PUG_SOW_for_Carter_Sole_Source_-_9_January_2017.docx

Statement of Work:

Pelvic Protection System – Protective Under Garment 9 January 2017

1.0 BACKGROUND

1.1 This Statement of Work (SOW) describes the work required to produce the Protective Under Garment (PUG), a sub-system of the Pelvic Protection System (PPS). The prevalence of IEDs during dismounted operations in Operation Enduring Freedom has caused a greater number of injuries to the lower body. These include blast injuries surrounding the groin area and affecting the colon, femoral artery, and genitalia. The US Army 10th Mountain Division issued 2011-03 Pelvic Protection Ten-Liner request from Theater seeking evaluation of a garment solution designed to provide protection to the pelvic region of dismounted troops. A Joint Urgent Operational Need (JUON CC-0457) has also been approved.

1.2 The current Improved Outer Tactical Vest (IOTV) add-on groin protector equipment currently only offers protection from frontal threats. Based on market research and a Soldier Protection Demonstration conducted by the Maneuver Battle Lab, Product Manager Soldier Protective Equipment (PM SPE) has determined that a two-tiered system provides the optimal combination of protection and user acceptance. The two tiered system consists of a Tier I PUG and Tier II Protective Outer Garment (POG).

2.0 SCOPE

This SOW sets forth the requirements to acquire PUGs for improved soldier protection of the pelvis, femoral arteries, and lower abdominal organs as a result of a blast or fragmentation event.

3.0 REQUIREMENTS

3.1 Material: PUGs shall meet all of the requirements of this SOW. The absence of any inspection requirements shall not relieve the Contractor of the responsibility of ensuring that all products and supplies, submitted to the government for acceptance, comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this does not authorize the submission of known defective material, either indicated or actual, nor does it commit the government to accept defective material. If there is a conflict between the stated requirements of the contract and the Quality Manual, the more restrictive requirement shall apply.

3.2 Design: The “next-to-skin” PUG shall provide the Soldier with femoral artery and soft tissue protection, including the genitals, perineum, anus, and inner thigh against sand, debris, and small fragmentation threats while also providing ease of movement, breathability, and comfort. The PUG shall be similar in style to male boxer briefs, including a fly front for the male version only. The female version shall incorporate standard female hip circumference in the design and both versions shall have the ability to stretch and function during athletic activity. The design shall include removable ballistic inserts which provide protection to the femoral artery region and shall not interfere with normal walking or running motion. The ballistic inserts shall be designed to fit in the pocket in a snug manner to minimize shifting and chaffing while walking and running. The pocket material shall be knit and snuggly retain inserts in place with a goal of not being ejected during a blast event (even an underfoot blast). The pocket opening shall be designed to allow for ballistic inserts to be inserted, however will not allow the inserts to fall out if turned upside down. One (1) pair of inserts shall be provided for every three (3) PUG shorts of the same size and this constitutes one PUG set (unless otherwise specified in the contract).

3.3 The PUG shall be constructed using breathable and durable knit fabrics meeting performance requirements in Table 1:

Table 1: PUG Material Requirements

Enhanced protection of genital region V50, 2gr RCC equal to or greater than 900 ft/s.

Removable ballistic inserts V50, 17gr Fragment Simulating Projectile (FSP) equal to or better than 1,120 ft/s.

All ballistic testing shall be conducted in accordance with MIL-STD-662F.

Shall provide a minimum 40 sq. in. of coverage for each side, in size medium and graded in accordance with commercial practices for the other sizes.

Shall have a maximum areal density of 0.40 lb/ft2 and 0.10 inch thickness.

A minimum of three (3) different insert sizes are required.

The female version will account for female hip dimensions, as specified in Table 2 of the SOW.

Ballistic insert pockets shall open toward the “centerline” of the body (as shown in Figure 1 below) approximately at the center of the insert pocket with an opening size of 3.5” +/- 0.5” in size medium and graded in accordance with commercial practices for the other sizes. Purpose is to prevent ejection during a blast event.

Able to be worn underneath the Flame Resistant Army Combat Uniform (FR ACU) and ACU trousers as well as the Army Combat Pants (ACP)/Enhanced ACP.

Ballistic fabrics will have an air permeability of at least 240 cfm/ft sq. when tested in accordance with ASTM D 737.

PUG shorts shall use fabrics that exhibit Moisture Vapor Transfer of 500g/sq. m/day when tested in accordance with ASTM E 96, procedure B (not including the ballistic inserts)

The weight for all other sizes shall be proportional to proper grading of patterns.

· Testing will be done in accordance with AATCC 100 with Staphylococcus aureus and Pseudomonas aeruginosa, using the attached Revised Natick TM100 Clarification dated 26 OCT 12.

· Laundering shall be in accordance with AATCC 135, 1, IV, Aiii.

