DRAFT_Section_E.docx

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DRAFT Section E - Inspection and acceptance.

E.1.0 First Article Requirements

E.1.1 First Article Requirements under this contract consist of the following First Article Tests:

a. Component First Article Tests (CFAT) (E.2.11)

b. First Production Vehicle Inspection (FPVI) (E.2.13)

c. Production Verification Test (PVT) (E.3)

d. Live Fire Testing (LFT) (E.4)

e. Operational Test (OT) (E.5)

E.1.1.1 First Article System Level Government Testing

E.1.1.1.1 The Contractor shall deliver 17 trucks and 5 trailers 450 Days After Contract Award (DAC) (See Attachment 0055, “Vehicle Configuration Tables”, Tab 1) to the Government at Aberdeen Test Center (ATC) for the PVT portion of the First Article Test (FAT). The shipping documentation shall contain this contract number and the Lot/Item identification. The characteristics that the First Article must meet and the testing requirements are specified elsewhere in the contract.

E.1.1.1.2 The Contractor shall deliver 4 trucks 450 DAC (See Attachment 0055, “Vehicle Configuration Tables”, Tab 2) to the Government at ATC for the Live Fire portion of the FAT. The shipping documentation shall contain this contract number and the Lot/Item identification. The characteristics that the first article must meet and the testing requirements are specified elsewhere in the contract.

E.1.1.1.3 The Contractor shall deliver 10 trucks 840 DAC (See Attachment 0055, “Vehicle Configuration Tables”, Tab 3) to the Government at Yuma Test Center (YTC) for the OT portion of the FAT. The shipping documentation shall contain this contract number and the Lot/Item identification. The characteristics that the First Article must meet and the testing requirements are specified elsewhere in the contract.

E.1.1.2 Within 120 calendar days of completion of all FAT for each model, the Contracting Officer will notify the Contractor, in writing, of the conditional approval, approval, or disapproval of the First Article. The notice of conditional approval or approval shall not relieve the Contractor from complying with all requirements of the specifications and all other terms and conditions of this contract. A notice of conditional approval shall state any further action required of the Contractor. A notice of disapproval shall cite reasons for the disapproval. The Government, at its discretion, may approve the First Article by model, separately.

E.1.1.3 If the First Article is disapproved for not meeting requirements, the Contractor, upon Government request, shall submit additional First Article vehicles and support at no additional cost to the Government. After each request, the Contractor shall make any necessary changes, modifications, or repairs to the First Article vehicle or select another First Article vehicle for testing. All costs related to these tests shall be borne by the Contractor, including any and all costs for additional tests and vehicles following disapproval of tests attributed to Contractor configuration or interface deficiencies. The Contractor shall furnish any additional FAT items to the Government under the terms and conditions and within the time specified by the Government. The Government will act on this First Article within the time specified in E.1.1.2.

E.1.1.4 If the Contractor fails to deliver any First Article vehicles on time, or the Contracting Officer disapproves any First Article, the Contractor shall be deemed to have failed to make delivery within the meaning of the DEFAULT clause of this contract.

E.1.1.5 If the Government does not act within the time specified in E.1.1.2, the Contracting Officer may, upon timely written request from the Contractor, equitably adjust, under the CHANGES clause of this contract, the delivery or performance dates or the contract price, and any other contractual terms affected by the delay.

E.1.1.6 The Contractor is responsible for providing operating and maintenance instructions and spare parts support during any First Article Test, IAW C.6.3.3, “PSP”. The Contractor shall be responsible for all costs resulting in delays to the test program from vehicle or component failures or for failure to provide adequate or timely parts support. The Government shall have the right to extend the specified program test period accordingly at no increase in contract price.

E.1.1.7 The Contractor, when directed by the Government, shall correct on-site any failure of the system which occurs during testing. Delays caused by defective test items shall not be a basis for adjustment of the contract delivery schedule or the contract price.

E.1.1.8 In accordance with FAR 52.209-3, “First Article Approval – Contractor Testing”, before First Article approval, the Contracting Officer may, by written authorization, authorize the Contractor to acquire specific materials or components or to commence production to the extent essential to meet the delivery schedules. If FAT’s reveal deviations from contract requirements, the Contractor shall make the required changes or replace all items produced under this contract at no change in the contract price. Before First Article approval, the cost thereof shall not be allocable to this contract for:

(1) Progress payments, or

(2) Termination settlements if the contract is terminated for the convenience of the Government.

E.1.1.9 Deficiencies found during or as a result of FAT (See E.1.1) shall be prima-facie evidence that all vehicles and components already produced prior to First Article approval are similarly deficient. Such deficiencies on all vehicles and components shall be corrected by the Contractor at no additional cost to the Government.

E.2 Quality Program.

E.2.1 Quality Program Requirements. The Contractor shall develop, implement, and maintain a quality system for all supplies and services as well as software and hardware to be provided under this contract. The quality system shall be registered to ISO/TS16949:2009, “Quality Management Systems – Particular requirements for the application of ISO9001:2008 for automotive production and relevant service part organizations” or the current revision.

