test Sample. The samples from each lot of propellant shall be sent to: Commander, U.S. Army RDECOM-ARDEC, ATTN: RDAR-AAR-MEE-P, Picatinny Arsenal, NJ

07806-5000.

C.3.3 Demilled Propellant – If the Government successfully qualifies 195,000 lbs of de-milled 19-perf

JA2 propellant, the contractor shall purchase and use the de-milled propellant on this effort for $0.01 per pound. The source for purchasing this propellant is AMC at Rock Island, D. Porterfield. This propellant will not be provided as GFM.

C3.3.1 Propellant Charge Establishment and Charge Verification tests: The contractor is responsible to conduct ballistic tests for the Charge Establishment test and Charge Verification test (to included test cartridges and warmer rounds) before loading each lot of propellant. The minimum test quantities for

Charge Establishment test, Charge Verification and warmers are nine (9), thirty (30), and twelve (12) respectively.

C.3.4 Propellant Qualification - The contractor is responsible for the qualification of any reclaimed or new propellant manufactured and utilized for the M1028 program.

C.3.5 Performance Oriented Packaging (POP) Test - Prior to shipment of any Hazardous Items, the contractor shall insure the packaging meets the requirements of CFR 49 and has been properly POP tested and/or periodically retested, by a USG approved POP Test Laboratory. The test will be to a weight at least

20% greater than the actual gross weight to be marked on the tested container. The POP marking shall not be applied to the container until verified and approved by the USG. The POP test report shall be generated by the Manufacturer/Laboratory (DI-PACK-81059A) following the test. The report must be kept on file by the contractor and must also be submitted to: U.S. Army RDECOM-ARDEC, ATTN:

RDAR-EIL-P, Tank Ammo Packaging Group, Picatinny, NJ 07806-5000 for approval. The contractor shall re-perform POP testing at a certified test laboratory if: (a) the initial POP test report expires before the end of the contract or (b) if there is a change in container manufacturer or design of the exterior shipping container. A retest is not required if all packaging is purchased while under an unexpired POP test.

C.3.6 The contractor shall develop a M1028 Skive Joint bonding process by using an epoxy that can meet the accelerated aging requirement as specified in ECP R15T2003. The contractor may submit a request to waive the accelerated aging test if the contractor's current Skive Joint bonding process is utilizing Adhesive and Hardener A1177 B1/B2, and the adhesive application process has been approved for Skive Joint bonding operation.

C.4.0 Quality Requirements

C.4.1 Quality Management System (QMS) – The contractor shall maintain a quality management system in accordance with ISO 9001:2008 (no tailoring permitted), or equivalent, and the supplemental requirements contained in C.4.1.1 and C.4.2 herein. Subcontractors with production responsibility only, shall maintain a quality management system in accordance with ISO 9001:2008 (excluding paragraph 7.3

Design and Development), or equivalent, and the supplemental requirements contained in C.4.1.1 and

C.4.2 herein. If the contractor desires to utilize an alternate quality management system, a request shall be submitted to the Contracting Officer for approval.

C.4.1.1 Calibration – The contractor shall implement a system for the calibration and control of all measuring and testing equipment used for the performance of this contract. The calibration system shall, as a minimum, comply with the requirements of ISO/IEC 17025 or an industry equivalent system acceptable to the Government.

C4.1.2 Product Traceability and Lot Control - Product traceability and lot control are requirements on all components and assemblies produced under this contract. Product identification and evidence of the acceptance status of all material shall be maintained throughout the entire manufacturing and assembly process to ensure traceability to original material identification and quality status. This requirement applies to both prime and subcontractors and includes “customer supplied material”. Lot control requirements are defined in the item specification and MIL-STD-1916. Evidence of product traceability and lot control documentation shall be available for Government review upon request.

C.4.1.3 Verification of Purchased Product - Verification of purchased product as specified in ISO 9001-

2008 is required. While type, place of performance and extent of verification is up to the contractor;

inspections and tests of components or assemblies that contain critical characteristics and identified key characteristics that are to be conducted only by and at subcontractors shall be subject to actual verification on production material during the performance of the contract by the prime contractor.

C.4.1.4 Subcontractor and Vendor Audits - The contractor shall include in the Quality Program Plan, provisions for quality system and statistical process control audits of suppliers to verify compliance to contract requirements. The plan shall include a schedule for the conduct of these audits; audit reports shall be provided upon request and audit schedules shall be provided to the Government. (DI-QCIC-

81722).

C.4.2 Quality Program Plan - The contractor shall maintain a documented quality program plan in accordance with the contractor’s quality management system. The plan shall include sections covering

Inspection/Test Plan, Critical Defect Program, Acceptance Inspection Equipment (AIE), Process Control

Documentation, and Rework. This document shall be available for Government review upon request.