The minimum PUG antimicrobial requirement is only for the innermost layer of the PUG (“next to skin”). Additional layers of the PUG may be antimicrobial treated but this is not a requirement. The waistband or ballistic inserts do not require antimicrobial treatment.

Figure 1. PUG – General insert pocket opening locations (for reference/general guidance only)

3.4 Sizing: Delivery of the identified quantities shall be made in accordance with the sizing distributions set forth in Table 2 below. Sizing shall be determined in accordance with best industry practices and fit the 5th – 95th percentile requirement for male and female using a nominal size system (XS-XXXL).

Table 2: PUG Male and Female Sizing

3.5 Workmanship: The finished PUG shall conform to the quality requirements established by this SOW. The Contractor shall verify and validate that all fabrication procedures will yield quality workmanship to meet product specification and contract requirements. All materials to be used in the construction shall consist of quality levels to assure conformance to all requirements, unless otherwise authorized. All workmanship shall be conducted to eliminate and avoid human induced defects. Manufacturing practices shall be capable of consistently yielding product that conforms to all requirements in this purchase description and internal specifications for the product and their components. All component materials shall be properly marked and identified, and protected during storage. Materials shall be produced and integrated to extend durability and provide consistency of appearance throughout life of the product. The Contractor shall ensure that the finished product, all subcomponents and parts are free of foreign objects, scaling, burrs, frayed edges, material tears, torn edges, stains, holes and other imperfections when visually examined. This section is applicable to all material or components of the product whether furnished by the Prime Contractor or by any of their suppliers or subcontractors. In any case, of material, process, or equipment change desired to be made by the Contractor, the written consent of the Government shall be obtained before making the change.

3.5.1 Stitching:

3.5.1.1 Stitching shall conform to ASTM D-6193, with primary construction seams (side, seat, crotch, back/front) being either 4 needle 606or 607 with cover flat lock or 3 needle 604 or 605 without cover types or similar stitching types. Elastic attachments can be 3 needle flat-lock, 2 needle 401 or 2 needle 602 or 603 without cover. Secondary construction such as leg hems or front opening fly hem shall be 2 needle 402 or 602 types or similar stitching types. All stitching shall be flat on both sides of garment offering no protrusion, which is a potential area of chafing.

3.5.1.2 End of seams and stitches that are not caught in other seams or stitching shall be securely back tacked or back stitched. Thread breaks or bobbin run-outs occurring during sewing shall be secured by stitching back of the break minimum of ½ inch. Thread tension shall be maintained so that there will be no loose stitching, resulting in loose bobbin or top thread, or excessively high stitching resulting in puckering of the materials sewn. Thread ends shall be trimmed to a length of not more than ¼ inch.

3.5.2 Seams:

3.5.2.1 Seamed stitches in needle /looper and cover threads shall be machine tensioned to allow for finished seam stretch properties to be maximized without restricting the base fabric stretch/recovery properties. Seams shall not exhibit signs of cracking or breakage, if hand pulled to maximum degree. Seam strength should match the overall fabric strength to the best possible degree

3.5.2.2 Any seam or attachment of any component which is twisted, puckered, pleated or caught in any unrelated operation or stitching, that is not properly forced out or contained in a fold, shall be classified and scored as a defect and rejected. Puckering is evidence of a failure to control stitching tension which results in tight tension. When puckering is evident, seams shall be tested by exerting and pulling in a lengthwise direction of the seam or stitching. Puckering due to the gathering of the material shall be classified and scored as a seaming defect and rejected. Failure of a seam to straighten or an occurrence of thread breakage shall be evidence of tight tension. A tight tension garment shall be deemed of poor quality and rejected. Loose tension (more than 1 inch) is evidence of a failure to control stitching tension resulting in a loose tension garment. A loose tension garment shall be deemed of poor quality and rejected.

3.5.2.3 Seam Allowance: All 2, 3 and 4 needle type seam operations shall be constructed such that the needle, looper and cover threads cover all raw edges and offer maximum strength with no open, puckered, twisted or distorted seam appearance.

3.5.3 Thread: Sewing thread should be of correct TEX size as to provide sufficient overall strength and prevent cracking and/or breakage when stretched to maximum degree. Stretch type threads are encouraged for use to assist in achieving maximum stretch quality. Thread selection shall not create needle cutting or exhibit condition that thread will slice through base fabric.

3.5.4 Waistband:

3.5.4.1 Use of knitted elastic or woven texturized nylon or polyester yarns for the waistband ranging from 1 to 1 ½ inches width shall be sewn such that the elastic interfaces in a smooth flat manner to body of the PUG. Stitching shall be adjusted to prevent seam cracking /breakage when pulled to maximum degree. Back center seam attaching sides of elastic ends shall be smooth and flat with no protruding stitches. Elastic shall be heat resistant to laundering/drying and be capable of enduring long term storage in hot conditions. Waistband shall be resistant to needle cutting in order to prevent elastic ends from protruding along back center seam during wearing and laundering.