Government approval of the Quality System is not required, if at the time of contract award, the Contractor is registered by a registrar who is approved by the International Automotive Oversight Board (IAOB). The quality manual shall be updated to reflect changes to the Quality Management System (QMS). The initial and subsequent revisions to the quality manual shall be submitted to the Government for approval in accordance with (CDRL E001, “QMS Manual and Revisions”).

E.2.1.1 If the Contractor does not meet the requirements of or is not registered to ISO/TS16949 at the time of the contract award, and they become registered to ISO9001:2015, then the requirements of ISO9001:2008 shall remain in effect. The systems and or processes in place under ISO9001:2008 shall not be dismantled or changed. The specific requirements of this contract with respect to the 2015 revision are listed below.

ISO9001:2015 Revision. If the Contractor and or Subcontractors register to this revision, contract provisions a - l (below) shall be exercised to ensure continued QMS effectiveness. These requirements consist of:

a. The Contractor’s and or Subcontractors’ QMS’s shall consist of a process for corrective action that addresses identification, development, and implementation of preventive actions. The corrective action** process shall not be ignored due to the emphasis and requirements in the ISO9001:2015 revision for risk based thinking.

b. Work instructions shall be written for all operations that directly and indirectly affect manufacturing. Such operations consist of engineering, quality, inspection, purchasing, outside services, retrofit, repair**, re-work**, shipping, service, warranty and related processes.

c. Procedures and documents in place during and after the implementation of the ISO9001:2008 revision shall remain in effect when the Contractor and Subcontractors are registered to ISO9001:2015.

d. Formal and documented training for all complex jobs relating to manufacturing (as explained in “b” above) shall continue to take place.

e. The Contractor’s written quality objectives shall be shared with the Government upon request.

f. The written output of the Contractor’s risk based thinking analysis shall be shared with the Government upon request. When risk analyses are done in areas of the company other than engineering, design and manufacturing, a quantitative scale shall be used for risk rating and ranking. Risk analyses for engineering, design, and manufacturing are covered under FMEAs (as further explained in E.2.4, “Failure Modes and Effects Analyses (FMEAs)”)

g. All linkages between procedures and processes that are required by ISO9001:2015 shall be documented and shared with the Government upon request.

h. All the requirements in this contract shall be flowed down to the Subcontractors of production parts and services. All requirements of this contract, Attachment 0001; “Performance Specification - FMTV”, all work directives, and the TDP shall be part of the Contractor’s and Subcontractors’ requirements and shall be part of the context of the organization*. PdM MTV shall be included in the category of interested parties*, so that the Contractors and Subcontractors shall meet PdM MTV needs and expectations*.

i. The Contractor and Subcontractors shall not exclude departments, functions, sectors, and business units within the boundary of the scope* of their certification. The products and services affecting the integrity and quality of FMTV trucks, trailers, kits, and services shall be included in the scope of the registration (reference ISO9001:2015, paragraph 4.3, “Determining the Scope of the QMS”)

j. No exceptions or exclusions to the requirements in ISO9001:2015 shall be taken by the Contractor or any Subcontractor.

k. All material purchased or manufactured by the Contractor that is classified by the Contractor, the Subcontractors, or the Government as non-conforming shall be marked, tagged, and segregated from conforming material. Traceability of the non-conforming items shall be maintained through the application of the disposition at the Contractor and Subcontractors. Government approval is required for the rework, repair, and use of material previously classified as non-conforming. All non-conforming material shall be subject to evaluation through the Contractor’s or Subcontractor’s corrective and preventive action process. Root cause or causes shall be determined, and subsequently eliminated or mitigated. The Government will hold authority for approval of all corrective action reports.

* Definitions of ISO9001:2015 terms used above:

Context of the Organization – Business environment combination of internal and external factors and conditions that can have an effect on an organization’s approach to its products, services, investments, and interested parties.

Interested Party – Person or organization that can affect or be affected by, or perceive themselves to be affected by a decision or activity of the organization.

Scope, Boundary of – (See ISO9001:2015 paragraph 4.3) The Organization determines the boundaries and applicability of the QMS to establish its scope. The organization shall consider external and internal issues, requirements of relevant interested parties, and the products and services of the organization.

Needs and expectations of interested parties – are those issues having an impact or potential impact on the organization’s ability to consistently provide products and services that meet the customer and applicable statutory and regulatory requirements. The organization shall determine if the requirements of these interested parties are relevant to the QMS.

Organization – This term as used in this contract is synonymous with the Contractor and Subcontractors.

Risk – The effect of uncertainty on an expected result. The effect can be positive or negative. Risk is often characterized by a reference to potential events and consequences or a combination of these.

** Definitions of PdM MTV specific terms used above:

Corrective Actions – Are a set of actions taken to eliminate root causes and prevent recurrence.

Rework - A procedure applied to a product to eliminate a non-conformance to the drawings, specifications, or contract requirements that will completely eliminate the nonconformance and result in a characteristic that conforms completely.