C.4.2.1 Inspection/Test Plan - The contractor shall identify and document all inspection and test requirements for all critical and key characteristics (including those already listed in the M1028

Performance Specification) deemed necessary for the acceptance of components, subassemblies, and final assemblies. A key characteristic is a controllable feature, property or attribute for which a tightened limit, within the required technical data limits, results in measurable improvement or consistency of performance. The contractor shall prepare and maintain detailed inspection and test procedures for the control and acceptance of all TDP and contractor key characteristics. The contractor shall maintain documented inspection and test records to include, as a minimum all key characteristics, required inspections and tests, the nature of observations made, and the number and type of deficiencies found.

Contractor plans on how inspection and test data will be recorded and utilized for process and product control shall be made available to the Government upon request.

C.4.2.2 Critical Characteristics – The TDP contains critical characteristics. Section E (52.246-4011 –

Critical Characteristics) contains additional requirements regarding critical characteristics with guidance for developing the Critical Characteristics Control Plan (CCCP) (DI-MGMT-80004A (Tailored)), classifying additional critical characteristics for the Critical Item Characteristic List (CICL) (DI-SAFT-

80970A), and developing the Critical Plan of Action (CPOA) (DI-MGMT-80004A (Tailored)).

C.4.2.3 Acceptance Inspection Equipment (AIE) – The contractor shall establish and maintain a documented system for the identification and approval of AIE to include the calibration and verification of inspection equipment as necessary to meet contract requirements. Approved AIE, in accordance with contractual requirements, shall be utilized for all hardware. The Government reserves the right to disapprove, at any time during the performance of this contract, the use of any AIE not meeting the requirements of the approved documentation. AIE for the acceptance of Critical Level I and Critical

Level II characteristics must comply with C.4.2.1 and C.4.2.2, and shall be submitted to the Government for approval (DI-MGMT-81979) prior to the manufacture of deliverable hardware.

C.4.2.3.1 AIE for Critical Level I and Critical Level II Characteristics – AIE for critical characteristics shall be capable of obtaining variables data and shall use non-operator dependent, automated decision-making inspection systems. Automated decision-making logic and the material handling devices included, as part of the inspection system, shall be designed to be fail safe. This is defined as always being set in the reject mode needing a positive signal to accept and pass product through the AIE station.

Decisions shall be made with variable output(s) proportional to the stimulation of the inspection system device or sensor assessing the Critical Level I or Critical Level II characteristic. Variance from these requirements shall require Government approval.

C.4.2.3.2 AIE System Reliability – Decision making reliability shall be demonstrated at a Confidence

Level of 80 percent (threshold), 90 percent (objective). The reliability demonstrated shall include a mixture of known-acceptable product, known-detectives and reject standards used for calibration. The test results shall indicate the expected result and whether the AIE’s decision was correct. The demonstrated reliability shall be included in the AIE package submitted for approval.

C.4.2.3.3 AIE System Error Rate – An acceptance (prove-out) test using reject standards shall be performed on the AIE prior to its use for the inspection of product destined for delivery to the

Government. The minimum sample required for this test shall be determined by calculating the lower confidence bound of the maximum error rate of the automated system. (Example: the 50% lower confidence bound of the Error Rate based on the Poisson Distribution can be calculated by dividing 0.7 by the inspection system’s Error Rate.) The maximum error rate is the ratio of the number of detectives accepted by the AIE to the total number of defectives inspected by the AIE. The error rate for any AIE shall never be greater than one-in-five-hundred. Acceptance of any reject standard during the prove-out test shall result in the disapproval of the AIE.

C.4.2.4 Process Control Documentation – The contractor shall establish Process Control Documents

(PCD’s) and prepare and maintain listings of classifications for all PCD’s. PCD classifications shall be defined by the contractor per the guidelines in 4.2.4.1 below and reviewed and approved by the

Government prior to the beginning of production. The contractor is responsible for the adequacy of all process documentation including control of changes in accordance with the configuration management plan. The Government will be provided access to PCD’s at contractor and subcontractor facilities for review to ensure that PCD’s are being followed. If the contractor has previously established classifications for PCD’s of components manufactured under a prior current government contract (i.e.

120mm common components), those classifications shall remain in effect for any subsequent award unless a PCD review is conducted.

C.4.2.4.1 Classification Level of PCD’s - There are three classification levels for PCD’s. The determination of classification levels is based on the following guidelines. The classification of a process is based on its importance, not where it is performed.