3.5.4.2 Tunnel type waistbands are disallowed. Any tunnel-type waistband, to include, but not limited to, covered elastic waistbands and drawstring waistbands, or any type of waistband that places gathered fabric (ruching) next to the wearer's skin is not allowed as these types of construction may cause discomfort to the wearer, especially when worn under clothing items and/or military gear. A tunnel-type waistband is defined as any type of elastic or drawstring partially or fully encased in fabric. The elastic or drawstring could be free-floating or the elastic could be stitched through all plies with one or several rows of stitching. The elastic may or may not be exposed to some degree if stitched in the aforementioned manner. The tunnel, or casing, need not be open internally for the full circumference of the waistband as would be required for a drawstring waistband in order to be considered a tunnel-type waistband.

3.5.5 Fly: Fly opening stitching shall be flat and smooth with no protrusions or obstructions and be capable of recovering from opening upon use.

3.5.6 Leg Hems: All leg hems shall be constructed as to offer a maximum degree of stretch that will not crack or break the stitch line upon stretching and recover to original shape. Tunnel type elastic constructions ranging from ½ to 1” width are allowed.

3.5.7 Ballistic pocket/panel: Ballistic pocket attachments shall not restrict or interfere with overall stretch of PUG. Attachments include 2 needle 402, 602 or Zigzag types 304, 308 or similar stitching types.

3.5.8 Bartacks: ⅜ - ½ inch bartacks at 24 - 32 total stitches shall be placed at all critical places such as top/ bottom of fly opening, ballistic panel pocket flaps or other high stress areas.

3.5.9 Labels: Care labels shall be in accordance with Federal Trade Commission labeling regulations. The size label shall include the nominal size (i.e. small, medium, etc.) and in parenthesis the waist measurement in inches. In addition, each PUG shall also have a hang tag stating the following: “Discoloration of this product when exposed to light is normal and has no effect on its ballistic protection performance.”

4.0 DELIVERY AND PERFORMANCE

4.1 Lot Acceptance Testing: Each production lot shall be subject to Lot Acceptance Testing (LAT). For each lot delivered eighteen (18) representative shootpacks shall be constructed, six for each ballistic protection level, as described in paragraph 4.2 below, using the same materials used to produce the lot. Failure to meet the ballistic requirements shall result in rejection of the lot. All test articles shall be delivered to Aberdeen Test Center (ATC) (Section 9.0).

4.2 Shootpack construction: A “shootpack” shall consist of a 15”x15” panel consisting of the proposed ballistic material, in the same configuration as the material used to construct the ballistic protection area. The panel shall be stitched diagonally across the four (4) corners with a five (5) inch line of thread at five (5) to ten (10) stitches per inch, and the panel shall be edge stitched approximately 1/8” from each edge to prevent raveling. A seam allowance of 3/8” is permitted in order to yield an overall dimension of 15”x15”. If the ballistic filler is an asymmetric system of different materials, the filler packet will be marked to clearly indicate the strike face from the back face. All shootpacks shall have a frame attached to secure shootpack material and to aid in securing the shootpack during testing.

4.3 Shootpack Construction Testing: The Government expects testing and approval to take approximately forty five (45) days from the date of delivery of LAT items received by ATC.

5.0 SAFETY

The Contractor shall certify that the safety inherent in the design and fabrication of the garment provided for FAT is achieved in accordance with Federal and Industry standards and regulations. The Contractor shall implement a System Safety Program that applies to the applicable safety design requirements and management controls. The Contractor shall develop and maintain documents that demonstrate early hazard identification, evaluation, and elimination or control to preclude injury or death to user/operators or maintainers of the PUG. All Material/Product Safety Data Sheets shall be included in the Production Process Plan (PPP). All safety documents shall be made available to the government for review and or audit.

6.0 SECURITY REQUIREMENTS

6.1 The contractor shall be responsible for safeguarding all government property for contractor use.

6.2 Neither the Contractor nor any of its subcontractor providers shall disclose or cause to disseminate any information concerning operations of military activities and or sensitive performance requirement. Such action(s) could result in violation of the contract and possible legal actions.

6.3 All inquiries, comments or complaints arising from any matter observed, experienced, or learned of as a result of or in connection with the performance of this contract, the resolution of which may require the dissemination of official information, shall be directed to the Contracting Officer Representative (COR) and the Contracting Officer (KO).

6.4 The Contractor shall only conduct business with designated government personnel listed as Points of Contact (POC). Names of authorized personnel shall be provided to the Contractor by the Government, in writing, and updated as necessary throughout the contract period.

