Attachment_0011_QA_Rqmts_U14A0U88HI.pdf

QUALITY REQUIREMENTS: INSPECTION, ACCEPTANCE, QUALITY ASSURANCE,

AND RELIABILITY

AMMUNITION DATA CARDS AND REPORT OF CONTRACTOR BALLISTIC

TESTING

(a) Ammunition Data Cards shall be prepared in accordance with

MIL-STD-1168 and shall follow the format required by the world wide web application identified as WARP or Worldwide Ammunition-data Repository Program. Information provided in paragraphs 6.7 through 6.16 of MIL-STD-1168 shall be considered mandatory requirements where all instances of the term “should” are considered to be replaced with the word “shall.” This shall also include, if required on the DD Form 1423, a Report of

Contractor Lot Acceptance/Ballistic Testing and Acceptance and

Description Sheets (for Propellants and Explosives). WARP will reside within the Munitions History Program (MHP). Additional details on these WARP applications are provided below.

(b) MHP-WARP Access Procedures

(1) Government or Contractor employee with CAC and AKO account:

(a) Click on the MHP hyperlink which is https://mhp.redstone.army.mil/

(b) Enter CAC PIN when prompted

(c) Click on WARP (ADC)

(d) Click on Help

(e) Click on WARP Request Access and follow instructions

(2) Contractor or Government employee without CAC and AKO account: MHP-WARP uses PKI authentication requiring a DoD approved digital certificate as a security measure to protect the integrity of stored data. There are three vendors that have been approved to issue DoD approved certificates per an External

Certification Authority (ECA) program. You are required to use one of the approved vendors listed on the following DISA website: http://iase.disa.mil/pki/eca/index.html

A nominal fee is charged for each certificate. The Contractor, including any subcontractors, shall assume the responsibility for all costs of obtaining each digital certificate needed.

(3) After the required certificate is obtained:

(a) Click on the MHP-WARP hyperlink:

https://mhpwarp.redstone.army.mil/

(b) Enter ECA password

(c) Click on Help and follow the instructions for obtaining the necessary access

(c) HELP Numbers are as follows:

MHP Access – (256)313-2143; DSN 897-2143

JMC Quality Administrators for WARP issues – (309)782-2697 or

(309)782-7107

(d) Worldwide Ammunition-data Repository Program (WARP)

An online user’s manual will provide additional help in the development of an ammunition data card. It is recommended that you download and read the user’s manual prior to inputting your initial data card. The user’s manual also contains screen shots, which depict what the inputter will see during the ADC input process.

(e) Ammunition Data Card Input

ADC input allows current contractors and government facilities the capability to create, and submit for approval, ADCs which meet the format requirements of MIL-STD-1168. ADCs are automatically forwarded to the respective Government Agency

Responsible for Acceptance (GARA). The GARA in most cases is the Defense Contract Management Agency (DCMA) Quality Assurance

Representative (QAR), who reviews contractor input for accuracy and completeness, and after updating the disposition code for the specific lot, submits the ADC to the database. The inputter is granted access only to ADCs identified with its specific manufacturing code. The use of previously inputted ADCs through the TEMPLATE option significantly reduces input effort, while increasing accuracy and consistency of data.

(f) Email Notification

WARP provides immediate, automated notification to process participants when actions are required. When the contractor has completed an ADC submission, an email message is routed to the

GARA advising that an ADC awaits review and approval. If the

GARA approves the ADC as submitted, the ADC is released to the base and an email, with approved data card, is routed back to the originator. If the ADC requires modification or correction to conform with MIL-STD-1168 and contract requirements, an email is provided to the ADC originator advising that corrective action is required prior to approval.

(g) Information Updates

It is important that the System Administrators are apprised when a contractor receives a new contract. The contractor shall notify usarmy.ria.jmc.mbx.warp@mail.mil within 30 days after receipt of a new contract. Information to be included shall be the contract number, item, GARA, Manufacturer’s identification symbol and the names of the individuals who will be inputting

ADCs into the system. If you are a new contractor and do not have a Manufacturer’s identification symbol, you can obtain one by sending an email to usarmy.ria.jmc.mbx.warp@mail.mil. The email must contain manufacturer’s name, address where performance of the contract will take place, and a point of contact.

(h) Report of Contractor Ballistic/Function Testing Module

(1) In addition to its ADC function, WARP also serves as a repository for reports of contractor ballistic (or functional) testing. Whenever the contract requires contractor performance of ballistic testing, the results of such testing shall be captured by you, the performing contractor, within a specially designed Lot Acceptance Test Report (LATR) module.

(2) Within the LATR module, you are required to provide a report of any contractor ballistic/function testing and to submit the report in electronic format via the WWW. The report must be a .pdf file for the upload process to work.