Class 1 Process - one where safety and/or major performance parameters may be affected by a change to the process and the product features are not easily verifiable. Changes to Class 1 Processes require

Government evaluation & acceptance prior to implementation. A change to a Class 1 process may require a First Article and/or an interfix number change. A detailed description of the change and when it has been implemented shall be recorded in a PCD history file maintained by the contractor.

Class 2 Process - one where any of the following items may be affected: storage life, performance, producibility, and/or assembly. Processes that are operator dependent, or have low repeatability may also be considered Class 2 processes. A change to a Class 2 process may require a First Article and/or an interfix number change. A detailed description of the change and when it is implemented shall be included in a PCD history file maintained by the contractor and the Government shall be notified of the change.

Class 3 Process - is one where the process is repeatable and/or the product features are easily verifiable.

A detailed description of each Class 3 PCD change shall be included in a PCD history file maintained by the contractor.

C.4.2.4.2 Rework – Rework procedures, along with the associated inspection and acceptance procedures, shall be documented by the contractor and submitted to the PCO for review and approval prior to implementation (DI-MISC-80508B).

C.4.2.5 Physical Configuration Audits (PCAs) – The contractor shall perform PCAs on all qualification hardware not common to other current U.S. Army tank ammunition production programs. Each PCA shall be conducted on three (3) of each components, subassemblies, and assemblies selected at random.

Inspection of these samples shall be performed for 100% of all drawing dimensions, characteristics, and associated Technical Data Package (TDP) requirements, including drawings, specifications and Quality

Assurance Provisions (QAPs) with actual variables data recorded. The contractor shall notify the

Contracting Officer ten (10) working days in advance of all PCAs. The Government will witness PCAs at its discretion. The contractor shall submit PCA reports (DI-CMAN-81022D) to the Government describing all audits and corrective actions planned. PCA reports shall be evaluated for acceptability by the Contracting Officer prior to Government acceptance of qualification hardware.

C.4.3 First Article Acceptance Test (FAAT) – The contractor shall establish documented First Article

Acceptance and Lot Acceptance requirements in accordance with the contract requirements.

Specifications and related documents (such as QAPs) shall contain First Article and Lot Acceptance provisions in compliance with MIL-STD-961 and MIL-STD-1916. The contractor shall conduct a FAAT on components, subassemblies, and assemblies in accordance with the contract and Performance

Specification requirements. The FAAT sample shall meet all contract, technical, and quality assurance requirements. The contractor shall submit FAAT Reports to the Contracting Officer for approval in accordance with contract provisions in Section E and I.

C.4.3.1 Government Ballistic Test Samples - The Contractor shall provide a First Article Test quantity as required for Government testing as defined in the Performance Specification. First Article samples are not considered deliverable quantities. Other than the initial First Article, the contractor shall pay for any additional design verification, First Article Tests required by the PCO.

C.4.4 Lot Acceptance – The contractor shall establish a plan containing prescribed methods for acceptance of product (reference MIL-STD-1916, DoD Preferred Methods for Acceptance of Product).

The lot acceptance sampling requirements shall be specified in the Performance Specification.

C.4.4.1 Alternatives to Lot Acceptance - The lot acceptance sampling requirements for deliverable hardware on this contract are specified in the applicable Performance Specification. The contractor may voluntarily propose alternatives to the lot acceptance sampling requirements to the Government in accordance with the applicable contract provisions. Mutual acceptance of any proposal is required. If the contractor elects to propose Statistical Process Control (SPC) as an alternative to lot acceptance sampling, guidance on historically acceptable SPC processes may be found in the SPC clause in section E.

C.4.4.2 Government Ballistic Test Samples - The Contractor shall provide a Conformance Test sample of

40 rounds (to include 10 rounds to be held at the contractor’s facility and will be delivered to Aberdeen

Proving Ground in the event that further Conformance testing is required) from each cartridge lot, for

Government testing as defined in the Performance Specification. If additional conformance testing is not required, the untested cartridges shall be delivered with remainder of units produced with this lot. While the rounds used for additional Conformance testing will come from extra 10 rounds, all other costs associated with the additional Conformance testing shall be borne by the contractor.

The ballistic test samples must meet the requirements in the Performance Specification prior to acceptance of the ammunition lot. Other than the scheduled Conformance Testing, the contractor shall pay for any additional design verification, excess Conformance Tests required by the PCO.

C.4.5 Test Incident Reports – The contractor shall submit test incident reports (DI-SESS-81315B

(Tailored)) for any test failure occurring at contractor or Government facilities. The Contracting Officer shall be notified of all corrective actions, including rework and screening procedures, prior to the contractor proceeding with the assembly of any affected material into deliverable cartridges.

