Draft Section E - Inspection and Acceptance(3).docx

E.1 QUALITY ASSURANCE (QA)

E.1.1 QUALITY ASSURANCE PROGRAM REQUIREMENTS

The contractor shall develop, implement, and maintain a quality system acceptable to the Government for all supplies and services to be provided under this contract. The quality system shall address all aspects of vehicle, trailer, and kit production and delivery, including but not limited to software and hardware contractual requirements. The quality system shall follow the requirements within ISO (International Organizational for Standardization) 9004 and be made available for Government review within three days of request.

The contractor shall be third party certified to International Automotive Task Force (IATF) IATF 16949, Automotive Quality Management System Standard, for the life of the contract at all of the facilities or locations that the contractor uses to produce, manufacture, assemble, test, inspect, repair, or deliver vehicles, trailers, and kits, or components/assemblies of those vehicles, trailers, and kits, required under this contract. The contractor shall obtain third party certification from a certification body that is under contract with the IATF at the time the certification is issued. A list of certification bodies can be obtained at https://www.iatfglobaloversight.org/. If the contractor is not already certified to IATF 16949 at the time of contract award, the contractor shall be, at a minimum, third party certified to ISO 9001 Quality Management Systems Requirement at the time production begins, and the contractor shall achieve certification to the IATF 16949 standard in effect at the time of certification no later than two years after the start of production. Once certified, the contractor shall maintain the certification throughout the entire period of performance of the contract, to include: recertification prior to expiration of the certification; transitioning and becoming certified to new revisions of IATF 16949 as they are released and required by the IATF; and adopting all sanctioned modifications and interpretations released by the IATF applicable to IATF 16949. The contractor shall provide the Government access to all audit findings and non-conformances identified by third party certification bodies. In the event the contractor fails to achieve the required certifications, the Government will impose a withhold on all hardware deliverables until the specified certifications are achieved in accordance with the requirements documented herein. The contractor shall notify the PCO of any non-conformance findings or loss of its certification within three days of receiving such notice from the contractor’s registration body. For the purposes of interpreting ISO9001 and IATF 16949 requirements of this contract, "the customer" shall correspond to the Government, and "the organization" shall correspond to the contractor.

E.1.1.1 IATF 16949 CUSTOMER SPECIFIC REQUIREMENTS

The requirements specified in Section E of this contract constitute the Customer Specific Requirements as defined in IATF 16949. All requirements contained within IATF 16949 apply as written within the standard unless specifically modified by Section E requirements.

E.1.2 QUALITY MANAGEMENT

E.1.2.1 PRIME CONTRACTOR MANAGEMENT SYSTEM

The prime contractor shall document and verify its review and acceptance of its subcontractor’s quality assurance systems. Documentation shall be made available for review upon Government request. The prime contractor shall audit subcontractors to the quality management system to which the subcontractor is third party certified when conducting quality audits. The Government reserves the right to perform quality audits at the prime contractor and subcontractor facilities.

E.1.3 CONTROL PLANS

The contractor shall develop and maintain process control plans that ensure compliance with the requirements in this contract (reference CDRL B004 Engineering Change Proposal (ECP), CDRL D001 Failure Analysis and Corrective Action Report (FACAR), and CDRL E001 Corrective Action Report (CAR)). The plans shall involve the entire production system as well as any STS/prototype work for which ECP development has been funded by the Government. Families of control plans (for multiple parts where the parts are very similar in application, design, manufacture, requirements and specification) are acceptable. The contractor shall identify specific operations in the manufacture of the JLTV products that are used to ensure conformance to the requirements. The Control Plans shall include outputs from the Process Failure Mode and Effects Analysis (PFMEA). Special characteristics, whether identified by the Government or the contractor, shall be used in the development of the control plans. Control Plans shall also include specific response plans when any undesirable measurement results are obtained. The response plans, in conjunction with the inspection/test frequency, shall ensure that zero suspect material leaves the contractor’s facility in the event of a nonconforming measurement. The control plans shall be treated as living documents and shall always reflect the current process. Control plans shall be revision-controlled documents and retained for the life of the contract. A master document shall be maintained to log date and description of control plan revisions, and made available upon Government request.

E.1.4 SUBCONTRACTOR QUALITY ASSURANCE PROGRAM

The contractor shall have a subcontractor quality assurance program that requires certification to ISO 9001, as a minimum, for each subcontractor. The contractor’s subcontractor quality assurance program shall ensure each subcontractor has, as a minimum, a documented quality system which includes development, implementation, and maintenance of quality procedures, work instructions, flow charts, and records for all products.

E.1.5 SUBCONTRACTOR QUALITY DOCUMENTATION

At a minimum, the prime contractor's documentation and acceptance of a subcontractor’s quality assurance system and any quality procedures, work instructions, flow charts, and records, shall be made available upon Government request. The prime contractor shall use the subcontractor’s quality system when conducting quality audits.

E.1.6 ACCESS TO SUBCONTRACTORS

The Government reserves the right to interface with, collaborate with, audit, and visit, without prior notification, all subcontractors and sub-subcontractors of the prime contractor. The contractor shall notify its subcontractors of this requirement and shall not limit its subcontractors from interfacing with the Government, collaborating with the Government, being audited by the Government, working with the Government on future design changes or improvements, or hosting Government personnel.

