ATTACH_0014_QAP-C-09_REVISION_A.pdf

QAP-C-09 REVISION A

QUALITY ASSURANCE PROVISIONS

FOR

SIGNAL, SMOKE AND ILLUMINATION, MARINE, MK 124 MOD 1

ADL 53711-8324647B

FY 18

1. The following Quality Assurance Provisions shall be made an integral part of the procurement contract/production order.

a. The following shall be inserted in Clause C-1 of a contract or in the production order:

“The following drawings, specifications, and documents are applicable to this procurement: ADL 53711-8324647B and revision of documents listed thereon. In addition, Supplementary Quality Assurance Provisions (SQAP) JXRT-SM-01 Latest Revision apply and are included as Attachment (2) of PDP.”

b. The following higher Level Quality Requirements shall be called out in the contract:

ISO 9001:2008 (Quality Management Systems - Requirements) (exclusion of Clause 7.3 permitted) or an approved equivalent

Proposed alternate Quality Plans shall be coordinated with NSWC Crane, Munitions Acquisition Branch (JXRT) Designated Technical Activity (DTA) and Procurement Quality Manager (PQM) prior to approval.

c. Statistical Process Control shall be applied to the contract/production order, documented in accordance with DID DI-MGMT-80004 latest revision.

d. Pre-Award Survey is required for this item. This requirement may be waived with written concurrence of the NSWC Crane, Munitions Acquisition Branch (JXRT) DTA and PQM.

Attachment (3)

1 FEB 2018

e. Post-Award/Facilities Assessment is required for this item. This requirement may be waived with written concurrence of the NSWC Crane, Munitions Acquisition Branch (JXRT) DTA and PQM.

f. A First Article Test (FAT) is required per the technical data. The FAT shall be as specified and shall be examined and tested in accordance with the contract, the item specification(s) and drawing(s). First Article Acceptance Testing and Inspection shall be:

Performed at Contractor’s plant with NSWC Crane, Munitions Acquisition Branch (JXRT) witnessing. Waiver of FAT shall require prior NSWC Crane, Munitions Acquisition Branch (JXRT) DTA concurrence.

g. Production Lot Acceptance Testing and Inspection samples per the technical data shall be tested at the following activity: Contractor Facility

h. Material Review Board authority shall be withheld.

i. Acceptance Inspection Equipment requirements of the

PDP.

j. Contract Data Requirements of PDP.

k. All Engineering Change Proposals and/or Requests for Variance affecting this item shall be documented in accordance with DID DI-SESS-80639 and DID DI-SESS-80640 latest revisions, respectively.

SQAP JXRT-SM-01

SUPPLEMENTARY QUALITY ASSURANCE PROVISIONS

1. Introduction. The following define Supplementary Quality Assurance Provisions to this contract and become an integral part thereof. These provisions define additional requirements of the Contractor in the performance of Quality Assurance (QA) duties.

In the event of any conflicting requirements, these provisions shall have precedence.

2. General Provisions.

a. Acceptability of a lot or batch of material will be determined by the use of sampling plans contained herein, Statistical Process Control (SPC) and/or 100 percent inspection as specified in the Contractor’s Government-approved quality or inspection plans. Final acceptance by Government inspection and/or testing may be required by the item specification, Automated Data List (ADL), or drawing.

b. The assignment of a sampling plan in no way alleviates the responsibility of the Contractor to furnish a product meeting all the requirements of the documentation. Material not meeting all the requirements of the applicable drawings and specifications shall be considered defective whether or not the characteristic is classified. The Contractor may not knowingly submit any non-conforming product to the Government for product acceptance.

c. Inspection and test records shall, as a minimum, indicate the nature of the observations, number of observations made, and the number and type of deficiencies found. Data included in inspection and test records shall be complete and accurate and shall be used for trend analysis and to assess corrective action effectiveness.

d. The Contractor’s gages and measuring and testing devices shall be made available for use by the Government, when required, to determine conformance with contract requirements. If conditions warrant, Contractor personnel shall be made available for operation of such devices and for verification of accuracy and condition.