Repair - A procedure which reduces, but does not completely eliminate, a nonconformance. Repair is distinguished from rework in that the characteristic after repair still does not completely conform to the applicable drawings, specifications, or contract requirements.

E.2.2 Subcontractors’ QMS

E.2.2.1 The Contractor’s QMS shall document and verify their review and acceptance of the Subcontractors’ QMS consisting of all Advanced Product Quality Planning (APQP) elements. Documentation shall be made available for review upon Government request. The Government reserves the right to perform ad-hoc quality audits at the Contractor’s and Subcontractors’ facilities.

E.2.2.2 Quality Planning. The Contractor and Subcontractors shall establish Quality Plans that define the steps to assure that the product meets the Government’s (interested party) needs and expectations. The Quality Plan shall use a multi-disciplinary approach for decision-making. The Contractor and Subcontractor shall employ APQP in accordance with the current revision of the “APQP Manual” published by the AIAG in the composition of the quality plans.

E.2.2.3 Subcontractors’ Quality Assurance. The Contractor shall have a Subcontractor quality assurance program and Plan. The Subcontractors’ quality assurance program shall ensure each Subcontractor has a documented QMS that includes development, implementation, and maintenance of quality procedures, work instructions, flow charts, and records for all products. The Subcontractors’ Quality Assurance Plan shall be available for Government review upon request. The Contractor shall include the Subcontractor quality assurance plan as part of the contractor’s quality manual. All corrections, rework activities, repairs, or retrofits done by a Subcontractor shall be documented in work instructions. These work instructions will be reviewed by and agreed to by the Government prior to the commencement of corrections, rework activities, repairs, and or retrofits.

E.2.2.4 Contract Flow Down. The Contractor shall flow down all contract requirements associated with the Subcontractor’s product or service. The Government will have the right to review or access contractual documents between the Contractor and their Subcontractors.

E.2.2.5 The Contractor shall ensure that all Subcontractors understand and are compliant with contract requirements prior to releasing contractual documents and subsequent changes.

E.2.2.6 The Contractor shall facilitate PdM MTV access to all facilities, processes, data, and records, comprising all tiers of Subcontractors. The Contractor or Subcontractors shall not change sub-tier Subcontractors after passing FPVI, Live Fire, PVT, or OT. All post-test hardware, software, and supply chain changes shall be subject to requalification by the FAT process, CFAT process or the PPAP.

E.2.3 Advanced Product Quality Planning (APQP) Linkages

The Contractor and Subcontractors shall establish the linkages between the quality tools consisting of Failure Modes and Effects Analyses, Production Part Approval Planning, Measurement System Analyses, Control Plans, Process Flow Diagrams, Quality Plans, and Statistical Process Control in accordance with the “APQP Manual” published by AIAG. Per the “APQP Manual”, the Contractor and or Subcontractors shall establish multi-disciplinary teams to define the linkages among the APQP tools. Multi-disciplinary teams consist of the Contractor or Subcontractor’s design, manufacturing, engineering, quality, production, purchasing, packaging, service, and other personnel germane to the product or process being analyzed.

E.2.4 Failure Modes and Effects Analyses (FMEAs)

E.2.4.1 Design and Process Failure Modes and Effects Analysis (DFMEA and PFMEA). The Contractor and Subcontractors shall conduct and provide DFMEAs and PFMEAs on all critical items and key subsystems. A list of DFMEAs and PFMEAs from the Contractor and Subcontractors shall be submitted to the Government for review and approval in accordance with CDRL E002, “List of DFMEAs and PFMEAs”. The Government will select DFMEAs and PFMEAs from the list for review. The information used to create this CDRL shall be available to the Government and discussed at IPTs and other reviews. The Contractor and their Subcontractors shall use the current edition of the “FMEA Manual” published by AIAG for the requirements needed to design, implement, and maintain the system, process, and documentation of DFMEA and PFMEAs.

E.2.4.2 The Contractor and Subcontractors shall identify the critical, special, or key characteristics of the product or process from the Technical Data. These characteristics shall be incorporated in the DFMEAs and PFMEAs. The potential failure modes and their effects that are deemed by the Contractor or Subcontractor’s team as high risk, shall be controlled, mitigated, or eliminated. The Contractor shall record recommended actions, responsibility, target completion dates, and actions taken and effective date for the DFMEA and PFMEA to be considered complete and compliant to the requirements of this contract. The Contractor shall ensure that the DFMEA and PFMEA reflects the current drawing revision levels being used at all times. Risk Priority Number (RPN) is the product of the rankings for severity multiplied by occurrence multiplied by detection. The Contractor and Subcontractor shall use the tables in the AIAG “FMEA Manual” for ranking severity, occurrence, and detection unless or until tables are developed by the Contractor that are approved by the PdM MTV Product Assurance Team. The Contractor shall develop a process of continual improvement using FMEA RPN reduction. Top RPN lists and RPN goals shall guide the Contractor, rather than setting an RPN threshold. RPNs shall be reduced by the use of process behavior charts to show improvement of the process. Process behavior charts, previously known as Statistical Process Control Charts (SPC charts), are a tool for characterizing the voice of the process. These charts separate variation into two components: common (process has not changed) and special (a signal the process has changed). Data are plotted in a time series. A central line (or average) indicates a visual reference for detecting shifts or trends. Upper and lower control limits (natural process limits) are computed from the data and placed symmetrically on either side of the central line.