(i) Acceptance and Description Sheets (for Propellants and

Explosives) Module: The WARP application now contains an area for on-screen data entry capturing requirements per MIL-STD-1171 for Acceptance and Description Sheets with respect to contract specified Propellant, Chemical and Explosive constituents.

2-D BAR CODING

(a) As a logistics measure to improve inventory, accountability, security and control, the supplier is required to provide 2-D

Bar Codes in accordance with MIL-STD-129 and MIL-PRF-61002 and as further detailed in Section D of the contract.

(b) An approval of the supplier’s 2-D Bar Code Label is required before each product with a unique national stock number (NSN) or federally recognized number (FRN) shall be presented for acceptance to the Government Quality Assurance Representative.

Prior to formal submission of product to the Government for acceptance, a first time sample of the supplier’s initial 2-D

Bar Coding Label, comprising of two (2) each of the exterior pack label and two (2) each of the pallet label, shall be submitted for approval to HQ, US Army Joint Munitions Command, 1

Rock Island Arsenal, ATTN: AMSJM-QAP, Rock Island, IL 61299-6500 to be read by a High Performance Bar Code Verification system.

(c) Within fifteen calendar days, the supplier will be notified electronically of the approval, conditional approval, or disapproval of the submitted 2-D Bar Code Label. A notice of conditional approval shall state any further actions required of the supplier. A notice of disapproval shall cite reasons for the disapproval.

(d) Once approval of the 2-D Bar Code Label is received, the supplier may begin presenting product to the Government for acceptance.

(e) During life cycle management of the product, the Government may randomly perform checks of the integrity and conformity of the 2-D Bar Code labeling that is affixed to the supplier’s product.

(f) The supplier is responsible for all costs associated with correcting 2-D Bar Code labels that do not meet contractual requirements.

MEASUREMENT SYSTEM EVALUATION

(a) Definitions. This paragraph defines specific terms utilized throughout the rest of this section and in the accompanying

Contract Data Requirements List (CDRL) and Data Item Description

(DID). This aids in clarifying the MSE requirements to

Government and contractor personnel.

(1) Acceptance Inspection Equipment (AIE). All equipment

(includes AAIE defined below), special and standard, including dimensional gages, measuring equipment, test fixtures, electronic and physical test equipment, and other test equipment used for examination and test of a product to determine conformance to the Technical Data Package (TDP) which may include drawings and specifications (e.g., Detail, Performance, Weapon specifications, and QAPs).

(2) Automated Acceptance Inspection Equipment (AAIE). AIE in which the inspection and acceptance determination of the product is performed, in whole or in part, in an automatic manner.

(3) Contractor Inspection Equipment. Government-approved equipment utilized by the contractor to perform examination and tests to assure conformance to contract requirements.

(4) Commercial Inspection Equipment. Industry-developed inspection equipment of universal application, without limitations to a specific part or item, which is advertised or cataloged as available to the trade or to the public on an unrestricted basis at an established price. Examples follow:

(i) Standard Test Equipment. Multiusage equipment that is specific to a function rather than to an item. It includes such items as hardness testers, tensile strength testers, meters, weighing devices, standard gear testers, ohmmeters, voltmeters, and oscilloscopes.

(ii) Standard Measuring Equipment (SME). Multipurpose equipment and standards used for performing measurements. It includes such items as micrometers, rulers, tapes, height gages, and protractors, etc. Standards include visual inspection equipment such as scratch and dig standards, surface finish comparator, color standards (FED-STD-595), etc.

(5) Nondestructive Testing. The development and application of technical methods to examine materials or components in ways that do not impair future usefulness and serviceability in order to detect, locate, measure and evaluate flaws; to assess integrity, properties and composition; and to measure geometrical characteristics. NDT includes

Radiography/Radioscopic, Ultrasonic, Eddy Current, Magnetic

Particle, and Liquid Penetrant.

(6) Measurement System Analysis (MSA). Per ASTM E2782

(Standard Guide for MSA), paragraph 3.1.7, MSA is any of a number of specialized methods useful for studying a measurement system and its properties.

(b) Scope. This section establishes requirements for design, supply, performance, and maintenance of AIE used for product inspection and acceptance. In addition, this section establishes requirements for the preparation, submission, and approval of AIE documentation.

(c) AIE. The contractor shall provide all AIE necessary to ensure conformance of components and end-items to contract requirements. AIE shall include inspection, measuring, and test equipment whether Government furnished or contractor furnished

(including commercially acquired) along with the necessary specifications and procedures for their use (see ISO 10012, paragraph 6.2.1). The AIE shall not create or conceal defects on the product being inspected. All AIE documentation shall contain sufficient information to permit evaluation of the AIE’s ability to test, verify, and/or measure the applicable characteristics or parameters (see applicable DID referenced in

DD Form 1423).

(d) AIE Designs & Government Furnished Gages. AIE designs are of two types – Government designs (see (d)(1)) and contractor designs (see (d)(2)). When applicable, Government designs or

Government furnished gages are designated in the TDP/contract;

responsibility for all other AIE is assigned to the contractor.