Attachment (2)

e. The Contractor’s software quality program shall be an integral part of the overall QA program. Software quality program controls shall be applicable to all project software that is developed, maintained, or modified within the following categories:

(1) All deliverable software.

(2) All deliverable software that is included as part of deliverable hardware or firmware.

(3) Non-deliverable software (commercially available or user-developed) used for development, fabrication, testing, or acceptance of deliverable software or hardware (includes automated fabrication, test, and inspection/acceptance equipment software and software design, test, and inspection tools).

(4) Commercially available, reusable, or Government software designated as part of a deliverable item.

f. Government Property.

(1) Government-Furnished Material (GFM). When material is furnished by the Government, the Contractor's procedures shall include, at a minimum, the following:

(a) Examination upon receipt, consistent with practicability to detect damage in transit.

(b) Inspection for completeness and proper type.

(c) Periodic inspection and precautions to assure adequate storage conditions and to guard against damage from handling and deterioration during storage.

(d) Functional testing, either prior to or after installation, or both, as required by contract to determine satisfactory operation.

(e) Identification and protection from improper use or disposition.

(f) Verification of quantity.

(2) Damaged GFM. The Contractor shall report to the Government representative any GFM found damaged, malfunctioning, or otherwise unsuitable for use. In the event of damage or malfunctioning during or after installation, the Contractor shall determine and record probable cause and necessity for withholding material from use.

(3) Bailed Property. The Contractor shall, as required by the terms of the Bailment Agreement, establish procedures for the adequate storage, maintenance and inspection of bailed Government property. Records of all inspections and maintenance performed on bailed property shall be maintained. These procedures and records shall be subject to review by the Government representative.

g. Criteria established by MIL-STD-1916 (Department of Defense Test Method Standard, DOD Preferred Methods for Acceptance of Product) shall be used by the Contractor to conduct (nondestructive) acceptance inspection. Use of other (nondestructive) Acceptance Inspection Plans requires prior Government approval.

h. Critical characteristics that are to be verified by nondestructive testing or inspection shall be inspected 100 percent regardless of any provisions or allowance to the contrary as may be contained, included or cited in the ADLs, drawings, or specifications. Reduced levels for nondestructive testing or inspection of critical characteristics are not allowed.

3. Applicable Definitions. QA terms applied to the material to be delivered under this contract, unless otherwise specified, are defined in ANSI/ISO/ASQC 9001:2008. However, definitions set forth in ADLs, drawings, and specifications of the contract shall take precedence over the definitions contained in ANSI/ISO/ASQC 9001:2008 or in the provisions, to the extent of the conflict.

The Procuring Contracting Officer (PCO) shall be advised of any such uncovered conflict.

a. Classification of Characteristics. A specific attribute, measurement, or functional feature identified in the ADLs, drawings, or specifications as a requirement and classified in accordance with the effect of conformance or nonconformance with the requirement as "Critical," "Major," or "Minor."

b. Inspection by Characteristics. The application of acceptance/rejection criteria to each individual characteristic of an ADL, drawing or specification, or to individually specified characteristics.

c. Acceptance Inspection/Process Control. Specified operations that must be performed by the Contractor to assure that the lot of item(s) conforms to the requirements of ADLs, drawings, and specifications. These operations (examinations, measurements and tests) shall be conducted prior to the submission of the item (or lot of items) to the cognizant Government representative for acceptance by the Government.

d. Cognizant Government Representative. The designated Government representative specified in the contract. In addition to the definitions of Purchaser and Customer found in the respective ANSI/ISO/ASQC standards, when used in the Quality Systems definitions of U.S. Government contracts, the term "Government" shall refer to the body of the Government Agency administering the particular contract involved, or the authorized representative of that Government body.

e. Contractor. The organization that provides a product or a service to the Government. When used in the Quality Systems definitions of U.S. Government contracts, the terms “Contractor” “Supplier” are synonymous.

f. Testing. That element of inspection by technical means that determines the properties or elements, including functional operation of elements and supplies or those components, by the application of established scientific principles and procedures.