E.2.4.3 The DFMEA, PFMEA, and related documents shall be continually updated to reflect lessons learned, updated reliability predictions, and corrective actions. The Contractor or Subcontractors shall provide DFMEAs and PFMEAs for review at the Government’s discretion. The Contractor or Subcontractors shall not consider DFMEA’s and PFMEA’s proprietary.

E.2.5 Control Plan (CP) The Contractor shall develop and maintain CP’s in accordance with the “APQP Manual”, published by the AIAG. The CP’s shall detail the execution of the production and STS contract requirements. Critical Safety Items (CSI) and special, or key characteristics, whether identified by the Government or the Contractor, shall be used in the development of CP’s. They shall also include specific response plans when any undesirable measurement results are obtained. The “Methods” section and the subsection “Evaluation Measurement Technique” shall employ statistical process control or process behavior charts to show when the process is in statistical control and is statistical capable. The response plans, in conjunction with the inspection and test frequency, shall ensure that zero suspect material leaves the Contractor’s facility in the event of an undesirable measurement. The control plans shall be living documents and shall always reflect the current processes. Control plans shall be controlled documents, retained for the life of the contract. The Government reserves the right to review control plans on request.

E.2.6 In-Process Inspection. In-process inspection shall be incorporated into the Contractor and Subcontractor’s overall QMS.

E.2.7 Inspection Equipment. The Contractor and or Subcontractor shall be responsible for the supply, calibration, and maintenance of all measuring, monitoring, inspection, and test equipment necessary to ensure that end item and components conform to contract requirements. All Contractor and or Subcontractor furnished inspection equipment shall be made available for Government review during the execution of this contract. The Government will use only the Contractor or Subcontractor’s calibrated inspection or test equipment.

E.2.8 Inspection Records and Drawings. The Government reserves the right to review inspection records, drawings, and process documents upon request.

E.2.8.1 Measurement of Continuity and Resistance. The Contractor shall measure continuity and resistance on the assembly line or in an offline cell or station every time a harness ground is added to the common grounding location. The Contractor shall take readings using calibrated go-no-go ohm meters specific for and dedicated to the measurement of resistance and continuity. The Contractor shall document that the readings have been taken during the in-process inspection on a Contractor-developed check-sheet. The Contractor shall note all deviations from the “go” state. The Contractor shall correct these deviations from the specifications before the vehicle progresses to the next station or operation. The Contractor-developed check-sheet shall also show the date of the readings, the name and inspection stamp of the inspector, the vehicle serial number or in-process identification number, the gage number, and gage calibration due date.

E.2.9 Production Part Approval Process (PPAP). (See also: paragraph E.2.11, “Component First Article Testing”) The Contractor and Subcontractors shall demonstrate that their manufacturing and measurement processes have the capability of meeting design or specification requirements prior to the first shipment of product in accordance with “PPAP Manual” from the AIAG. The product(s) shall be validated in accordance with the control plan developed by the Subcontractor’s multi-disciplinary team and approved by the Contractor. All testing equipment (manual or automated) used to verify compliance by the Contractor or Subcontractors shall be evaluated for its contribution to the overall variation in the process using the protocols defined in the “Measurement Systems Analysis (MSA) Manual” from AIAG. The PPAP’s must reach level 3, as defined in the PPAP Manual, for all Subcontractors and parts made in-house by the Contractor prior to Government acceptance of full rate production trucks or trailers. If this Level 3 PPAP requirement cannot be accomplished before the first trucks or trailers are ready for sale, then the Contractor shall submit a RFV and obtain Government approval before proceeding. The level of interim PPAP’s after Government acceptance of full rate production trucks or trailers shall be maintained at less than or equal to 3% of all PPAP’s currently required. Test results and verifications essential in meeting FAT or CFAT requirements in the TDP shall be part of the PPAP package. The PPAP shall contain dimensional verifications, as outlined in the “PPAP Manual” published by the AIAG. The Contractor and Subcontractors shall ensure that all Level 3 PPAP’s and FATs (or CFATs) are maintained after Government acceptance of full rate production trucks and or trailers.

If a Subcontractor alters the aspects of the manufacturing process that consists of:

a) Moving, replacing, or modifying the manufacturing process

b) Moving or modifying the manufacturing site

c) Changing a sub-supplier, material or parts

d) Changing owners

e) Changing processes from manual to automated or vice versa

f) Moving a part from internally to externally manufactured or vice versa

Then the PPAP/CFAT/FAT shall be redone and level 3 shall be achieved. The Contractor or Subcontractors shall use the current revision of the “Production Part Approval Process (PPAP) Manual” for requirements and associated processes used for submission and approval of PPAP’s at each level. The Government reserves the right to review all associated production part approval documents or records.