The designs, associated inspection procedures, and theory of operation shall have the level of detail to demonstrate capability of the proposed AIE to perform the required inspection.

(1) Government AIE Designs. Government AIE designs may consist of detailed drawings necessary for the fabrication and use of the AIE. Unless otherwise specified, the contractor may submit alternate or modified contractor designs of Government

AIE designs.

(2) Contractor AIE Designs. Contractor AIE design drawings shall meet the requirements of ASME Y14.100, ASME Y14.5 and ASME

Y14.43 and may include commercial inspection equipment.

[“Commercial inspection equipment” is defined as shown in paragraph (a)(4) above. It shall be fully described by catalog listings or other means which provide sufficient information to permit identification and evaluation by the Government and may include illustrations and engineering data.] Designs shall be submitted for any special fixture(s) to be used. Unless otherwise specified, Gage Tolerancing Policy shall be in accordance with ASME Y14.43, “Absolute Tolerancing (Pessimistic

Tolerancing).”

(3) Visual Inspection. Visual inspection standards used for the acceptance/rejection of product shall be submitted for approval.

(e) AIE Package Submittals. The contractor shall prepare the

AIE package submittal in accordance with the DID referenced in the applicable Contract Data Requirements List (CDRL – DD Form

1423). In addition, the contractor shall adhere to the following requirements:

(1) Designs for Approval. Contractor designs and/or the submission for the use of Government designs shall be approved by the Government. Partial submission of AIE designs is permissible in order to expedite the approval process; however, the response date for design review will be based on the date of the final complete submission of designs.

(2) Correspondence in English. The contractor shall ensure all AIE correspondence and documentation are submitted in

English.

(3) Units of Measurement. The units of measurement within the AIE package submittal shall be consistent with the requirements of the Technical Data Package (TDP).

(4) AIE Flow Down. The contractor shall flow down AIE requirements to sub-contractors at any tier who are performing acceptance inspections.

(f) Characteristics for Inspection. AIE documentation for

Critical, Special, and Major characteristic inspections shall be submitted to the Government for approval in accordance with

(IAW) the CDRL (see DD Form 1423). AIE for Minor characteristic inspections shall be submitted to the Government for approval

IAW CDRL (see DD Form 1423) and as required below:

(1) [X] Listed Minor (characteristics displayed on specifications and/or drawings

(2) [ ] Government selected list (as attached or as provided herein):

Click here to enter text.

(3) [ ] Not submitted

(g) Automated Acceptance Inspection Equipment. The AAIE shall accept only conforming material. All characteristics requiring

AAIE per the TDP shall utilize inspection equipment with a minimum demonstrated reliability of 99.8% at a 90% confidence level to detect non-conforming material unless otherwise specified below.

(1) Reliability of _____% at a _____% Confidence Level for

Critical/Special Characteristics

(2) Reliability of _____% at a _____% Confidence Level for

Major Characteristics

(3) For inspection of major and minor characteristics where contractor utilizes AAIE when it is not required by the TDP, the

AAIE package shall be submitted to the Government for approval.

If the Minor characteristic is not listed in paragraph (f)(2) or not required for submittal in paragraph (f)(3), then the AAIE requirements (e.g., verification, calibration, prove-out, etc.)

of the inspection shall still be performed.

(4) All AAIE packages submitted to the Government for approval shall be in accordance with MIL-A-70625 (Automated

Acceptance Inspection Equipment Design, Testing and Approval of). Furthermore, the contractor shall be responsible for producing the acceptance and rejection verification standards/masters representative of the characteristics the AAIE is designed to inspect. The verification standards and frequency of use require Government approval prior to use. When verification standards are used for the VL-VII “sampling plan” per MIL-STD-1916 paragraph 4.4, verification standards and frequency of use shall require Government approval prior to use.

(5) If the AAIE accepts a critical characteristic “reject” standard the contractor shall notify the Government and act in accordance with paragraph (f) of Critical Characteristic

Control. In addition, if the AAIE accepts a major and/or minor characteristic “reject” standard the contractor shall act in accordance with paragraph 8.3 of ISO 10012 or paragraph 5.2.3 of

ANSI/NCSL Z540.3.

(6) All AAIE shall be required to pass a Government-approved

Acceptance (Prove-Out) Test. The contractor shall conduct this test per the approved test plan and shall submit a test analysis report for approval. See applicable DD Form 1423. This test shall be performed at the contractor’s facilities whose manufacturing system has had the AAIE fully integrated and calibrated as per paragraph (j) of this section. The contractor shall allow Government personnel access to this facility and unobstructed monitoring of this test.

(7) The contractor shall notify the Government prior to a modification and/or relocation of the Government-approved AAIE.