6.5 U.S. Government records, copies of original results and reports, verified original data, corrected data, and corrected supporting final reports are maintained by the Contractor, but remain the property of the U.S. Government. These files and results must be surrendered to the COR when requested.

6.6 Awareness Training (AT) / Operations Security (OPSEC)

6.6.1 All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete AT Level I awareness training within forty-five (45) days after contract start date or effective date of incorporation of this requirement into the contract, whichever applies. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee to the COR/ATO (or to the contracting officer, if a COR is not assigned) within sixty (60) calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at https://atlevel1.dtic.mil/at.

6.6.2 The contractor and all associated subcontractors’ employees shall comply with applicable installation, facility, and area commander installation and facility access and local security policies and procedures (provided by the Government representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by the installation Provost Marshal Office, Director of Emergency Services, or Security Office. The contractor workforce must comply with all personal identity verification requirements as directed by DoD, HQDA, and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

6.6.3 The contractor and all associated subcontractors shall brief all employees on the local iWATCH program (training standards provided by the requiring activity ATO). This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the COR/ATO. This training shall be completed within forty-five (45) calendar days of contract award and within forty-five (45) calendar days of new employees’ commencing performance, with the results reported to the COR/ATO no later than sixty (60) calendar days after contract award.

6.6.4 The contractor will implement an employee verification process, whether through background checks or other similar processes and provide a written response explaining how the verification process was completed and attest to the trustworthiness of the workforce, within forty-five (45) days of contract award.

7.0 CONTRACTING OFFICER REPRESENTATIVE

The COR monitors all technical aspects of the contract and assists in contract administration. A letter of designation issued to the COR, a copy of which is sent to the Contractor, states the responsibilities and limitations of the COR, especially with regard to changes in cost or price, estimates or changes in delivery dates. The COR is not authorized to change any of the terms and conditions of the resulting contract.

8.0 ORGANIZATIONAL CONFLICT OF INTEREST (OCI)

PM SPE may use Contractor personnel to perform work in support of this contract; these personnel will have access to or participate in the review of proprietary or source selection information (e.g., cost or pricing information, budget information or analyses, specifications or work statements) or perform evaluation services (Quality Assurance Audits) which may create a current or subsequent OCI as defined in Federal Acquisition Regulation (FAR) Subpart 9.5. The KO will affect the appropriate agreement for any verified violation of OCI.

9.0 FIRST ARTICLE TEST, PRODUCTION LOT ACCEPTANCE TESTING, AND CONFORMANCE INSPECTIONS

9.1 FAT, LAT, and conformance inspections shall be conducted per contract, SOW, and Contractor procedures. Tests, inspections, and procedures used are subject to Government review and approval. The Contractor shall provide test data, traceability to materials, and procedures that verify the outcome contained in all Certificate of Conformance (CoC). The Contractor shall produce all products in accordance with an approved FAT and PPP. The Government reserves the right to suspend or revoke production authorization for non-compliance with the contract requirements, to include but not limited to the PD, FAT and PPP.

9.2 All production quantities submitted after approval of the FAT shall be produced using the same materials, processes, procedures, equipment and facilities that resulted in the manufacture of the accepted FAT. This includes all raw materials and/or sub-components. All proposed changes to the approved PUG FAT must be reported in writing to the KO, Contracting Officer’s Representative (COR), and PM SPE for approval and determination if a new FAT is required.

9.3 Corrective Action Report (CAR). In the event of a failure, the Contractor shall conduct initial failure analysis and provide a CAR response to the KO, though the Defense Contract Management Agency (DCMA) (Quality Assurance Representative (QAR) and Administrative Contracting Officer (ACO)), and PM-SPE in accordance with Exhibit 3.

9.4 The Contractor shall include all pertinent information for failure analysis (e.g., detailed failure analysis methodology, testing, identify the root cause, corrective action plan and validation plan) to assess the effectiveness of the corrective action and proposed disposition of the failed PUG and lot, and containment actions. The Contractor shall include in the CAR documented evidence that rejected PUGs are not sold to other USA Military Services, General Services Administration (GSA) and other venues in which Soldiers/Units may buy replacements using individual or unit funds. CAR procedures and delivery timeline are outlined in Exhibit 3.