4. MIL-STD-1916 (current revision) shall be used by the Contractor for (nondestructive) acceptance inspection.

Inspection shall be by characteristic. Acceptance criteria shall be accept on zero defects and reject on one or more defects for all verification levels. If sample size exceeds lot size, perform one hundred percent inspection.

5. Unless specified otherwise on ADLs, drawings, or specifications, Verification Level IV shall be used for "Major" characteristics and Verification Level II for "Minor" characteristics. Characteristics not defined as "Critical" or "Major" are defined as "Minor."

6. Critical Characteristics Control Planning (Six Sigma):

a. The Contractor’s processes shall be designed with the objective of preventing the creation or occurrence of non-conforming critical characteristics (see paragraphs d & e).

The Contractor shall establish, document and maintain a product specific, Critical Characteristics Control (CCC) Plan that shall be submitted to, and approved by, the PCO in accordance with DD Form 1423 and DI-MGMT-80004. The CCC Plan shall include or reference all procedures, work and handling instructions and process controls relating to any critical characteristics.

Mistake-proofing techniques of the material handling and inspection systems shall be a part of the CCC Plan. Guidance for developing this plan and submitting Critical Plans of Action (CPOA) (paragraph g) can be found at https://qa.pica.army.mil/QAW/qaw_p/safety_policy.htm

b. The Contractor shall assure its critical processes are robust in design, capable and under control, with the objective of not generating any critical non-conformances. The Contractor shall calculate, document, clearly identify, and have a schedule that routinely assesses the reliability and effectiveness of its critical processes to prevent generating critical non-conformances as identified in the CCC Plan.

c. An inspection and verification system shall be employed that will verify the robustness of all critical processes. The Contractor shall calculate, document, clearly identify, and have a schedule that routinely assesses the reliability and effectiveness of its inspection and verification system to detect and prevent critical non-conformance escapes as identified in the CCC Plan. The Government expects that a Contractor will allow zero critical escapes. To demonstrate its critical escape risk the Contractor will utilize the non-conformance escape risk goal provided below.

(1) Unless otherwise specified immediately below, the calculated critical non-conformance escape risk is 1 in a million (.000001) items delivered. Or:

Alternate calculated Critical Non-conformance Escape risk (fill-in -1-):

Unless otherwise approved by the PCO, the non-conformance escape risk is the sum of the individual characteristic escape rates.

The probability of escape for a single characteristic shall be calculated by multiplying the non-conformance rate(s) entering the inspection system(s) by the error rate of the inspection system(s). These escape rates are then summed and shall not exceed the tolerable critical non-conformance escape risk.

https://qa.pica.army.mil/QAW/qaw_p/safety_policy.htm

(2) Within 45 days after award, the Contractor can elect to submit a phased-in approach on how the non-conformance escape risk will be achieved over a period of time not to exceed 180 days from the date of First Article approval, or from initiation of production when First Article is not required. Submission will require approval by the Government and is subject to a technical review and analysis. Allowance for a phased-in approach will then become a part of the contract. Disapproval of the Contractor’s submission does not relieve the Contractor of its obligation to comply with the terms of this clause.

(3) Based on the maximum error rate defined for the inspection system, the Contractor shall develop a test procedure to demonstrate the error rate. As part of the test plan the Contractor shall include sufficient test quantities to assure 90% statistical confidence in the resultant rates unless otherwise approved by the PCO. Once established, the Contractor shall have a documented schedule to routinely monitor the non-conformance and inspection system error rates to assure they do not exceed the maximum rates allotted.

d. As a result of previous practices, the Government’s technical data may refer to “Critical I”, “Critical II”, and “Special” characteristics. The use of the term "critical characteristics" within this clause includes Critical I, Critical II and Special characteristics and the use of the term "critical nonconformances" includes those nonconformances pertaining to Critical I, Critical II and Special characteristics. Unless otherwise stated in Section C, these characteristics shall be subject to all requirements of this clause.

e. In addition to critical characteristics defined in the Government’s technical data (drawings, specifications, etc.), the Contractor shall also identify and document in Contractor developed technical data all known material, component, subassembly and assembly characteristics whose non-conformances would likely result in hazardous or unsafe conditions for individuals using, maintaining or depending upon the product.