The modified AAIE designs shall be submitted for approval. The modified and/or relocated AAIE shall require submission of the acceptance test plan (prove-out) and results for review and approval prior to use. The modified and/or relocated AAIE shall be in accordance with paragraphs (g)(1) – (g)(6).

(h) Measurement System Analysis (MSA). The contractor is responsible to ensure all AIE is, at a minimum, stable, repeatable, and reproducible for all characteristics. Refer to

ASTM E2782 and/or AIAG MSA for guidance. The contractor shall provide objective evidence, including the MSA assessment plan, associated data, and analysis, which demonstrates the AIE is, at a minimum, stable, repeatable, and reproducible for the following characteristics (MSA CDRL):

Specification: -1-

Paragraph No.: -2-

Drawing: -3-

Characteristic: -4-

Approval of submitted MSA(s) must be granted before the corresponding AIE can be used or continue to be used for acceptance of product. If at any time following approval of the

AIE and MSA the AIE is disapproved, then the MSA shall be disapproved. After the resubmitted AIE is approved, the MSA shall be conducted on the approved AIE and resubmitted for approval.

(i) Robust AIE System. The contractor shall ensure the AIE and its use is not negatively affected by any manufacturing/inspection environmental stimuli including, but not limited to production rate, noise, temperature, humidity, and vibration.

(j) AIE Calibration and Verification. The calibration system shall be in accordance with ISO 10012 or ANSI/NCSL Z540.3. All

AIE shall be subjected to scheduled calibration intervals to ensure that the equipment will accept only conforming product and reject all non-conforming product for the duration of the approved calibration period. AIE shall be subjected to periodic verification to ensure that the equipment will continue to accept and reject product with the same consistency as it did at the time of its previous calibration.

(k) Non-Destructive Testing (NDT). Contractor shall submit detailed plans for qualifying and certifying NDT personnel and plans for qualification and ongoing use of NDT methods used for inspecting product. If re-qualification of NDT personnel and/or

NDT methods is required, then the applicable plans shall be submitted.

(1) Personnel performing NDT examinations shall be qualified and certified in accordance with the standard practices prescribed by NAS 410 (NAS Certification & Qualification of NDT

Personnel), ANSI/ASNT-CP-189 (ASNT Standard for Qualification and Certification of NDT Personnel), or SNT-TC-1A (Recommended

Practice for Personnel Qualification and Certification in NDT), and additional procedures that may be identified by the

Government. Acceptance of product using NDT shall be performed by personnel at a level of qualification consistent with that defined in the applicable standard.

(2) The NDT method(s) shall be applied in accordance with

ASTM E 543 (Standard Specification for Agencies Performing

Nondestructive Testing) and the current nationally recognized standard practices appropriate to the NDT method(s) employed, such as ASTM E-1742 (Standard Practice for Radiographic

Examination) and SAE-AMS-STD-2154 (Inspection, Ultrasonic, Wrought Metals, Process For). Each application technique shall identify the standard(s) utilized. Non-destructive testing includes, but is not limited to, the following types of testing:

Radiography/Radioscopic, Ultrasonic, Eddy Current, Magnetic

Particle, and Liquid Penetrant.

(l) Contractor Alternate Inspection Method(s), Modifications and/or Relocation of AIE (Non-Automated) After Government

Approval. If the contractor proposes an alternate inspection method and/or modifies the AIE design(s) affecting hardware, software, or procedures after Government approval the intended change(s) shall be submitted to and approved by the Government prior to implementation. If an AIE is relocated and the relocation risks the integrity of the inspection system, notify the Government to determine information needed to assess impact to AIE. See DD Form 1423.

(m) Responsibility for AIE Package Submittal. The contractor shall submit the AIE design documentation package within contractual timeframes per CDRL (See DD Form 1423). The

Government will provide approval or disapproval within the timeframe specified in the CDRL. Disapproval of the AIE package will require re-submittal and subsequent Government review in accordance with the CDRL requirements. The AIE package and any required prove-outs must be approved prior to First Article (FA)

(if required) or production start-up if FA is not required.

(n) Government’s Right to Disapprove AIE. The Government reserves the right to revoke approval of any AIE that is not satisfying the required acceptance criteria at any time during the performance of this contract. See DD Form 1423.

(o) Navy Furnished Gages. When gages are listed in paragraph

(o)(9) below, the Navy Special Interface Gage (NSIG) Requirement paragraphs (o)(1) – (o)(8) shall be satisfied.

(1) The NSIG(s) are provided for verification of selected interface dimensions and do not constitute sole acceptance criteria of production items or relieve the contractor of meeting all drawing/specification requirements under the contract.

(2) The contractor is responsible for contacting the Naval

Surface Warfare Center (NSWC), Corona Division at least 45 days prior to FAT (if required) or production, for the delivery of

NSIG(s).