E.1.7 GOVERNMENT QUALITY AUDITS

The Government will monitor the contractor's performance using QA procedures established for the contractor in the Quality Assurance Program Requirements section (E.1.1) of the contract. This may involve quality audits (process audits, manufacturing audits, product audits) as required. The contractor shall provide the required documentation, product, personnel, or other resources to conduct the audits to the Government during such audits. Government audits of sub-contractors, if performed, will be conducted with the prime contractor.

E.1.8 MANUFACTURING PROCESS AUDITS

The contractor shall participate in all Government Manufacturing Process Audits (MPA). MPAs will consist of review of contractor manufacturing processes, including process layout, manufacturing documentation, material and information flow, tooling, error proofing, visual aids, and any other aspects of the process that may affect quality of the finished product. MPAs will be conducted quarterly as a single day event. The contractor shall enter all findings and issues documented during MPAs into the Total Enterprise Management System (TEAMS) Corrective and Preventative Action (CAPA) module for tracking to completion. The contractor shall correct all findings and issues and submit the corrective actions to the Government for acceptance IAW the requirements of E.12.

E.1.9 QUALITY MANAGEMENT SYSTEM AUDITS

The contractor shall support all Government Quality Management System Audits (QMSAs). QMSAs will consist of review of contractor processes as contained in the contractor’s QMS. Such audits may involve accompanying the contractor to a sub-subcontractor location to conduct audit activities.

E.2 FIRST ARTICLE TESTING REQUIREMENTS

E.2.1 FIRST ARTICLE APPROVAL REQUIREMENT

The first article approval requirements under this contract consist of successful completion of the following items:

a. All parts in production have achieved Production Part Approval Process (PPAP) approval IAW E.16.1 and E.16.1.1.

b. First Production Vehicle Inspection (FPVI) (reference Section E.2.1.3) has been approved by the Government.

c. Performance Testing (reference Section C.2.4.2.1), Reliability Qualification Testing (reference C.2.4.2.2), and Live Fire Test and Evaluation (reference C.2.4.2.4) are complete and all failures have been corrected.

d. The Manufacturing Readiness Assessment (reference C.1.3.6) has been approved by the Government and the contractor’s proposed production process (reference E.38) has been fully implemented.

E.2.1.1 FIRST ARTICLE TEST APPROVAL

First Article Test (FAT) approval will be conducted in accordance with FAR 52.209-3 First Article Approval – Contractor Testing Alternate II and FAR 52.209-4 First Article Approval – Government Testing Alternate II and additional requirements defined in Sections C and E. All vehicles, trailers, and kits produced prior to FAT Approval shall be retrofitted to resolve all failures (E.5.1) and deficiencies (E.5.2) discovered during the FAT activities specified in E.2.1 within 6 months of receipt of FAT Approval at no additional cost to the Government.

E.2.1.1.1. CHANGES AFTER FIRST ARTICLE TEST APPROVAL

In the event that the contractor proposes design or production process changes which the Government, at its sole discretion, determines will invalidate previously completed First Article Approval requirements (see E.2.1), the Government reserves the right to require the contractor to successfully complete those requirements again, up to and including the full set of FAT approval requirements as specified in E.2.1, at no additional cost to the Government. Any corrective actions which correct issues, failures, or deficiencies found during the completion of those activities shall be retrofitted into all products built after the proposed changes are effective at no additional cost to the Government.

E.2.1.2 COMPONENT FIRST ARTICLE TESTING (SEE ALSO SECTIONS ON Production Part Approval Process (PPAP) E.16.1 and E.16.1.1) Component First Article Testing (CFAT) shall be required for components from the list below that are critical to operation of the vehicle, kit or trailer. The Government reserves the right to be present at any test event. The contractor shall notify the Government at a minimum of 20 days prior to conducting a test at the PM-IPT and PMR. Failure to notify the Government within the time limit may, at the Governments discretion, be grounds to reject the test. Where a system is referenced, the contractor shall conduct the test on all major parts at the component part level; for example, Steering System requires component level testing of the steering pump, steering gear, steering column, steering wheel, steering shaft, steering assist cylinder, and damper shock, as a minimum. CFATs shall evaluate performance, durability, and environmental tests as applicable. CFAT requirements shall be specified on the component drawing in the JLTV FoV Technical Data Package and Computer Software Package (JLTV FoV TDP and CSP). Component First Article test shall be completed on items manufactured by the final production process. The contractor shall successfully complete all CFATs and shall submit to the Government in accordance with E.16.1.1. The contractor shall also notify the Government of components that require CFAT based on the requirements herein.

CFAT shall be performed on the items specified in the list below.