C.4.6 Ammunition Lot Numbering and Ammunition Data Cards – All hardware delivered by the contractor shall be assigned Ammunition Lot Numbers IAW MIL-STD-1168 and Contracting Officer instructions. Ammunition Data Cards shall be prepared in accordance with MIL-STD-1168 and DI-

MISC-80043B and shall follow the format required by the worldwide web application identified as

WARP or Worldwide Ammunition-data Repository Program at https://mhp.redstone.army.mil/.

Additional details on WARP are provided on the WARP website. Prior to gaining Access to WARP, contractor/facility personnel involved in the preparation of ammunition data cards shall obtain a user name and password for the Munitions History Program website.

C4.7 Product Quality Deficiency Reports - A Product Quality Deficiency Reports (PQDRs) shall be submitted for any defective Government Furnished Material (GFM) utilized on this contract (DI-QCIC-

80736).

C.4.8 Contractor Ballistic Testing – In-process ballistic testing during production shall be the responsibility of the contractor. The contractor shall notify the PCO 15 working days in advance of all ballistic testing of assemblies, sub-assemblies and components. The Government will witness testing at its discretion. For production, test plans shall be submitted to the PCO 10 working days prior to the test;

test results shall be available within 5 working days after test completion.

C.5.0 Program Management

C.5.1 Failure Reporting, Analysis, and Corrective Action System - A failure analysis system shall be prepared and implemented. Whenever there is a failure of a component, cartridge, or group of cartridges, to meet applicable performance or safety requirements, the contractor shall be responsible for documenting the failure, performing an analysis to determine the root cause of the failure and determining and implementing the appropriate corrective action to prevent recurrence of the failure (DI-SESS-81315B

Tailored).

C.5.2 Testing Data Base and Firing Records - The contractor shall maintain a database and provide test data in the form of firing records for contractor conducted testing. (DI-MISC-80246 (Tailored)). The database shall include the following testing data as applicable to the tests performed:

a) Propellant assessment

b) Ballistic performance (all projectile data)

c) Ammunition Data Card Information

C.5.2.1 Data shall include actual numeric and alphanumeric results of tests recorded to the accuracy limit of the test equipment. The contractor shall review the test data to verify accuracy and completeness.

C.5.2.2 Raw test data shall be made available to the Government on-site representatives when the data is generated. Test disposition, except for ballistic acceptance testing, and final data shall be submitted to the

Government (DI-MISC-80246 (Tailored)).

C.5.3 The contractor shall prepare Propellant Description Sheets (DI-MGMT-81978) for each propellant lot of the contract; MIL-STD-1171A can be used as guidance. The Propellant Description Sheets shall contain the following information:

a. Lot Number: The contractor shall assign a lot number and the year of manufacture.

b. Composition Number: Show the composition number and the type of grain.

c. Manufactured at: Give the manufacturers name and plant location.

d. Packed Weight: Show the weight in kilograms as packed.

e. Contract Number and Date: Give the applicable contract number and the date of the contract.

f. Nitrocellulose (NC): If applicable, blend numbers of nitrocellulose used in the lot. Indicate whether the lot is made from cotton linters or wood pulp.

g. Manufacture of Propellant: If applicable, list the weight of solvent per pound of NC and the percentages of ether, alcohol or acetone as solvents. List the percentage of remix to whole.

h. Process-Solvent Recovery and Drying: If applicable, list temperatures and time cycles for solvent recovery and drying operations. Drying operations includes water-dry and air dry.

i. Tests of Finished Propellant:

1. Enter the constituents of the propellant; its formula (nominal or as specified); and, the percentages determined by analysis.

2. Include absolute density; moisture content; energetic solids; particle size distribution; heat of

3. Enter the results of test for stability (minutes), form of grain, number of perforations, and compression test result.

4. Mechanical properties at -modulus and failure modulus.

j. Evaluation of physical appearance

k. Closed Bomb of Finished Propellant. Enter the lot number and the standard number, temperature, relative quickness, relative force, and method. Linear burn rate data as well as burn rate versus pressure curves at -32*C, +21*C and +49*C (3 samples per temperature).

l. Die: List the actual physical dimensions of the die used.

m. Finished Dimensions: List dimensions of finished propellant grain (average) as determined by measurement.

n. Uniformity: List (for length, grain diameter, web, perforation diameter) results of calculations for average and for standard deviation in percent of mean dimensions.

o. Reclaimed Propellant:

1. List all original propellant lots used and their stabilizer content. Data shall be supplied prior to reblending operations.