(3) NSIG(s) will be forwarded to the contractor for joint use by the Government and the contractor. Government furnished

NSIG(s) shall not be used by the contractor(s) or subcontractor(s) as in-process or working gage(s).

(4) For production items that fail to be accepted by the applicable NSIG(s), an alternate inspection method may be submitted for approval.

(5) The contractor may substitute contractor designed and built AIE for the NSIG(s) noted in paragraph (o)(9) below.

However, the designs require Government (Navy) approval and the contractor AIE hardware requires Government (Navy) certification. AIE designs shall be submitted in accordance with CDRL (see DD Form 1423).

(6) The Government (Navy) shall not be responsible for discrepancies or delays in production items resulting through misuse, damage or excessive wear to the NSIG(s).

(7) Calibration and repair of the NSIG(s) shall only be performed as authorized by the NSWC Corona Division. Repair is at no cost to the contractor unless repair is required due to damage to the gages resulting from contractor fault or negligence. Damaged, worn, or otherwise unserviceable NSIG(s) shall be brought to the immediate attention of the CAO and NSWC

Corona Division. The contractor shall not make any adjustments, alterations or add permanent markings to NSIG(s) hardware unless specified by the NSIG operating instructions or authorized by the NSWC Corona Division.

(8) Within 45 calendar days after final acceptance of all production items, the NSIG(s) shall be shipped to NSWC Corona

Division, ATTN: Receiving Officer, Bldg 575, Gage Laboratory, 1999 Fourth St., Norco, CA 92860-1915. The following shipping and marking specifications are applicable:

(i) Shipping, MIL-STD-2073, “DOD Standard Practice for

Military Packaging”

(ii) Marking, MIL-STD-129, “Marking for Shipment and

Storage”.

(9) The following NSIG(s) shall be provided and are mandatory for use except as noted by paragraph (o)(5) above.

Drawing: 923AS1101

Rev: A

Characteristic: DIA 7.659 +.000/-.070 X .766 Basic

NSIG No.: 2823992

Qty: 1

Dimensions: 21x16x5

Weight: 28 lb

Value: $5,500

Characteristic: DIA .312 MIN. X .50 MAX./.38 MIN. DP

NSIG No.: 1320AS116

Qty: 1

Dimensions: 5x5x3

Weight: 1 lb

Value: $1,000

Characteristic: 14.000 Basic Location of the 1/750-12 UN-2B

Threaded Holes

NSIG No.: 1205779

Qty: 1

Dimensions: 18x5x2

Weight: 40 lb

Value: $2,000

FIRST ARTICLE TEST (CONTRACTOR TESTING)

(a) The first article shall consist of:

The items and quantities specified in QAP 923AS1100 which shall be examined and tested in accordance with contract requirements, the item specifications, Quality Assurance Provisions (QAPS) and all drawings listed in the Technical Data Package.

(b) The first article shall be representative of items to be manufactured using the same processes and procedures and at the same facility as contract production. All parts and materials, including packaging and packing, shall be obtained from the same source of supply as will be used during regular production. All components, subassemblies, and assemblies in the first article sample shall have been produced by the Contractor (including subcontractors) using the technical data package provided by the

Government.

(c) The first article shall be inspected and tested by the contractor for all requirements of the drawing(s), the QAP(s), and specification(s) referenced thereon, except for:

(1) Inspections and tests contained in material specifications provided that the required inspection and tests have been performed previously and certificates of conformance are submitted with the First Article Test Report.

(2) Inspections and tests for Military Standard (MS) components and parts provided that inspection and tests have been performed previously and certifications for the components and parts are submitted with the First Article Test Report.

(3) Corrosion resistance tests over 10 days in length provided that a test specimen or sample representing the same process has successfully passed the same test within 30 days prior to processing the first article, and results of the tests are submitted with the First Article Test Report.

(4) Life cycle tests over 10 days in length provided that the same or similar items manufactured using the same processes have successfully passed the same test within 1 year prior to processing the first article and results of the tests are submitted with the First Article Test Report.

(5) Onetime qualification tests, which are defined as a onetime on the drawing(s), provided that the same or similar item manufactured using the same processes has successfully passed the tests, and results of the test are on file at the contractor’s facility and certifications are submitted with the

First Article Test Report.

(d) Those inspections which are of a destructive nature shall be performed upon additional sample parts selected from the same lot(s) or batch(es) from which the first article was selected.

(e) A First Article Test Report shall be compiled by the contractor documenting the results of all inspections and tests

(including supplier’s and Vendor’s inspection records and certifications, when applicable). The First Article Test Report shall include actual inspection and test results to include all measurements, recorded test data, and certifications (if applicable) keyed to each drawing, specification and QAP requirement and identified by each individual QAP characteristic, drawing/specification characteristic and unlisted characteristic. The Government Quality Assurance

Representative’s (QAR) findings shall be documented on DD Form

1222, Request for and Results of Tests, and attached to the contractor’s test report. Two copies of the First Article Test

Report and the DD Form 1222 will be submitted through the

Administrative Contracting Officer to the Contracting Officer with an additional information copy furnished to see First

Article Test Report CDRL for applicable distribution .