All additional critical characteristics identified by the Contractor shall comply with the critical characteristic requirements of the Technical Data Package, supplemented herein.

The Critical Item Characteristic List (CICL) review process shall be included in the CCC Plan. The Contractor's additional critical characteristics shall be classified in accordance with guidance located at https://qa.pica.army.mil/QAW/qaw_p/safety_policy.htm and shall be submitted to and approved by the PCO prior to production

(DI-SAFT-80970A).

https://qa.pica.army.mil/QAW/qaw_p/safety_policy.htm

f. In the event that a critical non-conformance is found anywhere in the production process, the Contractor, as part of its CCC Plan, shall have procedures in place to ensure:

(1) The non-conformance is positively identified and segregated to ensure that nonconforming product does not inadvertently remain in or reenter the production process. This control shall be accomplished without affecting or impairing subsequent non-conformance analysis. Final disposition of non-conforming product shall be documented and audited for traceability.

(2) The operation that produced the non-conforming component or assembly and any other operations incorporating suspect components or assemblies are immediately stopped. (See paragraph h for exceptions).

(3) The Government PCO is immediately notified of the critical non-conformance (electronic mail) (DI-SAFT-80970A).

(4) Any suspect material is identified, segregated and suspended from any further processing and shipment.

(5) An investigation is conducted to determine the root cause of the non-conformance and the required corrective actions.

An evaluation shall also be conducted with regard to suspect material to ensure that no additional critical non-conformances are present. A report of this investigation shall be submitted to the Government (DI-SAFT-80970A). The use of the Data Item Description (DID) report shall not delay notification to the Government as required in f(3) above.

(6) A request to restart manufacturing or to use any suspect material associated with the critical non-conformance is submitted to the Government (DI-SAFT-80970A). Restart of production shall not occur until authorized by the PCO, unless previously addressed in the approved CCC Plan. The Government will respond to a restart request within 3 working days. All objective evidence of the investigations to date shall be available for review at the time of restart. Suspect material shall not be used without PCO approval.

(7) The procuring activity reserves the right to refuse acceptance of any suspect material until the root cause or reasonably likely cause of the critical non-conformance has been identified, corrective action has been fully implemented and sufficient evidence has been provided to exclude non-conforming material from the conforming population.

g. The Contractor may develop alternative plans and provisions, collectively referred to as a CPOA, relative to Government or Contractor identified critical characteristics.

All CPOAs are independent and shall be evaluated by the Government for this contract. The CPOA and any subsequent revisions submitted in accordance with DD Form 1423 and DI-MGMT-80004 require PCO approval prior to implementation.

Unless otherwise specified at time of approval, Contractor shall review and evaluate CPOAs for currency and process improvements at least on an annual basis and submit results to the PCO.

Unless otherwise approved by the PCO, each critical characteristic shall require a separate CPOA. If the CPOA includes other documents by reference they shall be submitted upon request. Guidance for the development of a CPOA can be found in the referenced guidance located in paragraph a of this clause.

h. The Contractor may continue production with an approved CPOA provided that the critical non-conformance is consistent with the failure mode(s) and rates established in the CPOA.

Failure to meet all CPOA requirements will require the Contractor to revert back to paragraph f requirements.

i. If a critical non-conformance is discovered beyond its designated inspection point and prior to Government acceptance the Contractor shall take actions specified in paragraph f above.

If a critical non-conformance is discovered after Government acceptance the Government has the right to invoke the requirements of paragraph f with respect to the Contractor’s remaining production under this contract.