2. List blending scheme used to create final lot.

3. Enter screening data (metallic and nonmetallic contamination) collected during product purity inspection.

p. Dates: List date packed, date offered, date sampled, date tests complete and date description sheet forwarded to the Contracting Officer. The term “date offered” is defined as the date on which the lot is ready to be sampled. Show type of packing box used, including box drawing number and applicable revision date.

q. Remarks: Enter the name of the organization that the lot is manufactured for. Enter a statement that lot either meets the requirements of the contract or fails to meet one or more of such requirements. Add any additional information as to unusual conditions of manufacture, which would affect usability of the lot.

r. Contractor Representative: The representative signing for the contractor should be an official of sufficient authority to exercise control over the contractor’s inspection and production. The representative’s signature should appear above their typed name.

C.5.3.1 Supplemental description sheets shall be prepared under the following conditions:

a. When the status of a lot is changed, or when a previously suspended, rejected, or incomplete lot is submitted for test, a supplemental lot description sheet shall be prepared, outlining the reason for the changed status.

b. When a rejected or suspended lot is reworked, a supplemental description sheet shall be prepared for such renovated lot, describing the background of the lot, the rehabilitation performed, and the results of plant inspection and testing after rework. All reworked lots will contain annotation to reflect as such.

C.6.0 System Safety

C.6.1 System Safety Program - The contractor shall develop and maintain a System Safety Program using

MIL-STD-882D as guidance to ensure that system safety activities are executed during the contractual effort.

C.6.2 Energetic Materials Manufacture and Quality Assurance – The contractor shall provide a report identifying the U.S. military or commercial specifications that are used to manufacture each energetic material (i.e., explosives, propellants, etc.). All applicable commercial specifications shall be provided in the report. Commercial specifications shall provide a description of manufacture and quality acceptance procedures (i.e., lot acceptance requirements, first article requirements, quality conformance requirements, etc.) (DI-MISC-80508B).

C.6.3 Accident/Incident Report - The contractor shall report immediately any major accident/incident

(including fire) resulting in any one or more of the following: one or more fatalities; one or more disabling injuries; damage to government property exceeding $10,000; changes to program planning or production schedules; degradation of the safety of equipment under contract such that personnel injury or property damage could result; identification of a potential hazard requiring corrective action. The contractor shall prepare the report (DI-SAFT-81563) for each incident.

C.6.4 Hazard Classification Documentation

C.6.4.1 For energetic materials or energetic items made in the United States of America, the contractor is responsible for obtaining Hazard Classification from the Department of Transportation prior to any shipment of energetic materials. All U.S. manufacturers shall make certain that the material is tested in accordance with Part 173, Subpart C, Section 173.58(a) of Title 49, CFR Parts 106-180 to assign proper class and division for all explosives (Division 1.1, 1.2, 1.3, 1.4, 1.5 and 1.6 explosives). Registration with the Associate Administrator of Hazardous Materials Safety is required in accordance with Part 173, Subpart C, Section 173.56(b)(1) or 173.56(c) of Title 49 CFR so that markings in accordance with 172, Subpart D, Section 172.301(a) and 172.32(a) are met. Hazard classification documents shall be forwarded to the U.S. Army RDECOM-ARDEC, ATTN: AMSRD-AAR-QES-C, Picatinny Arsenal, NJ

07806-5000 (DI-MISC-80508B), Technical Report – Hazard Classification Documentation for U.S. Made

Ammunition and Explosives.

C.6.4.2 The contractor may, at his option, utilize the capability of ARDEC to obtain Interim Hazard

Classification (IHC) for shipment of R&D quantities of energetic materials/items in support of this contract. If the contractor elects to use RDECOM-ARDEC for this support, the contractor will need to provide technical data to RDECOM-ARDEC 60 days prior to shipment of the energetic materials/items.

The necessary data is explained in Army Technical Bulletin (TB) 700-2 and DI-SAFT-81299C -

Explosives Hazard Classification Data. DOT and UN serial number information and packaging method is available in Title 49, Code of Federal Regulations (CFR). The explosive weight for quantity-distance determination is obtained using the guidance of AR385-10, DA PAM 385-16, MIL-STD-882E.

C.6.5 Energetic material qualification:

C.6.5.1 The contractor shall prepare and submit a Qualification Report. (DI-MISC-80508B). The following information shall be included in the report:

a) Technical data: Provide energetic material compatibility data, energetic material sensitivity data, propellant stability data, pyrotechnic material sensitivity data, and electric primer sensitivity data, as applicable and required by the Performance Specification, PRF-14000044A, for each energetic material that has not been previously qualified for use by the U.S. military. Data shall be collected in accordance with the approved Energetic Material Qualification Plan. Data shall be submitted to the U.S. Army

RDECOM-ARDEC, ATTN: AMSRD-AAR-QES-C, Picatinny Arsenal, NJ 07806-5000 (DI-MISC-

80508B).

b) Programmatic data: Provide programmatic data as specified in section 17 of the DOD Energetics

Qualification Program Matrix located as an appendix to the RDECOM-ARDEC Draft Technical Report, QUALIFICATION OF EXPLOSIVE MATERIAL FOR USE BY THE U.S. ARMY RESEARCH, DEVELOPMENT AND ENGINEERING COMMAND, ARMAMENT RESEARCH, DEVELOPMENT

AND ENGINEERING COMMAND (RDECOM-ARDEC), dated 01 Mar 04.