(f) Notwithstanding the provisions for waiver of first article, an additional first article sample or portion thereof, may be ordered by the Contracting Officer in writing when (i) a major change is made to the technical data, (ii) whenever there is a lapse in production for a period in excess of 90 days, or (iii)

Whenever a change occurs in place of performance, manufacturing process, material used, drawing, specification or source of supply. When conditions (i), (ii), or (iii) above occurs, the

Contractor shall notify the Contracting Officer so that a determination can be made concerning the need for the additional first article sample or portion thereof, and instructions provided concerning the submission, inspection, and notification of results. Costs of the first article testing resulting from production process change, change in the place of performance, or material substitution shall be borne by the Contractor.

AMMUNITION DATA CARDS

Detailed requirements and guidance for the preparation of

Ammunition Data Cards (ADCs) and Ammunition Lot Numbers are contained in MIL-STD-1168, the applicable DD Form 1423 and the

Worldwide Ammunition-data Repository Program (WARP) online user’s manual. Detailed requirements for obtaining and using a manufacturer’s identification symbol, which is an integral component of the ammunition lot number, can be found in MIL-STD-

1168 and the WARP user’s manual. Information provided in paragraphs 6.7 through 6.16 of MIL-STD-1168 shall be considered mandatory requirements where all instances of the term “should” are considered to be replaced with the word “shall.”

(a) The contractor shall develop and submit ADCs in accordance with the requirements of this section, MIL-STD-1168, and the user’s manual located on the WARP database. The WARP application is accessed through the Munitions History Program

(MHP) website. (Refer to “Ammunition Data Cards and Report of

Contractor Ballistic Testing” for more information.) The ADC requirement is a flow-down requirement that applies to contractors and their suppliers, vendors or subcontractors.

(b) The contractor shall prepare an ADC for each lot of item(s) being produced under this contract, regardless of whether or not those lots are accepted or rejected by the Government. The ADC shall comply with MIL-STD-1168 and WARP requirements.

(c) Unless otherwise authorized by the Procuring Contracting

Officer, the contractor shall include, in the components sections on the ADC representing the deliverable item, as a minimum; all assemblies, sub-assemblies, components, explosives, and propellants listed below for the item being procured.

End Item Component Listing:

Drawing Number: 923AS1101 Rev A, Nomenclature: Bomb Body, BDU-50

D/B Practice Bomb

Drawing Number: 4512206 Rev C, Nomenclature: Insert Lug

Drawing Number: MS3314, Nomenclature: Lug, Suspension (1000LB

Class) Airborne Equipment

Drawing Number: 4512224 Rev C, Nomenclature: Plate, Burst, AFT

Drawing Number: 4512225 Rev C, Nomenclature: Plate, Burst, Midbody

Drawing Number: 923AS185 Rev M, Nomenclature: Plug, Nose

Drawing Number: 2518425 Rev AG, Nomenclature: Plug, Shipping, Nose and Base

Drawing Number: 4512228 Rev C, Nomenclature: Ring, Retaining, AFT

Drawing Number: 4512226 Rev C, Nomenclature: Ring, Retaining, Midbody

(d) The component items identified below are from paragraph (c) above and will require their own component ADC in addition to being listed on the end item ADC. The component ADCs shall also comply with MIL-STD-1168 and WARP requirements.

Drawing Number from paragraph (c) above -3-, components as follows:

Component Drawing Number: -4-, Nomenclature: -5-

(e) Lot numbers shall be in accordance with MIL-STD-1168 lot number convention and the technical data package requirements.

Lot numbers shall be used for all ammunition end items and their major components, including inert, dummy, or non-energetic items and components. When not required by technical data package and not an end item or major component, the component lot number may be constructed through contractor lot number convention.

(f) The flowdown of the requirement for component ADCs generated via WARP is highly encouraged for other items not identified in paragraph (d) above when the prime contractor is purchasing components, assemblies, and subassemblies from subcontractors or vendors.

(g) All component RFD/ECPs shall be listed on the ADC for the deliverable item, as well as on the component ADC, when that component is identified in paragraph (d) above. The WARP user’s manual provides information on the level of detail required.

(h) A sample ADC shall be developed and submitted to the WARP system 30 days prior to First Article testing or 30 days prior to production in the event a first article is not required. The

WARP ADC program will not allow the submission of additional

ADCs until such time as the sample ADC has been approved in the system.

PROCESS CAPABILITY, CONTROL AND IMPROVEMENT REQUIREMENTS

(a) The Contractor shall establish a Process Control System that

Includes, but is not limited to, procedures, systems and software. This Process Control System shall complement the requirements of an ISO 9001-2008 or equivalent Quality

Management System as well as all contract quality requirements.