9.5 LAT will be executed on production lots under this contract, following test requirements outlined in the contract and the PUG FAT/LAT test plan. A production authorization remains in effect and acceptance may continue unless:

9.5.1 The Contractor fails any single LAT. The KO will notify DCMA that acceptance shall be withheld after a LAT failure. The Contractor shall segregate the material of the lot in question from all other production lots in process, conduct a failure analysis, and provide a CAR response to the KO, DCMA and the COR in accordance with Section J, Exhibit 5. The KO will determine within thirty (30) working days of receipt of the final CAR response if it is technically acceptable. If found to be technically unacceptable, the Contractor will be notified by the KO to resubmit the CAR response. The KO will notify the Contractor of Government acceptance of the CAR and if production under a previously approved FAT configuration may resume or if the Contractor must conduct a new FAT. If a new FAT is required, the Contractor shall submit the required samples for testing (at the Contractor’s expense), as directed by the KO. Schedule delays as a result of product failure to fully satisfy the Government's requirements, as documented in the KO's correspondence to the Contractor is the responsibility of the Contractor. Cost to retest FAT products will be borne by the Contractor.

When a lot fails LAT and is subsequently rejected, that lot is rejected in total and no component parts may be used in the production of any other lot, or any other Government contract, without written Government authorization. Failed lots shall not be delivered and products failed shall not be commingled with other lots. The Government will have the right to revoke acceptance of any and all items that may contain the same root cause failure mode, and to require the Contractor to replace all affected units at the Contractor’s expense, including transportation costs. Failures occurring during Government testing are also subject to this requirement. The Contractor shall remove all Government Labels from items within the reject lots in accordance with contract clause 52.246-9039, Removal of Government Identification from Non-Accepted Supplies.

9.5.2 The Contractor fails LAT requirements on two (2) consecutive lots. Consecutive lots are defined by production dates and not testing dates. Should this occur, the Government will withhold acceptance and may immediately cease all production (Stop Acceptance) from the Contractor. The Contractor shall segregate the lot in question from all other ongoing production lots, conduct an analysis, and submit a CAR to the KO, DCMA, and the COR after notification of failure. The CAR process will follow the same provisions outlined in the section above; see Section J, Exhibit 5 for detail submission timeline.

9.5.3 A Pattern of Negative Trending or Failure (outside of the two (2) failed consecutive lots rule stated above). This could include statistically significant shifts in performance, whether improvement or degradation. Should this occur, the Government will withhold acceptance and may immediately require the Contractor to cease all production until a validated and effective corrective action plan is developed. The Contractor shall segregate the lots in question from all other ongoing production lots, conduct an analysis, and submit a CAR to the KO, DCMA and the COR NLT ten (10) working days after notification of failure. The CAR process will follow the same provisions outlined in the section above. Schedule delays due to a pattern of negative trending or failure are the sole liability of the Contractor.

9.5.4 A Contractor Out of Production with an Approved First Article Design (for more than a period of one hundred eighty (180) consecutive days). When multiple designs have been approved over the course of the contract, each design production time-line will be considered individually. Production is defined as the complete activation of all manufacturing operations established for an approved product under contract, components and assembly; the associated processes and activities (purchasing, manufacturing, personnel) necessary for the manufacturing of a finished product. The production clocks shall run from the date on which the Contractor presents the production lot to the DCMA QAR for inspection/acceptance to the next date on which the Contractor requests to present the next production lot to the DCMA QAR for inspection/ acceptance; all production operations shall be activity during this period for consecutive lots. A Contractor not in production for an approved design under the stipulations identified above will be subject to automatic revocation of production approval; a new FAT approval shall be required and borne by the Contractor.

9.6 Additionally, when a lot fails LAT and is subsequently rejected, that lot is rejected in total and no component parts may be used in the production of any other lot, or any other Government contract. Failed lots shall not be delivered and products failed shall not be co-mingled with other lots. The Government shall have the right to revoke acceptance of any and all items that may contain the root cause failure mode, and to require the contractor to replace all affected units at the Contractor’s expense, including transportation costs. Failures occurring during Government testing are also subject to this requirement.

9.7 The Contractor is encouraged to witness all FAT and LAT events and it is the responsibility of the Contractor to be at the test events on time; testing will commence with or without Contractor witness (es). The absence of a Contractor witness does not invalidate the test/sub-test and is not grounds for challenges. Contractor challenges shall be addressed immediately to the Aberdeen Test Center Director at the time of the test/sub-test in question and within 48 hours, in writing, to the KO and the COR. The Government shall respond within ten (10) working days with a determination.

9.8 Address for PUG FAT/LAT test item submission: Test items shall be submitted, in a DD1222 format, for evaluation to the following address:

CONTACT INFORMATION

DODACC: W81C5M

U.S. Army Aberdeen Test Center Building 358 400 Colleran Road Aberdeen Proving Ground, MD 21005

410-278-8641; DSN: 298

Kelly.e.hacker.civ@mail.mil

Dave Nottleman

410-278-4584; DSN: 298

David.l.nottelman.civ@mail.mil

9.9 Once a Lot has been approved, the Lot shall be delivered to:

CONTACT INFORMATION

DODACC: W912H7

Peckham Vocational Industries Inc PM-SPIE Staging Facility 7100 Millett Highway Lansing, MI 48917

517-316-4315/4072

9.10 ACCOUNTING FOR TEST ITEMS CONSUMED AND USED IN THE CONDUCT OF QUALITY ASSURANCE LOT TESTING

Accounting for Items Consumed and Used in the Conduct of Quality Assurance Lot Testing. The contractor shall pay for the transportation and the quantities consumed, expended, and otherwise rendered unusable as a result of testing. The Government will pay for the actual testing whether conducted at Army Test Center or a third party certified testing facility. In the event of a lot failure, the contractor shall pay for any costs related to failed lots, including test items, test costs and shipping costs. Quantities consumed during the conduct of LAT will not be included as part of deliverable quantities stated in this contract.