E.2.10 Production Parts from Outside the US. If the Contractor or Subcontractors purchase parts or assemblies bought outside the United States of America, then the PPAP shall be presented to PdM MTV Quality for approval during the PPAP process (CDRL E014, “List of Production Parts from Outside the US”). This requirement shall apply in particular to forgings, castings, electronic components, and elastomeric products (rubber and plastic). All documents submitted as part of a PPAP shall be in English or shall have been translated into English prior to submission to PdM MTV Quality.

E.2.11 Government Component Testing Requirements.

E.2.11.1 First Article Testing (FAT) or Component First Article Testing (CFAT). (See also Section titled, “PPAP”, E.2.9) FAT/CFATs shall be required for components, systems, or sub-systems as indicated in the FMTV TDP. The Technical Data specifies the testing requirements. Some of the requirements in the TDP do not specifically state the term CFAT or FAT requirements. Regardless, the tests in the notes and in the specifications listed in the notes on the drawings (listed below) shall be treated as CFAT/FAT requirements. The Contractor shall complete the PPAP Parts Submission Warrant (PSW) with the test results for the FAT/CFATs included under requirement 17, “Records of Compliance with Customer-Specific Requirements.”

E.2.11.2 Components, systems, and sub-systems consist of the following:

(43) Frame System

Items which have not been finalized at the time of this proposal, because of the technical insertions detailed in this RFP and listed above shall still require a CFAT or PPAP. The actual tests and requirements shall be defined in the individual ECP’s governing each technical insertion.

The Government reserves the right to be present at all testing. The Contractor shall notify the Government a minimum of 20 calendar days prior to conducting a test. Failure to notify the Government within the time limit may, at the Government’s discretion, be grounds to reject the test. CFATs shall be performed in accordance with the TDP. Components in a system or sub-system requiring a CFAT shall be tested individually prior to performing the system and or sub-system FAT. When the components are combined to form a system, the system FAT shall be performed (see table above).

The FAT or CFAT shall include a dimensional inspection that validates the component, system, or sub-system conforms to the TDP.

The approved FAT or CFAT procedures shall become the baseline test requirements of the Quality Assurance Provisions. The component, systems, or sub-systems tested during FAT or CFAT shall be representative of items to be manufactured for production using the same processes, facilities, and procedures. Delays in schedule as a result of the Contractor's failure to identify the FAT or CFAT components, systems, or sub-systems shall be considered a Contractor-caused delay.

E.2.11.3 FAT and or CFAT Plan. The plan shall describe the methods for testing and inspection required by the TDP. The information contained in the plan shall consist of details as to how the Contractor or Subcontractors shall determine compliance with all dimensions, drawing notes, standards, or specifications listed in the TDP.

The Contractor shall prepare and submit a FAT or CFAT plan for each component, system, or sub-system subjected to FAT or CFAT. The plans shall be submitted within 90 calendar days after contract award and 30 calendar days prior to the start of Production Vehicle Testing (PVT). They shall be submitted into Windchill under, “FAT or CFAT Plan” (CDRL E003 including the TDP (Drawing) number and title of the test – component, system or, sub-system, represented by the plan” – so the submission can be identified by the Government). The Government will have the right to monitor all FAT or CFATs. The Contractor shall provide a list and time schedule of FAT or CFATs as part of the plan, including anticipated completion dates.

E.2.11.4 FAT or CFAT Report. The Contractor shall submit a FAT or CFAT Report in accordance with MIL-HDBK-831, “Handbook - Preparation of Test Reports,” for each component, system, and or sub-system tested within 30 calendar days of FAT and or CFAT completion. Submittal shall be made in Windchill under “FAT and or CFAT Test Report” (CDRL E003, “FAT and or CFAT Report” including the TDP (Drawing) number title of the test – Component, System, or Sub-system represented in the report – so the submission can be identified by the Government). FAT and or CFAT reports shall contain a summary table showing:

a) each test and inspection performed

b) results of each test (pass/fail) if attribute test

c) test results – required result or range versus actual test data if variable test data are generated

d) corresponding page where data are located

e) corrective action, if required

E.2.11.5 Conditional Acceptance of Components Pending FAT and or CFAT Completion. The Government may allow the Contractor to use components, systems, or sub-systems pending FAT or CFAT approval in the manufacture of FMTV vehicles. The following conditions shall apply:

a. The Contractor agrees to comply with all FAT and or CFAT testing requirements.

b. The Contractor shall remedy all non-conformities, deficiencies, or discrepancies in each component, system, or sub-system discovered during the FAT and or CFAT.

c. If a pending FAT or CFAT of a component, system, or sub-system results in a failure, the Government reserves the right to:

1. Cease acceptance of vehicles with components, systems, or sub-systems that have failed FAT or CFAT.

2. Require the Contractor to repeat a portion or all of the FAT or CFAT testing at the Contractor’s expense.

3. Deficiencies found during, or as a result of, FAT or CFAT shall be prima-facie evidence that all components, systems, or sub-systems already produced prior to completion of FAT or CFAT are similarly deficient. Such deficiencies on all components, systems, or sub-systems shall be corrected by the Contractor at no additional cost to the Government.