(1) Engine

(2) Transmission

(3) Transfer Case

(4) Alternators/Generators

(5) Steering System

(6) Vehicular Frame

(7) Cargo Bed

(8) Hydraulics

(9) Air, Hydraulic Oil, and Fuel Tanks/Reservoirs

(10) Fire Suppression System

(11) Propeller Shaft

(12) Powertrain Cooling System

(13) HVAC System

(14) Brake System

(15) Pressure Release Valve(s)

(16) Wheels

(17) Electronic Control Modules

(18) Electrical Wiring System

(19) Control Stations/Instrument Panel/Gauges

(20) Suspension System

(21) Tires

(22) Starter

(23) Air Cleaner

(24) Cab

(25) Winches

(26) Transparent Armor

(27) Opaque Armor

(28) Transportability provisions

(29) Personnel Safety Systems (including but not limited to Seats, Seatbelts/Restraints, and Energy Absorbing Devices)

E.2.1.2.1 NUMBER OF COMPONENTS REQUIRED

The contractor shall perform CFAT testing on a minimum of two component units for the items specified in E.2.1.2. All testing shall be performed on the two component units. If a test results in degradation or damage to a test component while successfully completing a specified CFAT test (i.e. reduced life, performance, destructive testing, etc.) and additional CFAT tests are required, additional component units shall be tested to complete all specified CFAT tests with a minimum of two component samples for each test.

E.2.1.2.2 COMPONENT FIRST ARTICLE TEST FAILURE

If a component fails the specified CFAT requirements, the contractor shall notify the Government within 7 days of the failure, establish containment, investigate root cause, implement corrective action, repeat the CFAT with the revised component or test criteria (if applicable), and achieve Government approval prior to incorporation of parts onto the assembly line (vehicles, trailers, and kits). All costs shall be borne by the contractor, including any and all costs for additional tests following failure and corrective action to hardware built with parts from all failed lots going back to the start of production for that component. Root cause and corrective action activities shall meet the requirements of section E.12.

E.2.1.2.3 MANUFACTURE

The Component First Article units offered for test(s) shall be manufactured at the facilities in which that item(s) is to be produced and shall be manufactured using the final production process and production released tooling. The contractor shall certify to this requirement within the applicable PPAP document. In the event CFAT reveals deviations from contract requirements, the contractor shall, at the location designated by the Government, make the required changes to the items, or replace all the items manufactured under this contract, at no change in contract price, within 3 months of failure.

E.2.1.2.4 CFAT SAMPLES

The Component First Article samples shall be taken from within the first 10 component units produced for this contract unless otherwise approved by the Government. In the event that the first 10 component units are not available, the Government reserves the right to select the CFAT quantity from any lot.

E.2.1.2.5 SUBCOMPONENT FIRST ARTICLE CONDITIONS

Subcomponent FAT requirements may be met during the performance of the FAT of a higher assembly, only if the required characteristics can be tested. If any characteristic of the subcomponent is not or cannot be tested during the higher assembly testing (as determined solely by the Government), the subcomponent shall be tested separately. If tested separately, all conditions listed above shall apply to the subcomponent first article test.

E.2.1.2.6 APPLICABILITY OF PREVIOUSLY APPROVED CFATs The contractor may be permitted to utilize previously completed and Government-approved CFAT test data to meet the CFAT documentation requirement for PPAP provided all of the following conditions are met:

a. The component is identical to that which has been utilized for a previous JLTV production contract.

b. The contractor/subcontractor for the component has not changed.

c. The contractor/subcontractor has experienced no production break longer than 12 months for the component.

d. The contractor/subcontractor has not changed design (drawing revision, ECP change, etc.), production process, or manufacturing site, as identified in Table 3.1 of the Fourth Edition of the Automotive Industry Action Group (AIAG) Production Part Approval Process (PPAP) manual since the last successful CFAT test for that component.

The Government reserves the right to require retesting of any component with a CFAT requirement at no additional cost to the Government.

E.2.1.3 FIRST PRODUCTION VEHICLE INSPECTION

E.2.1.3.1 FPVI NOTIFICATION

The contractor shall send written notification to the Administrative Contracting Officer (ACO) and Contracting Officer Representative (COR) at least 14 calendar days prior to the start of the FPVI. The written notification shall include the location, date, and time of the FPVI.

E.2.1.3.2 FIRST PRODUCTION VEHICLE INSPECTION.

The Government will inspect two vehicles of each JLTV mission package configuration (one vehicle with B-Kit installed and one without B-Kit installed) to complete FPVI. The contractor shall present the eight (8) FPVI vehicles one month prior to the first vehicle contractual delivery date, and shall submit the first trailer produced for FPVI one month prior to its contractually required delivery date. The contractor shall inspect and road test each item selected at the place of manufacture. The Government reserves the right to witness and/or participate in the contractor's inspections and road tests, to include driving the vehicles during the FPVI event. During FPVI, the vehicles will be audited against the requirements identified in Attachment 0111 – First Production Vehicle Inspection (FPVI). In addition to the requirements identified therein, the contractor shall demonstrate that its proposed technology enhancements are installed and functioning properly on the FPVI test vehicles. Also, the contractor shall demonstrate that the technology enhancements meet the applicable JLTV Purchase Description (PD) requirements. Required performance for each identified PD requirement (including those in Attachment 0111 - FPVI as well as any requirements related to its technology enhancements) is specified in Attachment 0101 - JLTV Purchase Description (JLTV PD). The Government reserves the right to defer testing to a Government test facility if the performance requirement(s) cannot be demonstrated at the contractor facility. At the time of the FPVI the contractor shall make available to the Government representative(s) all the reports of prior inspections, tests, vendor quality requirements, Qualified Product List (QPL) documentation, drawings, material and component certifications. (CDRL E004, FPVI Report)