10.0 QUALITY MANAGEMENT SYSTEM (QMS)

The Contractor shall have a QMS that follows the requirements of FAR 52.246-11, Higher-Level Contract Quality Requirement, contained in this contract. The Contractor shall establish, document, implement and maintain a QMS and continually improve its effectiveness in accordance with the requirements of ISO 9001:2008. All requirements of the contract apply to subcontractors and suppliers. The Contractor shall monitor, assess, and audit quality and reliability at all Subcontractor and Supplier facilities. The Government reserves the right to audit products and processes, as well as the quality management system, at any stage of contract performance. The Contractor shall maintain a calibration system in accordance with ANSI/NCSL Z540.3-2006 or equivalent to ensure that all test/inspection, measurement, and diagnostic equipment to include all accessories and ancillary equipment are properly calibrated, identified, labeled appropriately and traceable to national measurement standards.

11.0 QUALITY AUDITS

The Government reserves the right to audit the Contractor’s QMS for all products/processes related to the contract. These audits may be of the QMS, a particular process, or the product. These reviews and audits by the Government will not relieve the Contractor of their responsibility.

12.0 SUBCONTRACTOR MANAGEMENT

12.1 The Contractor shall ensure that all procedures and policies for managing Subcontractor and Supplier quality are documented. The Contractor shall develop and maintain a Subcontractor and Supplier Management Plan (SMP). The SMP shall be included in the proposal. The SMP shall identify processes for selecting, qualifying and managing Subcontractors and Suppliers (to include the schedule and assessment cycle for physical audits and reviews), managing product and processes, flowing applicable requirements to Subcontractors and Suppliers, assessing Subcontractor and Suppliers capabilities, verifying compliance of Subcontractors and Suppliers and establishing metrics for continuously monitoring and rating supplier performance. The SMP shall identify subassembly manufacturing or processes to be performed by any subcontractor and supplier; the Contractor shall maintain a list of qualified Subcontractor/Suppliers and their current rating. The Supplier Rating System shall be provided to the Government at the Post Award Conference and reviewed during the In-plant Audit. The SMP shall address product acceptance requirements (if not already specified in the contract or performance specification) for Suppliers and emphasis shall be placed on product verification at the Supplier level in order to identify and correct defects at the earliest point of inspection and test. The Contractor shall identify key features, characteristics and performance requirements that shall be verified at the component acceptance test level. The Contractor shall include a flow chart showing the supply chain for the product in the SMP. Subcontractors and Suppliers of all raw material, components, and assemblies shall be clearly identified on the flow chart.

12.2 The Contractor shall be responsible for work performed by their Subcontractors and Suppliers including any inspections and tests. The Contractor shall ensure that all applicable quality requirements, associated specifications, and all contractual requirements applicable to the component or materials, and spare part are conveyed contractually to their Subcontractors and Suppliers, and that compliance is verified for the ordering period of the contract. The Contractor shall allow the KO or their authorized representative(s) to enter the Contractor’s or any Subcontractor and Supplier facility for the purpose of audits, production surveillance/verification, and observation during contract performance. The Contractor shall identify all Subcontractors and Suppliers of all components or processes by names, location, contact information for key personnel, identify component for each and or working for each. The Contractor shall maintain documented evidence that the Subcontractors and Suppliers meet all criteria related to the contract materials and processes, including ISO 9001:2008 compliant QMS. The Contractor shall provide a list of proprietary and sole source materials in the appropriate section of the PPP.. The list should identify each category (proprietary versus sole source materials) including the Supplier and subcontractor name and location as well as any agreements with the Suppliers and Subcontractor to address the proprietary or sole source nature of the product under contract and contingency plans for potential short term, long term impacts and a recovery strategy that meets product requirements and contract schedule.