E.2.11.6 Disapproval. If the FAT or CFAT is disapproved, the Contractor shall repeat the FAT or CFAT tests in whole or in part to address Government concerns. After such a request for additional tests, the Contractor shall make changes, modifications, or shall rework the test components, system, or sub-system. If the situation warrants, the Contractor shall conduct a repeat FAT or CFAT. All costs related to these tests shall be borne by the Contractor. The Contractor shall then conduct the repeat FAT(s) or CFAT(s) and deliver the revised report in accordance with CDRL E003, “FAT and or CFAT Test Report”. The Government reserves the right to request consideration for a delivery schedule extension resulting from a need to retest.

E.2.11.7 Changes. If changes are made to the technical data, production processes, facilities, or type of material (substitution), a subsequent FAT or CFAT may be required. The results of the FAT or CFAT shall be submitted in accordance with CDRL E003, “FAT and or CFAT Test Report”. Costs of FAT’s or CFAT’s resulting from Contractor proposed changes shall be borne by the Contractor.

E.2.11.8 Manufacture. The FAT or CFAT component, system, or sub-system offered for test shall be produced at the same place of manufacture using the same production process to be used for production. The Contractor shall certify the place of manufacture. This certification shall be included in the (CDRL E003, “FAT and or CFAT Test Report”) submission.

E.2.11.9 Components, system, and or sub-system test specimen selection for FAT or CFAT shall be selected from the first ten units produced under this contract. In the event that the first ten units of a lot are unavailable, the Government reserves the right to select the FAT or CFAT quantity from a selected lot.

E.2.11.10 FAT or CFAT Conditions. The FAT or CFAT requirement may be considered met if the Contractor certifies to the Government that:

a) The supplier has FAT or CFAT approval on an identical component, system, or sub-system delivered for use in a previous Government tactical wheeled vehicle production contract.

b) The Contractor or Subcontractor have been in continuous production (defined as one which has not had a break in production in excess of six months, and the design, manufacturing, assembly process, or place of manufacture have not been changed).

The FAT or CFAT requirement may be considered not met and another FAT or CFAT shall be required if one or both of the conditions listed below exist:

a) Military or federal specifications applicable to the component, system, or sub-system have changed and may impact form, fit, function, or performance.

b) PQDR’s are received or corrective actions have been written showing that the component, system, or sub-system have failed in the field or at the Contractor or Subcontractor.

E.2.11 Software. All software provided to PdM MTV by the Contractor and Subcontractors shall be in compliance with AS 9115, “Quality Management Systems – Requirements for Aviation, Space and Defense Organizations – Deliverable Software” and ISO/IEC 27001, “Information Technology - Security Techniques - Information Security Management Systems.” (NOTE: AS 9115:2016 will be released in 2016. At that time, the 2016 revision shall replace both the current version of AS 9115 and ISO/IEC 2701 as the sole software quality and cyber security requirement.) The requirements shall apply to all software developed and or modified, and all effected subsystems and or subcomponents. The requirement for compliance to the standards (above) shall apply to software:

1. Integrated into and required to operate a component system, or sub-system of a truck or trailer.

1. Used to develop all truck, trailer, or kit manuals

1. Required to operate, troubleshoot, or maintain equipment for trucks or trailers

d) Required to operate all Computer Numerically Controlled (CNC) machinery, all Coordinate Measuring Machines (CMMs) – portable and stationary, and all other manufacturing and inspection equipment operated using software.

This requirement shall apply to equipment that is owned, leased, or rented by the Contractor and Subcontractors.

E.2.12 First Production Vehicle Inspection (FPVI).

E.2.12.1 FPVI is a Government inspection of the first vehicles of each variant produced under contract. The inspection is performed at the place of manufacture using verification methods consisting of a review of process records and interfaces of items in accordance with the FMTV Performance Specification. The Contractor shall send written notification consisting of test location, date, and time to the ACO and PdM MTV Product Assurance no less than 14 calendar days prior to the start of the FPVI. The Government will randomly select one vehicle from the first production run of each variant. At the time of the FPVI the Contractor shall make available all the reports of prior inspections, tests, Subcontractor quality requirements, QPL documentation, drawings, material, or component certifications to the Government representative(s).

E.2.12.2 FPVI will include the installation of an armor kit (side with Fuel Tank Fire Suppression and underbody armor) to ensure proper dimensional tolerances are achieved in production and acceptable gaps are attained during armor installation, tarp and bow kit (Cargo variant only), and Weapon Station Interface Ring. The Contractor shall use the underbody kit as developed under this contract and a side armor kit, B-Kit (Supplemental Armor Kit), supplied by the Government as GFE to perform these tests. A plan for the fit-up tests shall be submitted to PdM MTV Quality through Windchill in accordance with CDRL E004, “FPVI Report and Modifications. The actual Fit-up Tests shall not be accomplished until the plan is approved by the Government.