C.7.0 ENVIRONMENTAL REQUIREMENTS:

C.7.1 Environmental Compliance - All activities shall be in compliance with applicable Federal, State and

Local Environmental Laws and Regulations, Executive Orders, Treaties and Agreements.

C.7.2 Environmental Management System – The contractor shall maintain an Environmental

Management System to specifically address life cycle environmental, safety, and health aspects of the

M1028 cartridge. The contractor shall create and update, as necessary, a Hazardous Material

Management Program Plan (DI-MGMT-81398C) and the National Aerospace Standard 411 (NAS 411).

The plan’s outline shall be made part of the contractor’s proposal and the full HMMP shall be generated within 90 days after contract award, for review and approval by the Procuring Contracting Officer. The plan’s purpose is to eliminate, reduce, or minimize hazardous material in the acquisition demilitarization phases of the M1028 cartridge life cycle for the protection of human health and the environment.

Continuous improvement as well as compliance shall be addressed. The list of hazardous chemicals can be prioritized using the Environmental Protection Agency Waste Minimization Master Plan Software and documents (Federal Register: June 23,1997 (volume 62, number 120, Notices page 33868-33870), EPA, Office of Solid Waste, Waste Minimization Branch, 401 M Street, SW., (5302W), Washington DC 20460 telephone (703) 308-8402. Production efforts under this contract shall be conducted in accordance with the plan.

C.8.0 DATA

C.8.1 Management, Technical and Quality Reviews – The contractor shall conduct Program

Management/Technical Reviews every six months to review technical performance and schedules. The

Program Management/Technical Review may be either at a Government or a contractor facility. Program

Reviews shall include a more detailed review of programmatic performance, technical data, and issues.

Presentation materials shall be provided to the Government. (DI-ADMN-81373 (Tailored)).

C.8.2 Reporting – The contractor shall submit a quarterly progress report (DI-MGMT-80227 (Tailored)).

The Progress Report can be combined with other data to be delivered under the contract and the report can be furnished electronically to the addressees listed on the Form DD1423. The final progress report for each Production Year shall be a closeout report for that year which will detail problems encountered, how they were solved and lessons learned. The Government will review and provide comments and/or approval within 14 days of receipt.

C.8.3 Industrial Facilities – The contractor and associated subcontractors shall maintain production facilities that can manufacture the required quantities of M1028 cartridges per year in accordance with the delivery schedule. A facilitization plan shall be maintained.

C.8.4 Configuration Management

C.8.4.1 The contractor is responsible for the production of the M1028 to the contractor’s Production

Technical Data Package (TDP) using the supplied reference TDP as guidance. The TDP shall be used to manufacture all hardware for production. All modifications to the TDP will be processed in accordance with the contractor supplied configuration management plan (DI-SESS-81000A(Tailored)). The

Government, through the PCO, will make a determination of testing (i.e. First Article, partial First

Article, Design Verification testing, etc) and evaluation per the Performance Specification. Any variation from the qualified design/process may require full or partial re-qualification as determined by the PCO.

This will be done at the contractor’s expense and will be required prior to accepting any hardware.

Proposed changes shall be submitted no later than two weeks prior to their planned implementation date.

C.8.4.2 Configuration Management Plan – The contractor shall create a configuration management plan and submit it for Government approval (DI-SESS-80858C). The plan must detail the chain of command for all design or process/ procedure approvals. All hardware will be under configuration management.

C.8.4.3 Material Review Board (MRB) – Copies of all MRB minutes, including attendee’s list, descriptions on non-conformance, impact on higher assembly, quantity involved, cause of non-conformance, and corrective actions planned or taken shall be provided to the Government (DI-ADMN-

81373 (Tailored)). Requests for a variance for production shall be submitted (DI-SESS-80640D) using

MIL-HDBK-61A as guidance.

C.8.4.4 Configuration Changes – The contractor may submit Engineering Change Proposals

(ECPs), Value Engineering Change Proposals (VECPs) (Code V shall be assigned to an engineering change that will affect a net life cycle cost), Notices of Revision (NORs), and

Requests for Variance (RFVs) for the documents in this Technical Data Package (TDP). The contractor shall prepare these documents in accordance with (IAW) SAE EIA-649 and SAE EIA-

649-1.