E.2.1.3.3 FPVI FAILURE

If the FPVI vehicles are disapproved by the Government, the contractor may be required, at the discretion of the Government, to repeat any or all of the FPVI at no additional cost to the Government. After notification of the required additional inspections, the contractor shall make any necessary changes, modifications, or repairs to the first production vehicle and any subsequent (and prior) vehicles at no additional cost to the Government. The Government has the discretion to select other production vehicles and trailers for FPVI in lieu of the original first production vehicles. Upon completion of additional FPVI inspections, the contractor shall again submit the FPVI report (CDRL E004, FPVI Report). The contractor shall bear the responsibility of delays resulting from additional inspections. All discrepancies found during FPVI shall be investigated and corrected in accordance with the requirements of E.12 on all vehicles produced before and after the FPVI, to include the FPVI vehicles.

E.2.1.3.4 INSPECTIONS PRIOR TO FPVI

During fabrication of the first production vehicle(s) of each variant type, the contractor shall conduct in-process inspections to determine conformance of materials and workmanship to specified requirements. These inspections shall be performed at the contractor's or subcontractors facilities, prior to the application of primer and paint. Processing and welding procedures, quality system, inspection records, calibration procedures, non-destructive test procedures, material certification, and welder certifications will be reviewed as a minimum and evaluated during the in-process inspection.

E.2.1.3.5 FPVI SELECTION

The Government will select the eight FPVI vehicles from the first production lot.

E.2.1.3.6 FPVI REPORT

The first production vehicle shall be inspected and documented by the contractor. The contractor shall record the actual results of these activities using contractor format and shall include, as a minimum, the inspections located in the approved Final Inspection Record (FIR) and the results of the testing performed in accordance with Attachment 0111 - FPVI. The contractor shall prepare and deliver an FPVI report upon completion of FPVI which documents the inspection records, vehicle performance, and all material and component certifications (CDRL E004, FPVI Report).

E.2.1.3.7 FPVI APPROVAL

The Government will withhold final FPVI approval until a determination has been made regarding conformity of the vehicle to contractual requirements, including but not limited to workmanship and materials.

E.2.1.3.8 FPVI RE-INSPECTION

Any defect discovered during the FPVI process shall be repaired, inspected, and certified by the contractor prior to presenting the vehicle to the government for re-inspection and approval. As a minimum, the FPVI shall have blocks for the contractor's inspector's initials indicating that each characteristic or function was inspected and either accepted or rejected, and another block for re-inspection and acceptance of any rejected characteristic or function. Final review and acceptability shall be indicated by a signature block containing the full name, title of the company official rendering approval, and the date of approval, and shall be provided at the start of the FPVI re-inspection event.

E.3 QUALITY CONFORMANCE INSPECTION (QCI)

E.3.1 ONE HUNDRED PERCENT (100%) FINAL INSPECTION

Each vehicle produced shall be subjected to a complete final inspection by the contractor, as described in this paragraph and all of its subsections, utilizing a contractor-proposed, Government- approved Final Inspection Record (FIR) (reference CDRL E008, Production Process and Acceptance Documents), prior to presentation to the Government for acceptance. Verification and inspection of torque, dimensions, routings of hoses and electrical harnesses, and characteristics that are masked by subsequent assembly operations shall be accomplished during in-process assembly and inspection operation. In-process defect prevention techniques shall be implemented to prevent the occurrence of defects during FIR activities. A complete copy of all in-process inspection records, the manufacturing Bill of Material, and FIR shall be submitted to the Government with each vehicle offered for acceptance and uploaded to the TEAMS database record for each vehicle presented. The contractor shall inspect each vehicle for the characteristics/defects listed in E.3.1.4, E.3.1.5, and the FIR. If a characteristic is found defective (whether minor or major, as defined at paragraphs E.3.1.5 and E.3.1.4, respectively), the contractor shall provide corrective action and perform re-inspection prior to offering the vehicle to the Government for final acceptance. The contractor shall also conduct functional/operational checks on all systems identified in E.3.1.6. All vehicles, trailers, and kits delivered under this contract must meet all requirements specified within the JLTV Technical Data Package and Computer Software Package, or will otherwise be viewed as nonconforming product. The requirements specified in this paragraph and the subparagraphs herein apply to all vehicles regardless of whether Final Inspection by Sampling (section E.3.2) has been implemented or not.

E.3.1.1 DYNAMOMETER TEST

Each vehicle shall be operated on a roller-type dynamometer fixture for a minimum 3 miles and checked for proper operation of the transmission and transfer case. All transmission and transfer case selections/configurations shall be demonstrated during the track test defined below. The vehicle shall be run from a stop through maximum governed speed. The vehicle shall be checked for reverse operation. Before, during, and after the dynamometer test, all vehicle equipped instrumentation shall be monitored for proper operations and readings. Upon completion, a printout from the dynamometer which displays the as-tested and recorded values from the test shall be provided with each vehicle upon presentation to the Government. The vehicle shall be stopped and engine idled for not less than 2 minutes after vehicle roller run. While idling, the vehicle shall be subjected to a walk-around inspection. Transmission, engine oil, radiator fluid, power steering fluid and hydraulic brake fluid levels shall be checked and adjusted if necessary before track test.