The Contractor shall fit-up aforementioned kits on three FPVI trucks. All fit-up issues (non-conformances, defects, and or discrepancies) and the times it took to fit-up the kits shall be documented in a fit-up inspection report and submitted IAW CDRL E004, “FPVI Plan Report and Modifications”

In the event non-conformances, defects, or discrepancies are discovered during the fit-up that are not due to dimensions of the GFE, the Contractor shall correct and document the corrections. These corrections shall be documented as part of a formal corrective action see Section E.2.20, “Corrective Action Submissions and Re-Submissions” for instructions concerning corrective actions. Root causes shall be determined by the Contractor.

The Contractor shall be responsible to correct any non-conformances on vehicles built up to and after the FPVI Fit-up Test at no additional cost to the Government.

E.2.12.3 During fabrication of the first vehicles of each variant produced, the Contractor shall conduct in-process inspections to determine conformance of materials and workmanship to specified requirements. These inspections shall be done at the Contractor's or Subcontractors’ facilities prior to the application of primer and paint. The Government will review and audit the Contractor’s and Subcontractors’ evidence to contractual requirements as follows:

a) Processing and welding procedures

b) QMS procedures and work instructions

c) Inspection records

d) Calibration records

e) Non-destructive testing records

f) Material certifications

g) Welder certifications

E.2.12.4. The FPVI shall be completed using a two-phase approach. During the first phase, the Contractor shall inspect the vehicle without B-Kit (Supplemental Armor Kit) armor and all other survivability kits. During the second phase, the Contractor shall inspect the vehicle with installation of the B-Kit and all other survivability kits. The Contractor shall document all issues pertaining to form, fit, and function that arise during B-Kit and all other survivability kit installation(s). This documentation shall be submitted in accordance with CDRL E004, “FPVI Report and Modifications.”

E.2.12.5 FPVI Documentation and Road Test. The Contractor shall road test the previously selected vehicles from the first production run of each variant at the place of manufacture. The Government may elect to witness or participate in the Contractor's road tests. During the road test, the Contractor shall verify compliance to the “Performance Specification - FMTV” (Attachment 0001). The Contractor shall document the actual values resulting from road testing. The Contractor shall record the actual values using Contractor format and submit in accordance with CDRL E004, “FPVI Report and Modifications.” Upon completion of the FPVI road test, the Contractor shall submit vehicle inspection records to the Government. If a delivery order specifies a B-Kit or other survivability kit installation(s) on a vehicle, the Contractor shall road test the vehicle with the kit(s) installed.

E.2.12.6 If the Contractor’s FPVI vehicles fail, the Contractor shall be required to repeat all of the FPVI consisting of all changes, modifications, rework, or repairs at no additional cost to the Government. The Government has the option of selecting another production vehicle for FPVI in lieu of the original first production vehicle. The Contractor shall bear the responsibility for delays resulting from vehicle re-inspections. Upon completion of re-inspections, the Contractor shall submit the revised inspection report incorporating the modifications resulting from the re-inspection. The Contractor shall correct all discrepancies found during FPVI on the FPVI vehicle(s) and all vehicles covered by this contract or other contract modifications.

E.2.12.7 FPVI Report. The Contractor shall prepare and deliver a FPVI report as described in CDRL E004, “FPVI Report and Modifications.” The FPVI report shall have blocks for the Contractor inspector's initials indicating that all characteristics or functions were inspected and given a disposition. There shall also be a block on the form for re-inspection and a disposition of rejected characteristics or functions prior to Government re-inspection. Final review and acceptance shall be indicated by a signature containing the full name and title of the company official rendering approval. The Contractor shall include a statement attesting to the inspection of all welds prior to application of pre-treatment conversion coatings and or primer and or paint (topcoat CARC). The Contractor shall provide the FPVI report to the Government within 15 calendar days of completion of the initial vehicle inspection(s). The ACO will send written notification to the Contractor within 20 calendar days after receipt of the FPVI Report with one of the following dispositions of the first production vehicle by variant:

a) approval

b) conditional approval

c) disapproval The Contractor shall correct all defects cited by the conditional approval or disapproval. The Contractor shall document the correction of all defects into the FPVI modified report that crosswalks the defects to the corrections, which can be verified by the Government. The Contractor shall submit the FPVI modified report within ten calendar days after Government conditional approval or disapproval of a FPVI report in accordance with CDRL E004, “FPVI Report and Modifications.”

E.2.12.8 FPVI Standard for Vehicle Variant(s). Once the FPVI vehicle variants are approved, they will become the production standard for all future vehicles.