13.0 QUALITY MANUAL

The Contractor shall plan for achieving customer satisfaction and assure that the product meets contractual and internal requirements. The Contractor shall establish and maintain a Quality Manual that is compliant with the requirements of ISO 9001:2008 or higher Industry Standard for Quality Management System. The Contractor shall submit the Quality Manual for Government review and acceptance with their proposal package. Copies should be submitted to PM SPE Quality Assurance, the KO, and appropriate DCMA representative. The Quality Manual must include: the scope of the QMS, the documented procedures established for the QMS, and a description of the interaction between the processes of the QMS. All procedures describing the activities needed to implement the system shall be submitted in their entirety. In conjunction with the Quality Manual, the Contractor shall provide a crosswalk matrix (Technical Exhibit 4 – PM SPE Form 11) that demonstrates that their Quality Manual is compliant with and or equivalent to the requirements of ISO 9001:2008. The Quality Manual and the crosswalk matrix shall be submitted in electronic format Microsoft Word; electronic mail is the preferred method of delivery.

14.0 PRODUCTION PROCESS PACKAGE (PPP)

A PPP shall be prepared by the Contractor, reviewed by DCMA, and submitted for KO acceptance. The PPP was submitted in conjunction with the First Article build on their W91CRB-13-D-0020 PUG contract, and is required to be re-submitted ten (10) working days after contract award (based on DCMA signed date on DD1222). Copies should be submitted to PM SPE Quality Assurance, the KO, and appropriate DCMA office. The PPP will be reviewed and re-approved by the KO prior to first delivery. Government acceptance of the PPP does not relieve the Contractor from their responsibility to ensure that all production documentation, processes and procedures shall be effective, product development and realization is demonstrated and available to the Government; and that all documentation, processes and procedures shall yield an effective product that meet all product specification as stated in the contract and performance specification. The PPP is to be design specific.

· The PPP shall include detailed product information, to include at a minimum:

Section 1

1. Company name

2. Contract Number

3. Approval Authority

4. Approval Date

5. Design designation (per design)

6. Product description (per design)

Section 2 (per design)

1. Raw materials

2. Raw material suppliers

3. Identify all materials that have a shelf-life

Section 3

1. FAT component material test data and certifications (to include Berry Amendment compliance certification for all applicable materials); all test reports shall identify the Investigators/Title and approval authority for the test. All test reports submitted as part of the PPP shall, at a minimum, contain the following information: test report number, test date, the material tested, Lot number, Customer name, Customer P.O. Number, BOM (with appropriate identification number), Government Contract Number, test standard, quantity, requirement for acceptance, test performance value, pass or fail results, date report was approved, the investigator (name and signature) and test report approval authority (name, title and signature). The laboratory name, laboratory certification information and location shall be identified on all reports. The Contractor shall submit test reports for the specific product/design configuration submitted and approved by the Government; test reports shall not be older than 180 days. The contractor shall verify and validate all sizes of the design.

Section 4:

1. All work instructions shall be provided and referenced in the Process Control Plan (Exhibit 6, PM SPE Form 15).

Section 5: The PPP shall also include detailed process information, to include at a minimum:

1. Process Flow Chart (to include all steps, critical inspection points and sequence in the manufacturing process)

2. Process Control Plan, to follow steps in process flow chart, including:

a) Process/operation number and description; all critical processes shall include an explanation as to why a process is considered critical or mandatory to the manufacture of the item or part.

b) Machinery/equipment/tools

c) Product/process characteristic to be controlled

d) Specification/tolerances

e) Reference drawing/criteria

f) Evaluation/measurement method

g) Sample size and frequency

h) Control method

i) Reaction plan

j) A statement as to whether or not the process or portions thereof are considered contractor proprietary and the status of Government rights in technical data.

Section 6: The Contractor shall develop Technical Data Package (TDP-Production Level) in compliance with MIL-STD-31000A. The Contractor shall ensure completeness and accuracy of the TDP data in describing the design, all subassemblies, and component parts. The design described by the TDP documents is that configuration submitted for FAT testing and approval. TDP for all design variants, to include the following as a minimum shall be included in the submission:

1. Product/Material Safety Data Sheets

2. Design nomenclature

3. Drawing/Pattern by size

4. Material configuration by size

a) Type of materials used

b) Build Sheet/Cut Patterns

c) Dry layup and assembly

d) Orientation/sequence of layers of the design

5. The Contractor shall submit samples to the government in accordance with the performance description prior to FAT. The Government will treat all information provided as Proprietary and deem it close hold with restricted access. This information is required by the Government in order to baseline and to maintain configuration management of the submitted design. The Contractor shall minimize the use of proprietary materials and sole source materials in the design. The Contractor shall disclose any remaining proprietary materials or sole source materials to enable the government to maintain effective life-cycle planning. A list of each proprietary materials and sole source materials by category shall be delivered to the Government as part of the TDP. Any changes to the TDP or manufacturing process shall be in compliance with the change process defined in paragraph 2.3 Engineering Change Request (ECR).