E.3.1.2 TRACK AND ROUTE (T/R) TEST

Subsequent to examinations and corrections of deficiencies found during Dynamometer Test (section E.3.1.1), each vehicle shall be operated for a minimum of 12 miles on a relatively level, hard surfaced test T/R. The test T/R shall be capable of allowing the test vehicles to operate at a minimum of 70 mph. During the T/R test, the contractor shall verify that the vehicle successfully shifts through all forward transmission shift points. The T/R test shall also include speeds up to maximum governed speed. As an option, operation at maximum governed speed may be performed and demonstrated during the dynamometer test. The vehicle shall be operated to verify that the transmission transfer case operates properly. The vehicle shall also be driven in reverse for a distance of not less than 50 feet. At the completion of accumulated miles, the vehicle shall be stopped and the engine allowed to idle for not less than 5 minutes. At this time a contractor performed walk-around inspection shall be performed.

E.3.1.3 EXAMINATION OR TEST FAILURE

If any vehicle fails to pass any examinations or tests specified in the contract, the Government may withhold acceptance until the contractor provides evidence that corrective action has been made.

E.3.1.4 MAJOR DEFECTS

Any defects which could impact safety, or that will likely result in decreased vehicle performance, mission failure, or reduced operational capability, renders the vehicle non-mission capable, or results in a loss of function to any major component or sub-system (i.e. engine, transmission, steering, hydraulics, brakes, HVAC, etc.), are considered major defects. For the purposes of inspection of major defects, the following definitions of leaks apply: Class I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops; Class II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being inspected; Class III - Leakage of fluid great enough to form drops that fall from the item being inspected. Examples of major defects include, but are not limited to, the following:

(a) Steering mechanism: malfunction, unusual noise, malfunction of pump, gear or other major component resulting in loss or degradation of steering function, or condition that could result in same (i.e. loose pitman arm), Class III leak. Assessed by visual/functional inspections.

(b) Engine: malfunction resulting in loss of power, stalling, failure to start, or Class III leak, loss of oil or fuel pressure, improper installation, loose or missing engine mounting hardware, unusual noise. Assessed by visual and functional inspections.

(c) Transmission: malfunction, unusual noise, improper shifting, Class III leak. Assessed by visual and functional inspections.

(d) Drivetrain: Transfer case assembly, differentials, propeller shafts, half-shafts, wheel ends: malfunction, improper clearance, Class III fluid leaks, improper installation. Assessed by visual/functional inspections.

(e) Cooling system and component(s): (i.e. radiator, surge tank, water pump): malfunction, Class III fluid leaks vehicle overheating. Assessed by visual/functional inspections.

(f) Vehicle Electrical Charging System and components: malfunction, voltage not within +/- 10% of nominal, improper installation of components, improper routing. Assessed by visual/functional inspections.

(g) Service, parking brakes: malfunction, inability to hold vehicle on required slopes, unusual noise, pulling greater than 24 inches to one-side, air leaks exceeding system pressure drop of 3 psi/min with engine stopped (if applicable), Class I, II, or III brake fluid leaks (if applicable), failure to properly burnish. Assessed by visual/functional inspections.

(h) Tires: damage, improper assembly. Assessed by visual inspection.

(i) Fuel tanks and system: welding defects, leakage (Class I, II or III), cracked tank mounting brackets, improper sealing, cracked fuel/water separator, cleanliness (water in the fuel/water separator is acceptable). Assessed by visual/functional inspections.

(j) Exhaust system: damage, exhaust leaks that could result in unsafe condition, excessive noise, and improper installation. Assessed by visual/functional inspections.

(k) Suspension system: malfunction, improper installation. Assessed by visual/functional inspections.

(l) Winch and wire or synthetic rope: malfunction, improper size, damage. Assessed by visual/functional inspections.

(m) Instrumentation/gauges/switches/displays: malfunction, location, functional damage. Assessed by visual/functional inspections.

(n) Weld defects: Defects in structural or ballistic welds. Assessed by visual/weld gauge inspections.

(o) HVAC system: malfunction of heater or A/C unit (if installed). Assessed by visual/functional inspections.

(p) Cab structures and B-Kit Armor fit-up. Assessed by visual/functional inspections.

(q) Missing parts.

(r) Seats and seat belts: malfunction, improper mounting/installation, damage. Assessed by visual/functional inspections.

(s) All other defects not specifically listed, but which fall into the major category, based on the definition of a major defect as described above. Assessed by visual/functional inspections.

(t) Transparent Armor: damage or any delamination. Assessed by visual inspections.

(q) Paint application defects: stage 2 or stage 3 corrosion. Assessed by visual/functional inspections.

E.3.1.5 MINOR DEFECTS

Any defects which may result in an inconvenience to the operator or crew, require maintenance or repair at the next convenient stop in operations, are cosmetic in nature but readily visible, exhibit obvious departures from normal and accepted manufacturing practices (example: chaffing, loose or missing hardware, easily visible paint defects on class A surfaces, etc.), but which would not likely result in an immediate concern for safety, mission failure, diminished vehicle capability or operational readiness or require immediate maintenance for continued vehicle operation, should be considered minor defects. For the purposes of inspection of minor defects, the following definitions of leaks apply: Class I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops; Class II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being inspected; Class III - Leakage of fluid great enough to form drops that fall from the item being inspected. Examples of minor defects include, but are not limited to, the following:

(a) Fluids: low or improper fill. Assessed by visual inspections.