(a) If a contractor wishes to permanently depart from a requirement as spelled out in the TDP or any other baseline documentation, it may propose to do so by submitting an ECP or

VECP IAW 5.3.1 of SAE EIA-649. Both ECPs and VECPs must be submitted to include

Notices of Revision (NORs). Contractor ECPs shall describe and justify all proposed changes and shall include NORs completely defining the changes to be made. The contractor shall not present any units incorporating any change to Government documentation until notified by the Government that the ECP or VECP has been approved and has been incorporated in the contract.

(b) If a contractor wishes to temporarily depart from a requirement as spelled out in the TDP or any other baseline documentation under Government control, it may request to do so by submitting an RFV IAW 5.3.1 of SAE EIA-649. The contractor shall not present any units incorporating any variance to Government documentation until notified by the Government that the RFV has been approved and has been incorporated in the contract.

(c) If the Government receives the same or substantially the same VECPs from two or more contractors, the contractor whose VECP is received first will be entitled to share with the

Government in all instant, concurrent, future, and collateral savings.

(d) Duplicate VECPs, which are received subsequently, will be returned to the contractor(s) without formal evaluation, regardless of whether or not the first VECP has been approved and accepted by the Government.

If an Engineering Change Proposal (ECP) requires a new document to be prepared; the contractor shall prepare (MIL-DTL-31000B may be used as guidance) and submit it as part of the ECP (DI-SESS-

80639D) and Notice of Revision (DI-SESS-80642D). This requirement includes, but is not limited to, engineering drawings, source control drawing requests and justifications, and military specifications. The preferred, but not mandatory, forms in both MS-Word and fillable-pdf formats can be found in Section J.

C.8.4.4.1 The contractor shall prepare and submit Engineering Change Actions (ECPs and RFVs) in MS-

Word format to the Government PCO and usarmy.ria.rdecom-ardec.mbx.ardec-ecp-input@mail.mil. The

ARDEC configuration management officer, devin.k.reimers.civ@mail.mil (CMO), should also be copy furnished. Devin Reimers will also be the POC to provide ECP/RFV Procurement Activity Numbers

(PANs) for contractor - submitted actions.

C.8.4.5 Configuration Control Boards (CCB) – The contractor shall participate in Configuration Control

Boards (CCB), configuration management meetings, and other Government/system contractor meetings on an as-needed basis.

C.8.4.6 Technical Data Maintenance – The contractor shall provide the technical data maintenance for the M1028 Program on the contractor prepared or Government supplied reference M1028 Technical Data

Package (TDP). The TDP will be formatted and maintained in accordance with the TACOM –

TARDEC/ARDEC 3-Dimensional Technical Data Package Solid Modeling Standard Operating

Procedures, dated November 2007. The contractor shall review all Government initiated Engineering

Change Proposals (ECPs) for format, completeness, accuracy and integration into the product baseline defined by the TDP. The contractor shall distribute the change action documentation as required by the applicable CDRL item.

C.8.4.6.1 Engineering Drawings and Associated Lists – After an ECP has been approved, the contractor shall prepare engineering drawings, using paragraph 3.6.3 of MIL-DTL-31000B as guidance ((DI-SESS-

81000E (Tailored)) and Quality Assurance Provisions (QAPs). QAPs shall be prepared as separate documents and referenced in the Notes portion of a drawing. The CMO, Devin Reimers, will assign the contractor a block of unused drawing numbers for new engineering drawings initiated under this effort.

C.8.4.6.2 The contractor shall release Engineering Change Actions (ECPs), and Requests for Deviations

(RFVs)) to the Government. The CM Status Accounting System shall track the actions through all of the appropriate milestones. All milestone actions shall be entered within 24 hours of the action at the contractor’s facility or after official notification of the Government. The contractor shall provide a monthly listing of all outstanding Engineering Change Actions as part of the monthly progress report (DI-

MGMT-80227 (Tailored)).

mailto:usarmy.ria.rdecom-ardec.mbx.ardec-ecp-input@mail.mil

C.8.4.6.3 Source Control Drawings – If an Engineering Change Proposal initiates the preparation of a

Source Control Drawing during the maintenance of the TDP, the drawing and justification shall be submitted (DI-SESS-81010). The contractor may use MIL-DTL-31000B and ASME Y14.100-2004 as guidance.

C.8.4.6.4 Quality Assurance Provisions – The contractor shall maintain Quality Assurance Provisions

(QAPs) to be available to Government upon request.

C.8.4.6.5 Program Unique Specifications – The contractor shall maintain program-unique specifications in accordance with MIL-STD-961E to be available to Government upon request.