E.2.13 Metrics

A system for the use of statistical methods and tools shall be developed, maintained, considered, and assigned at the product planning stage in accordance with APQP manual published by the AIAG. The outputs of the planning and identification of the statistical tools shall be included in the control plans and in the quality planning process. These statistical methods shall be evidenced at all critical phases of the product realization process consisting of product development, purchasing, manufacturing, field analysis or returns, continual improvement, measurement systems analysis, safety, and cost of quality. Statistical data analysis using process behavior charts for the production processes shall be used as the basis of continual improvement. Process behavior charts (previously known as SPC charts) are a tool for characterizing the voice of the process. These charts separate variation into two components: common (process has not changed) and special (a signal the process has changed). Data are plotted in a time series. A central line (or average) indicates a visual reference for detecting shifts or trends. Upper and lower control limits (natural process limits) are computed from the data and placed symmetrically on either side of the central line

Therefore, the Contractor shall demonstrate that methods of data organization, data gathering, data analysis, and the conclusions drawn from these data are done in accordance with the accepted and agreed to methods outlined in the, “Statistical Process Control Manual” published by AIAG. The Government will review this process on a discretionary basis. The voice of each process is the combination of the average, upper control limit, and lower control limit. These parameters shall drive the selection of targets or goals. Targets or goals shall be dictated by the process potential as defined by the process behavior charts.

E.2.13.1 The Contractor shall define critical manufacturing processes, explain each element in the list in a narrative form and submit both to the Government for review in accordance with CDRL E005, “List of Critical Manufacturing Processes and Modifications”. The List of Critical Manufacturing Processes shall be the origin of process behavior charts. Copies of all data and completed process behavior charts shall be treated as controlled documents and retained for the life of the contract. The Contractor shall allow the Government to review all process behavior charts.

E.2.14 Error-Proofing.

The Contractor shall be responsible for developing and implementing error proofing to ensure part presence and orientation of all assembled or kitted parts. Each assembly requires in-process checks and error-proofing tools be used so that assembled or kitted parts are conforming to the Technical Data and SPI’s prior to release of product for shipment to the customer. When error proofing through design cannot be achieved, process error-proofing measures shall begin with prevention and then employ detection techniques. The Contractor shall avoid the use of inspection methods. Inspection shall be used only when necessary to provide conforming product. Error-proofing approaches used to improve the production process shall be reviewed during the APQP, FMEA, and control plan meetings.

The error proofing process shall be planned and executed in accordance with the following requirements:

a) An error-proofing plan shall be developed by the Contractor. It shall describe how the Contractor and or Subcontractors shall address error proofing from the organizational level.

b) Part of this plan shall be the development, labeling, handling, and contingencies for boundary samples. Boundary samples may consist of go-no go samples, master samples, and red rabbits.

c) The plan shall require risk mitigation for all RPN’s in the DFMEA and PFMEA’s that are seven or higher in severity, and if the occurrence number is greater than one. In such instances, the Contractor shall employ error proofing in assembly or kitting processes. The severity and occurrence limits assume the Contractor and Subcontractors use a 1 through 10 scale.

d) Error proofing is required for all special processes and key, special or critical product characteristics (as defined in E.2.4.2., “Critical Characteristics”)

e) A list of all the error proofing techniques used shall be compiled by the Contractor and Subcontractors and included as part of a control plan. Error proofing verification shall be added to written preventive maintenance plans (E.2.18).

f) All assembly or packaging process equipment shall leave physically identifiable marks or using software, such as a barcode, on the parts that are indicative of a successful operation.

g) Dimensional features affecting form, fit, or function, which may not be capable or consistent, are to be evaluated in the error-proofing process.

h) When positive alignment features cannot be designed into the product then process features shall be added to error proof the assembly or kitting processes. Equipment examples consist of:

a. Laser lights

b. Fixtures

c. Equipment modifications

d. Dead man outlines

e. Templates (for type, size, or number of parts).

i) Assembly or kitting processes involving mirror image parts (right and left hand parts) shall have error-proofing techniques employed by the Contractor and Subcontractors to prevent assembly and packing errors.

j) To ensure the correct parts are picked for assembly or kitting, one or more of the following methods shall be used:

a. Barcodes

b. Pick lights

c. Templates

d. Light curtains

e. Color coding

f. Kan Ban

k) The Contractor and Subcontractors awarded an order under this contract, to either assemble parts or kit parts for the Government, shall select an audit form from the Automotive Industry Action Group (AIAG), “Error-Proofing Manual, CQI 18” based on organizational requirements and the type of effort. The audit form shall be completed by the Contractor and Subcontractors prior to start of kit, truck, or trailer production CSEMin accordance with CDRL E006, “Error-Proofing Audit Results and Corrective Actions”. If the audit score is less than 75%, the Contractor shall write an audit plan to crosswalk the audit deficiencies with associated corrective actions. The Contractor shall write a corrective action report to demonstrate how to raise the score above 75% and submit it in accordance with CDRL E006, “Error-Proofing Audit Results and Corrective Actions”.

E.2.15 Cost of Quality

A Cost of Quality System shall be implemented and maintained by the Contractor. It shall encompass all the recognized sources of quality cost. These consist of costs in the standard categories of Prevention, Appraisal, and Internal and External Failure costs.