Statistical Process Control (SPC), when utilized, shall be implemented in accordance with ISO 11462-1 and ANSI/ASQC B1, B2, and B3 or equivalent. A Process Control Plan (PCP), which describes actions and methods to assure production processes will be in a state of control, shall be submitted to the

Government for review and acceptance as stipulated on DD Form

1423. Demonstration of process capability in accordance with the accepted PCP shall be accomplished prior to or at first article (if required) or prior to start of production.

Acceptance of product shall be contingent on verification of acceptable process capability in accordance with the accepted

PCP, provided all other contractual requirements are met. The

Government reserves the right to withhold acceptance of product when there is evidence of noncompliance to the PCP. Should a finding of noncompliance to the PCP be made, a corrective action plan shall be submitted to the Government.

(b) Characteristics for process control are as follows:

[ ] (1) Characteristics for process control are attributes or features whose variation have a significant effect on product fit, form, function, performance, service life or producibility, that require specific actions for the purpose of controlling variation. Characteristics for process control result from an in depth Government-only review and analysis as specified in

Technical Data Package (TDP) documentation as required below:

[X](1.1) Government selected list, see paragraph g below

[ ](1.2) As listed key characteristics

[ ] (2) Characteristics for process control are attributes or features whose variation have a significant effect on product fit, form, function, performance, service life or producibility, that require specific actions for the purpose of controlling variation. Characteristics for process control shall be determined using an in-depth Contractor review and analysis as specified in the PCP documentation. The Government reserves the right to identify any characteristics for process control as well as any additional characteristics identified in paragraph g.

[ ] (3) Characteristics for process control are features within a product, subassembly, part and process whose variation from nominal (i.e., target value) significantly impacts safety, performance in terms of customer’s requirements, or final cost of a product. Special controls should be applied where the cost of variation justifies the cost of control. These shall be developed from an in depth Government-Contractor review and analysis of design as specified in paragraph g below.

(c) The Contractor’s analysis shall include processes and operations under the control of the prime Contractor and those under the control of sub-Contractor including subtier suppliers.

The Contractor shall create a process flow chart for the entire process (including manufacturing, inspection and material handling) and perform Process Failure Modes and Effects Analysis

(PFMEA) for all processes identified on the process flow chart

[If option b(3) is selected, a PFMEA and process flow chart will not be necessary]. The Contractor shall identify, define and document specific controls applicable for each process and operation that affects all characteristics required for control.

The Contractor shall: (a) conduct process capability studies on all process and operation parameters affecting characteristics for process control; (b) verify that all automated inspection equipment used to validate process capability has been properly calibrated and certified; and (c) conduct Measurement System

Analysis (MSA) studies on all applicable corresponding measurement systems utilized to monitor process capability.

(d) The Contractor shall prepare and implement a PCP. The PCP shall be based upon and include the process flow chart, PFMEA

[If option b(3) is selected, a PFMEA and process flow chart will not be necessary], process capability studies and Measurement

System Analysis (MSA)for all process and operation parameters affecting characteristics for process control. For each characteristic, the PCP shall describe the entire process

(including manufacturing, inspection and material handling), control methods and action plans for all out of control conditions and process capability at the stated production rates. When utilizing statistical methods, a process capability index such as Cpk shall be calculated. A characteristic for process control shall be considered to have an acceptable (and capable) process if it has a Cpk of at least 2.00 for Critical characteristics, 1.33 for all other characteristics selected for control, or as stated as follows: N/A. The Contractor shall notify the Government when the minimum process capability values

(Cpk) of 2.00 for Critical characteristics and 1.33 for all other characteristics for process control, or the alternative established minimum Cpk values, are no longer being maintained.

(e) In accordance with MIL-STD-1916 the Contractor may request, in writing, that alternate methods of acceptance be evaluated once the processes and applicable operation parameters have been demonstrated to be both stable and capable. Any alternate methods may not be implemented until accepted by the Contracting

Officer.

(f) Corrective Action Requests (CARs) and Requests For

Deviations (RFDs) generated for identification of product nonconformances shall result in an evaluation of the Process

Control Plan (PCP). The evaluation will consider addition of new characteristics for process control to the contractually required process control list and require implementation of actions per paragraphs (c) and (d) above with submittal to the

PCO for Government acceptance. If the CARs and RFDs are related to characteristics, processes and/or operations already identified in the PCP then those actions required by paragraphs

(c) and (d) will be reassessed and submitted to the PCO for

Government acceptance. The Government reserves the right to withhold acceptance of product until the revised PCP is accepted by the Government.