(b) Lubricants: Component damage from improper lubrication, or insufficient or no lubrication present. Assessed by visual inspection.

(c) Controls/handles/knobs: malfunction, improperly adjusted, loose, missing, or damaged. Assessed by visual/functional inspections.

(d) Steering system: components not falling within the major category: hoses misrouted, loose hardware, class II leaks, chaffing. Assessed by visual/functional inspections.

(e) Central Tire Inflation System (CTIS): malfunction, improper installation, leaks. Assessed by visual/functional inspections.

(f) Pulleys and fans: misalignment, improper clearance. Assessed by visual inspections.

(g) Engine components and subsystems that fall within the minor defect category: loose hardware, improperly installation, class II leaks, misalignment, improper clearance. Assessed by visual/functional inspections.

(h) Transmission and related components: brackets, hoses, tubes that require adjustment, class II leaks, dipstick or sampling valve issues, loose bolts. Assessed by visual/functional inspections.

(i) Coolant system components not falling into the major defect category: improper coolant mixture, hoses, lines need adjusting, chaffing. Assessed by visual inspections.

(j) Lubrication System Components (engine): Damage, Class 2 fluid leaks, cleanliness. Assessed by visual/functional inspections.

(k) Drive train: Issues falling within the minor defect category, inoperative grease fittings, class II differential leaks, vent hoses misrouted/kinked. Assessed by visual inspections.

(l) Body, doors, access covers, tie-downs, lifting points: improper fit, defective welds, inadequate sealing. Assessed by visual/functional inspections.

(m) Paint application defects: improper color, improperly applied camouflage pattern, coverage, cosmetic defects, stage 1 corrosion. Assessed by visual/functional inspections.

(n) Lube fittings: defective, missing, improperly installed. Assessed by visual/functional inspections.

(o) Bolts/nuts/washers/keepers/or other non-critical miscellaneous hardware: defective, loose, missing or damaged. Assessed by visual/functional (i.e. torque wrench) inspections.

(p) Cushions/Seats and Belts: improper fit, tears, mold or mildew, rot, discoloration or fading. Assessed by visual/functional inspections.

(q) Decals, marking, data and instruction plates: incomplete or incorrect data, missing, improper location or size. Assessed by visual/functional inspections.

(r) Batteries/Battery Cover/Battery Tray: malfunction, cracks, improper installation, operation. Assessed by visual/functional inspections.

(s) Radio Brackets/Connectors: improper installation. Assessed by visual/functional inspections.

(t) Lights: improper installation, cracked lenses, moisture evidence in the light housing, malfunction. Assessed by visual/functional inspections.

(u) Air compressor/pneumatics: improper installation, malfunction, low pressure, and leaks. Assessed by visual/functional inspections.

(v) Windows: improper installation, leaks. Assessed by visual/functional inspections.

(w) Vehicle Lifting and Tie-down devices: improper fit, loose hardware. Assessed by visual inspections.

(x) Parking Brake: minor air leaks (if applicable) not affecting vehicle braking and can be corrected with minimal effort (i.e. tightening a fitting), hose routing, chaffing. Assessed by visual/functional inspections.

(y) Windshield Wiper System: Inoperative, wiper arms, wiper blades, wiper arm parking location (to be within 5 degrees of normal parking location). Assessed by visual/functional inspections.

(z) ABS system, minor: ABS indicator light illuminated, malfunction correctable by adjusting or resetting wheel sensor, connector, or clearing history codes. Assessed by visual/functional inspections.

(aa) Wire or tubing: defective, improper assembly or installation, improper protection, kinks, improper identification. Assessed by visual inspections.

(bb) Weld Defects (Minor): Defects on non-structural or ballistic welds, as well as weld quality defects such as weld spatter. Assessed by visual/weld gauge inspections

(cc) All other components/characteristics not listed in the minor defects section of this table, but which fall into the minor defect category based on the definition of a minor defect as described above. Assessed by visual/functional inspections.

(dd) Workmanship Defects: All workmanship deficiencies that have no effect on function, safety, interchangeability, life, vehicle performance or jeopardize mission capability but are considered departures from good workmanship. Examples of such deficiencies may include, but are not limited to, foot and or finger prints, trash or debris left over from the manufacturing process, cable wraps not trimmed, rivet stubs and or washers not removed from under the floor mats, etc. Assessed by visual inspections.

(ee) Rust Preventative: missing or improper application. Assessed by visual inspections.

E.3.1.6 FUNCTIONAL AND OPERATIONAL CHECKS

As applicable, the functional and operational tests referenced below, shall be conducted on all vehicles as a part of QCI. All tests shall be clearly identified in the FIR (reference CDRL E008, Production Process and Acceptance Documents)). In addition, any Critical Safety Item IAW ASME Y14.100 that requires a functional check prior to delivery to ensure proper operation shall also be tested as a part of QCI.