C.8.4.6.6 Within one month of contract award the Contractor shall provide a baseline electronic TDP in

Pro/Engineer format, version CREO 2.0 or later. In addition, the contractor is expected to submit updates of the complete TDP, in Pro/Engineer format, every 6 months if necessary. One month prior to contract end the Contractor shall deliver a complete updated electronic copy of the TDP. (DI-SESS-81000E

(Tailored). The Government shall have government purpose rights to the TDP and all changes proposed/approved to it. The electronic TDP shall be sent to:

U.S.Army RDECOM-ARDEC

ATTN: RDAR-EIS-PE

Integrated Product/Technical Services, Building 12

Picatinny Arsenal, NJ 07806-5000

C.8.4.6.7 Any proposed changes to the TDP, vendor base, or manufacturing process as defined in paragraph C.3.0 shall be submitted to the Contracting Officer for review. Additional testing, the cost of which shall be borne by the contractor, may be required as determined by the Contracting Officer. The contractor shall insure that there is no impact to form, fit function or safety for any proposed changes.

C.8.5 SYSTEMS APPLICATION PRODUCT (SAP):

C.8.5.1 Systems Application Product (SAP) is an interactive, online, relational database management system.

C.8.5.2 No later than six (6) months after award, and every six (6) months thereafter, the contractor shall conduct an audit of the product baseline currently maintained in their Configuration Status

Accounting System to ensure it matches the Government Systems Application Product (SAP) system.

This audit shall be performed with the coordination of the Government representative (RDAR-EIS-CL)

C.8.6 Engineering Release Records (ERRs) – The contractor shall establish an electronic storage file for the purpose of processing ERRs The contractor shall notify the Government by email when ERRs are ready for access.

C.8.6.1 Engineering Release Records – The contractor shall prepare and submit Engineering Release

Records in MS-Word format to the Government, electronically by E-mail and attachment, for processing

(DI-SESS-80463).

C.8.6.2 The Government will verify the accuracy of the revised documentation, ERRs and the quality of electronic images (see Concept of Operations in Section C.8.10). The Government will load electronic images into the repository within four (4) days after receipt. Corrective actions by the Government will be taken upon discovery and the contractor will be informed by electronic communication.

C.8.6.3 The Government will maintain the authority to review and approve all ERR packages, including drawings, related to the M1028 program, IAW MIL-DTL-31000B.

C.8.7 The Government will provide on-going assistance in the interpretation of the various elements of the drawings and associated documents.

C.8.7.1 Government Furnished Information (GFI) – The contractor shall maintain any documentation that the Government makes available for use on the program.

C.8.7.2 The Government CMO, Devin K. Reimers (RDAR-EIS-CL), will provide a list of drawing numbers for new drawings.

C.8.8 The contractor shall return to the Government all documentation contained under this contract. A list of Pro/Engineer engineering documentation shall also be provided.

C.8.9 CONCEPT OF OPERATIONS

C.8.9.1 Purpose – Technical Data Maintenance portion of the Concept of Operations (Business and

Technical Process) is as follows:

C.8.9.2 Reserved

C.8.9.3 Government Infrastructure

C.8.9.3.1 SAP (Systems Application Product) - SAP is a new electronic Product Data Management

(PDM) system that has replaced several electronic data programs, such as, TD/CMS, Tracker, JEDMICS and CM Status Accounting. TD/CMS Detail and Configuration data and Change Release has been replaced by SAP Meta Data but is not available to contractors because contractual data cannot be separated from the database for accessing. Detail, Configuration, and Change Release data is maintained by ARDEC personnel.

C.8.9.3.2 3D images shall be delivered in Pro/E CREO 2.0 or later format via email or CD/DVD.

C.8.9.3.2.1 Media images which can be accepted for delivery include: FTP (File Transfer Process) and

CD ROM.

C.8.9.3.2.2 Reserved

C.8.9.3.3 REFERENCES

MIL-STD-1840 Automated Interchange of 26 Jun 97 - Technical Information

MIL-PRF-28002 Requirements for Raster 30 Sep 97 - Graphics Representation in Binary Format

C.8.9.3.4 HOURS OF OPERATION – The SAP system is available for access 24 hours per day, 7 days a week.

C.8.9.3.5 TRAINING - The Government will provide training to contractor personnel as the need arises and as new functionality is added to any of the Government’s automated systems.

8.10 Access and general protection/security polity and procedures. Contractor and all associated sub-contractors employees shall provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Officer, Director of Emergency

Services or Security Office. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DoD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation changes, the Government may require changes in contractor security matters or processes.

8.11 OPSEC Training. Per AR 530-1 Operations Security, the contractor employees must complete Level

I OPSEC Awareness training. New employees must be trained within 30 calendar days of their reporting for duty and annually thereafter.