6. Production Master Schedule (this schedule is an integrated schedule that shows subcontractor material incoming materials, prime contractor setup and surveillance of their subcontractors, material delivery to the government, etc.)

· The Contractor shall submit the PPP in electronic format. All internal documentation must state the controlled document revision used for the PPP under consideration. The PPP is design specific, the contractor shall ensure that the information submitted in the PPP represents all design variants and is clearly identified by size/design type (direction of material, changes in material processing – coating process, design type (protection level, etc.).

15.0 WARRANTY

The Contractor is required to deliver a product that conforms, and continues to conform, to contractual requirements after acceptance. The warranty period shall be 365 calendar days from the date of acceptance of each lot, and the Government shall give written notice to the Contractor of any breach of warranties within 60 days of the Government’s discovery of any defect or other warranty breach. Products provided shall comply with FAR Clause FAR 52.246-17 Warranty of Supplies of a Noncomplex Nature, (June 2003).

If the Contractor offers a normal commercial warranty for any item the Government purchases or will purchase under the contract, and that warranty exceeds 365 days, the Government shall receive the benefit of the longer warranty period as well as any commercial warranty terms that are more favorable to the Government than the warranty terms contained in FAR 52.246-17. Additionally, the Contractor shall deliver to the Government the written terms of the commercial warranty for use in returning non-conforming products identified after acceptance. Even if a commercial warranty is supplied, the conditions for return, correction, or replacement to the Government, as stated in FAR 52.246-17, shall apply, unless the Contracting Officer determines the terms of the commercial warranty are more favorable to the Government, in which case the Contracting Officer may elect to use the commercial warranty provisions.

16.0 QUALITY – LIMITED LIFE MATERIALS

The Contractor shall ensure that shelf life, cure date, date of manufacture, and expiration date are provided to the Government for all limited life materials, and shall be recorded on the CoC. Limited life materials shall have a minimum of 95% shelf life remaining unless otherwise approved in writing by the Government.

17.0 DELIVERY AND ACCEPTANCE

17.1 Lot Schedule and Acceptance/Rejection. Lot acceptance/rejection will be in the form of an auto-generated email from PM Soldier Protection and Individual Equipment Management Analysis Requirements Resources Test Evaluation Database (SMARRTED) system.

17.2 On Time Delivery: Shortly after award, vendors will receive a Production Lot Schedule Template to complete once the dates (shootpack pull dates, planned lot completion dates, final inspection dates and ship dates) are determined. The contractors shall update this template weekly, prior to each weekly tele-con. Upon receipt of Full FAT Approval, the contractor shall submit a final Schedule which will be incorporated into the contract. To determine “On Time Delivery” for a Lot, the Government will compare the following two dates from the Schedule: “AQR Shootpack Pull Date” (date shootpacks are sent to ATC by DCMA per DD Form 1222) and “Date for Final Inspection / Acceptance”.

17.3 When determining the “Date for Final Inspection”, contractors shall take into account that it may take ATC (approximately) three (3) weeks to complete a ballistic LAT; however, for any of the LAT tests, it may take more or less time to complete LAT. The contractor shall be ready to ship the completed Lot once notification of a passed LAT is received. The Government will not hold a contractor responsible for testing delays caused by the Government taking longer than three (3) weeks to test, prepare and approve the LAT Test Report. If the Government should take longer than three (3) weeks to approve a Lot, PM-SPE will review the “AQR Shootpack Pull Date” for that Lot and determine if the shootpacks were delivered on time. If so, then the Lot will not be considered late. Contractors shall have the Lot ready for final inspection once the Test Report is approved. “On Time Delivery” is NOT the same as “Lot Acceptance” and the Contractor will not receive payment until the completed, LAT-approved Lot is inspected and accepted by DCMA.

17.4 Late Deliveries and Consideration. If the quantities delivered are less than the quantities “scheduled” to be delivered, Contractor will provide, at no additional cost to the Government, one (1) PUG set in “consideration” for every three (3) PUG sets delivered late. Sizes and quantities will be in accordance with the applicable size tariff. A new CLIN will be incorporated for consideration items into the Delivery Order which it applies. Consideration will not be assessed without discussions between the Government and Contractor.

18.0 CONFIGURATION MANAGEMENT

18.1 Configuration Management. The Contractor shall establish a configuration management program for PUG program that addresses all new and/or modified hardware, firmware, software and documentation resulting from this contract. The Contractor, at no additional cost to the Government, shall correct all non-conformances. The Contractor shall use configuration control to manage proposed changes beginning with the submission of the FAT item(s). Configuration control shall be used to document the impact of proposed changes and to update configuration documentation. Following acceptance of the First Article Unit(s), the Contractor shall not alter the design in form, fit, or function without prior approval from the KO.

18.2 Configuration Status Accounting (CSA). All baselines, Engineering Change Proposals (ECPs),…