(g) If box b(1)[1.1], b(2) or b(3) are checked above, the selected characteristics and applicable tools, techniques, control methods or method of analysis to obtain these are specified as follows:

Drawing: 923AS1100

Sheet: 1

Zone: C8

Classification: None

Characteristic/Requirement: Note 3, Dry film coating thickness

Sheet: 1

Zone: D8/D2/C8

C6/B8

Classification: M102, 201, 203

Characteristic/Requirement: Casing soundness: Note 1, A, II/Note1, B, I; Note 1, C, II; Note 1, C, III/Wall Thickness;

Note 11 and table 1

Sheet: 4

Zone: D5

Classification: M113

Characteristic/Requirement: 2.500-12 UN-3B Thread and Geometric

Controls

Sheet: 4

Zone: C2

Classification: M115

Characteristic/Requirement: 2.500-12 UN-3B thread and Geometric

Controls

Drawing: 4512206

Zone: B4

Classification: M102

Characteristic/Requirement: 1.750-12 UN-3B Tread and position

Drawing: 4512206

Zone: C1

Classification: M105

Characteristic/Requirement: 2.500-12UN-3A Thread

DESTRUCTIVE TESTING

(a) All costs for destructive testing by the Contractor and items destroyed by the Government are considered as being included in the contract unit price.

(b) Where destructive testing of items or components thereof is required by contract or specification, the number of items or components required to be destructively tested, whether destructively tested or not, shall be in addition to the quantity to the delivered to the Government as set forth in the

Contract Schedule.

(c) All pieces of the complete First Article shall be considered as destructively tested items unless specifically exempted by other provisions of this contract.

(d) The Contractor shall not reuse any components from items used in a destructive test during First Article, lot acceptance inprocess testing, unless specifically authorized by the

Contracting Officer.

(e) The Government reserves the right to take title to all or any items or components described above. The Government may take title to all or any items or components upon notice to the

Contractor. The items or components of items to which the

Government takes title shall be shipped in accordance with the

Contracting Officer’s instructions. Those items and components to which the Government does not obtain title shall be rendered inoperable and disposed of as scrap by the Contractor.

REWORK AND REPAIR OF NONCONFORMING MATERIAL

(a) Rework and Repair are defined as follows:

(1) Rework - The reprocessing of nonconforming material to make it conform completely to the drawings, specifications or contract requirements.

(2) Repair - The reprocessing of nonconforming material in accordance with approved written procedures and operations to reduce, but not completely eliminate, the nonconformance. The purpose of repair is to bring nonconforming material into a usable condition. Repair is distinguished from rework in that the item after repair still does not completely conform to all of the applicable drawings, specifications or contract requirements.

(b) Rework procedures along with the associated inspection procedures shall be documented by the Contractor and submitted to the Government Quality Assurance Representative (QAR) for review prior to implementation. Rework procedures are subject to the QAR’s disapproval.

(c) Repair procedures shall be documented by the Contractor and submitted on a Request for Deviation/Waiver, DD Form 1694, to the Contracting Officer for review and written approval prior to implementation.

(d) Whenever the Contractor submits a repair or rework procedure for Government review, the submission shall also include a description of the cause for the nonconformances and a description of the action taken or to be taken to prevent recurrence.

(e) The rework or repair procedure shall also contain a provision for reinspection which will take precedence over the

Technical Data Package requirements and shall, in addition, provide the Government assurance that the reworked or repaired items have met reprocessing requirements.

(f) Rework and repair is a supply chain flow-down requirement that applies to contractors and their suppliers, vendors or subcontractors.

MIL-STD-1916

The Department of Defense (DoD) Preferred Methods for this

Acceptance of Product, MIL-STD-1916, shall be used for this procurement action. All references to MIL-STD-105, MIL-STD-414, MIL-STD-1235, and ANSI Z1.4 appearing in the Technical Data

Package (TDP) are replaced by MIL-STD-1916. Verification Levels

(VL) shall replace AQLs and shall be VL IV for major characteristics and VL II for minor characteristics.

SUPPLEMENTAL WARRANTY INFORMATION

(a) Whenever a request for waiver, deviation, or other change to a requirement in the contract is approved, Contractor responsibilities arising out of provisions of this section are relieved only to the extent of the terms and conditions specified in the approval.

(b) For purpose of identifying the warranted material to facilities receiving it, the following instructions will apply:

(1) For a quantity of warranted material which has been accepted at origin by the Government, the pertinent DD Form 250

(and the pertinent Ammunition Data Card if the card is contractually required) shall bear the following annotation:

“The warranty period of the quantity stated hereon of (enter the item serial/lot number(s) as applicable) begins on (enter the date of acceptance of the quantity) and ends on (enter the date of the end of the warranty period for the quantity).”

(2) For a quantity of warranted material which has not been accepted at origin by the Government, the pertinent DD Form 250

(and the pertinent Ammunition Data Card if the card is contractually required) shall bear the following annotation:

“The warranty period for the quantity stated hereon of (enter item serial/lot number(s) as applicable) begins on the date of the acceptance of the lot and ends (enter the length of the warranty period) days later.”