(a) Service Brake Test. Service brakes shall be tested for proper function and operation. The ABS system shall also be checked to ensure proper functionality, and that the vehicle is free from excessive pulling to the left or right more than 24" during panic braking. Tests shall be conducted on a dry, hard, approximately level, road surface that is free from loose material. Testing shall be conducted without the aid of engine or transmission retarders, if applicable.

(b) Parking Brake Test. The parking brake system shall be tested for its ability to hold the vehicle stationary. This may be accomplished by demonstration utilizing the required grade or another method submitted to the Government for review and approval as a part of the FIR.

(c) Glad Hands Test. The glad hands shall be checked for presence, location, function, and marking and shall not leak.

(d) Engine Air Induction System Check. All hoses and filters shall be checked for proper position and contamination. System intakes shall be checked for proper installation to prevent entrance of foreign matter during normal vehicle operation, including fording.

(e) Exhaust System Certification/Check. The vehicle shall be checked for proper installation of exhaust system components to preclude exhaust leaks and heat damage.

(f) Transmission Check. The automatic transmission shall be checked for proper installation and smooth operation/shifting in all gears including reverse. The transmission shall be checked for proper installation, oil leaks, and excessive heat during vehicle operation.

(g) Transfer Case Check. The transfer case shall be checked for proper operation/shifting in all gears including reverse. In addition, the transfer case shall be checked for proper installation, oil leaks, and excessive heat during vehicle operation.

(h) Transparent Armor Leak Check. The transparent armor seals shall not allow any water leakage when exposed to an evenly distributed spray of water from a supply source IAW MIL-STD-810G, Method 506.5, para 4.4.3 Procedure II for not less than 3 minutes each. If any of the seals fail to meet this requirement, the contractor and his subcontractor shall be responsible for providing corrective action to correct the fault of the deficiency. An alternative method may be used by the contractor with Government approval.

(i) Windshield Wiper and Washers Test. The windshield, windshield washer and wipers shall be checked for proper location, installation, assembly and operation of washer and wipers, to include effectiveness of wipers.

(j) HVAC Test. The HVAC system shall be tested for motor operation, flow of hot/cold air, proper installation, condition and location of hoses.

(k) Controls and Operating Mechanisms Check. The vehicle control system and illumination shall be checked for compliance with the specified standards and proper operation of the intended/designed system.

(l) Lighting System Test. The vehicle lighting system shall be checked for proper operation and installation of the lights and equipment specified.

(m) Instrument Check. All vehicle instruments and gauges shall be checked for proper function, operation, and compliance with the requirements specified.

(n) Vehicle Winch. If equipped, the winch shall be checked for proper assembly, installation, length of cable, cable type, and shall be tested by a functional check to ensure the winch and electrical systems are operating as designed. The contractor shall assure that the winch cable is properly wound, free of corrosion, bird nesting, twist, kinks and other defects caused by an improperly spooled cable.

(o) Horn Check. The vehicle horn shall be checked for proper operation and mounting.

(p) Cab Water Resistance Test. For water resistance testing, the windshields, door windows, cab seams, and door seals shall each be exposed to an evenly distributed spray of water from a supply source IAW MIL-STD-810G, Method 506.5, para 4.4.3 Procedure II (Water tightness) for not less than 3 minutes. The contractor may utilize an equivalent alternate method for the water resistance test with Government approval. Each seal shall not allow any water leakage past the seal

E.3.1.7 WELDING INSPECTION

All welds shall be visually inspected per Attachment 0159 - Welding Standards. Alternate Weld Standards may be utilized by the contractor if submitted to and approved by the Government. For the purpose of this contract, weld quality and workmanship shall be verified by qualified inspectors trained to perform the specific functions they are assigned. Acceptable training may be based on: a) current or previous certification as an AWS Certified Welding Inspector, b) current or previous verification by the Canadian Welding Bureau (CWB) or c) an Engineer or technician by formal training or experience, or both, in metals fabrication, inspection and testing, who is competent in the use of weld inspection techniques and equipment. Welds will be checked, at a minimum, prior to and at the completion of testing. Welds not easily viewed in the completed product may be inspected prior to or during the assembly process.

E.3.2 FINAL GOVERNMENT INSPECTION OF PRODUCTION VEHICLES BY SAMPLING

The Government reserves the right to conduct final Government inspection of vehicles on a sampling basis. Should the Government elect to begin inspection by sampling, the requirements of this section will apply.

E.3.2.1 SAMPLING INSPECTION FAILURES

If any vehicle in a production lot fails to pass any inspection as a result of conditions specified in E.3.1.4, E.3.1.5, or the required tests as specified in E.3.1.6, the Government reserves the right to withhold acceptance of all vehicles in the specific production lot until the contractor provides evidence of root cause, provides evidence that the defects have been corrected on all impacted vehicles in the production lot, and the Government is satisfied that the corrections are acceptable.

E.3.3 QUALITY CONFORMANCE INSPECTION FOR KITS

The contractor shall perform complete inspections on 100% of all kits (including but not limited to proper component count per the applicable bill of material, condition, and configuration) using the approved FIR. The Government, at its option, may elect to witness and/or participate in the contractor’s final inspection. The Government may also elect to have the applicable kit installed on its appropriate end item at no additional cost to the Government. The general definitions of major and minor defects found in Sections E.3.1.4 and E.3.1.5 also apply to kits where applicable.

E.4 CONTROL TEST

The contractor shall conduct control tests for maintaining control of manufacturing operations for the vehicle and for transparent armor as specified below. The Government reserves the right to be present at the control tests. For each vehicle subjected to control test, all records and findings generated during conduct of the testing/inspections shall be uploaded to the TEAMS database record for that specific vehicle.

E.4.1 VEHICLE CONTROL TEST

The contractor shall conduct vehicle control tests. The formal validation of the requirements will be performed by the Government.

E.4.1.1 FREQUENCY

The Government will select one vehicle at random for control test every two weeks of vehicle production. Additional inspections, tests, conditioning, or break-in above and beyond what is performed for every new production vehicle shall not be performed on any Control Test vehicle. The Government reserves the right to change the frequency of the control test based on program risk.

E.4.1.2 50 MILE TEST

The contractor shall conduct a 50 mile road test. The test vehicles shall be payloaded to full payload capability and operated for a distance of not less than 50 miles on the relative level, hard-surfaced test track/route. Prior to conducting the control tests, the test vehicle shall be subjected to the Quality Conformance Inspection as depicted in E.3.1. The control test shall be performed at the place of manufacture. Prior to the contractor conducting the 50-mile control test, each control test vehicle shall be inspected to ascertain conformance to the requirements as referenced in Section E.3.1.

E.4.1.3 PERFORMANCE TESTS

The contractor shall conduct the following Performance tests:

(a) Grade climbing and holding (braking) capability.

(b) Side slope capability.

(c) Maximum speed capability.

(d) CTIS performance (e.g. tire pressures, time to change modes)

(e) Winch performance measurement (if equipped)

(f) GFE functionality (if applicable)

(g) Suspension functionality (e.g. function, capability to achieve proper height, time to achieve height settings)

(h) Vehicle Weight Calculation Accuracy (conducted at the vehicle’s as-built weight and at GVWR)

Tests shall be conducted at GVWR unless a lower weight is required in the applicable JLTV Purchase Description requirement. These performance tests shall be performed to provide assurance to the Government that the vehicle, as produced, meets the performance requirements listed in Attachment 0101 - JLTV Purchase Description (JLTV PD) without additional processing, conditioning, break-in, or preparation.

E.4.1.4 CONTROL TEST FAILURE

If the vehicle selected fails to pass any of the control test requirements stated within this section, the Government reserves the right to stop acceptance inspection and testing on subsequent vehicles or conditionally accept and withhold a portion of the unit price from payment until such time the condition(s) causing the failure has been investigated and resolved. The investigation shall include the determination of root cause(s) and implementation of corrective action(s) in accordance with the requirements of E.12 to the satisfaction of the Government. The contractor shall present evidence of root cause and corrective action to the Government prior to initiation of the next following scheduled control test. Any major defects found during, or as a result of the control test, shall be prima facie evidence that vehicles accepted subsequent to the previously acceptable control tests were similarly defective, until the Government is furnished evidence by the contractor that they are not similarly deficient. All defects shall be corrected by the contractor at no cost to the Government. The Government may require another vehicle with corrective actions implemented to complete control test to verify that the corrective action(s) is (are) effective.

E.4.2 TRANSPARENT ARMOR PRODUCTION CONTROL TEST

Transparent Armor (TA) shall be subjected to the Production Control Test (PCT) as specified in ATPD-2352, Table V and as described in ATPD-2352, paragraphs 3.1.1.3 and 4.1.1.3 and other references included in ATPD-2352.

E.4.2.1 FREQUENCY

PCT (ballistic and non-ballistic) shall be conducted every three months or 2,000 production parts, whichever comes first. Multiple part numbers of the same design recipe (composition, manufacturing processes, and assembly processes), neglecting the presence of de-icing elements, with different lateral dimensions shall only conduct a PCT on one part number. The Government reserves the right to conduct ballistic tests of production parts at any time during a production order. The contractor is responsible for correcting all failures that occur at no additional cost to the Government, up to and including retrofitting any vehicle or kit equipped with transparent armor from the same production lot that has failed PCT.

E.4.2.1.1 PCT SCHEDULE

The contractor shall provide written notice to the Contracting Officer and the Defense Contract Management Agency (DCMA) Quality Assurance Representative (QAR) 14 days prior to the date when the test samples will be tendered for inspection/selection for testing . A detailed schedule of multiple PCT dates can be given and updated as the production schedule changes. The contractor shall provide to the DCMA QAR all documentation and records necessary to establish that the tendered material to be tested was constructed in accordance with the declaration associated with the unique identifier or code (recipe number) and is traceable to the contractor’s process control specification.

E.4.2.2 LOCATION

Ballistic testing location shall be:

Request for an alternate ballistic test facility shall be sent to the Contracting Officer. All testing shall be at SABL unless written approval from the Contracting Officer is received.

E.4.2.3 DECLARATIONS

All ballistic tests shall include the Design Declaration (Recipe), manufacturing process declaration, and assembly process declaration of TA composition per ATPD-2352, sections 3.2.1.1, 3.2.1.2, and 3.2.1.3.

The design declaration shall include:

(a) An alpha-numeric code (recipe) for the transparent armor traceable to the…