Xband_Statement_of_Work.pdf

Volatiles Investigating Polar Exploration Rover

(VIPER)

X-Band Communication System Statement of Work

Revision: RFP Baseline

Dated: May 4, 2020

Johnson Space Center Houston Texas

National Aeronautics and Space Administration

Table of Contents

1.0 Introduction

1.1 Purpose

1.2 Background

1.3 Scope

2 Applicable Documents 3 Equipment and Documents to be delivered

3.1 Contract End Item (CEI) Descriptions

Engineering Development Unit Protoflight Unit Spare Flight Unit Ground Crypto Processor Mating Connectors

3.2 Customer-Furnished Equipment (CFE)

3.3 Tooling

3.4 Ground Support Equipment (GSE)

3.5 Customer-Furnished Drawings (CFD)

3.6 Services

Subcontractor Services Master Schedule Management of Lower Tier Suppliers Design and Analysis Fabrication

3.7 Data

Data Deliverables (SDRLs) Requirement Compliance Matrix in Proposal Data Format

Units Software Format Analyses

4 Management, Reporting, Documentation and Reviews

4.1 Management and Reporting

4.2 Documentation

4.3 Reviews and Meetings

System Requirements Review (SRR) Preliminary Design Review (PDR) Critical Design Review (CDR) Pre-Environmental Test Review (PETR) Pre-Ship Review (PSR) Weekly Status Meetings

4.4 Schedule Milestones

5 Engineering

5.1 General Requirements

5.2 Engineering Documentation

5.3 Thermal Analysis

5.4 Structural Analysis

6 Hardware Manufacture

6.1 Long Lead Parts

6.2 Connector Savers

7 Field Programmable Gate Array (FPGA) Engineering

7.1 Insight and access

7.2 FPGA Process Requirements

7.3 FPGA Delivery

8 Software Engineering

8.1 NASA software insight and access

8.2 Software Process Requirements

9 Quality Assurance

9.1 General Requirements

Quality Assurance Manual Software Assurance Requirements

Certificate of Compliance (CoC) Test Reports Calibration System Processes and Products Quality Requirements for Lower Tier Suppliers Government Source Inspection

Contractor Source Inspection Government Right of Access Government Mandatory Inspection Points (MIPs)

Configuration Management Software Configuration Management

Record Retention Anomaly Reporting Non-Conforming Material

9.2 System Safety Requirements

9.3 Reliability Requirements

Failure Modes and Effects Analysis EEE Parts Stress Analyses Worst Case Analyses Reliability Predictions

9.4 Ground Support Equipment (GSE)

9.5 Design Verification Requirements

Verification Requirements Analysis / Trending / Reporting Of Test Data Demonstration of Failure-Free Operation

9.6 Workmanship Standards and Processes

Workmanship: Use of Alternate Workmanship Standards Training and Certification of Contractor Personnel Hardware Handling, Cleaning and Packaging

Shipping Electrostatic Discharge Control Requirements Workmanship Requirements for Flight Unit Hardware

Printed Wiring Boards (PWBs)

Workmanship Requirements Lead-Free Tin (<3% Pb) Technology Polymeric Processes Reserved Crimping, Interconnecting Cable, and Harness Assemblies Electronic Assembly and Soldering Fiber Optics Electrical Wire Wrapped Connections Foreign Object Debris (FOD) New or Advanced Packaging Technologies

9.7 Parts Requirements

General

EEE Single Lot / Date Code Supply Chain Traceability

Custom Devices Plastic Encapsulated Microcircuits (PEMs) Radiation Hardness Parts Age Control NASA Advisories and GIDEP Notices Reuse of Parts and Materials Part Notification of Failure Counterfeit Parts

9.8 Materials, Processes, and Lubrication Requirements

Materials Selection Requirements Vacuum Outgassing of Polymeric Materials Stress Corrosion Cracking of Inorganic Materials Lubrication Systems Process Selection Requirements Fasteners Materials Used in "Off-the-Shelf”-Hardware Materials Procurement Requirements Limited-Life Items

APPENDIX A: Abbreviations and Acronyms APPENDIX B: VIPER Rover Material Usage Agreement Form APPENDIX C: Applicable Documents List

1.0Introduction

1.1 Purpose

This document defines the tasks and associated effort to be performed by the Contractor in supplying the X-Band Communication System for the Volatiles Investigating Polar Exploration Rover (VIPER) Program. The accompanying performance specification document describes the electrical, mechanical, operating environment, and verification testing requirements.

1.2 Background

VIPER is a lunar volatiles detection and measurement mission that will be launched to a lunar polar region to characterize the nature of the volatiles in the area and extrapolate this data to create global lunar water resource maps. Utilizing lunar resources to produce oxygen and propellants could enable new mission architectures for human exploration to a number of different targets. VIPER will also utilize Commercial Lunar Payload Services (CLPS), where commercial entities provide the service of delivering NASA hardware directly to the lunar surface. Once on the moon, the expected lunar surface mission duration is up to four lunar days, with active surface operations completed during the periods when both sun exposure and X-Band direct to Earth (DTE) communication conditions overlap.

1.3 Scope

Figure 1.3-1 illustrates the basic conceptual block diagram for VIPER’s X-Band subsystem.

The scope of this document (and described herein as the “X-Band System”) includes requirements typical of a crypto module, transceiver, power amplifier, and diplexer/filter.

The supplier can choose to integrate any or all of the functions in a single chassis or provide multiple components to satisfy the requirement set described herein. The RF switch and antennas will be subject to separate requirement documents and separate procurements.

Scope of this document

Figure 1.3-1 X-Band Subsystem Block Diagram

2 Applicable Documents

The applicable documents are listed in Appendix C of this Statement of Work.

3 Equipment and Documents to be delivered

3.1 Contract End Item (CEI) Descriptions

CEI #

1 One (1) set of Engineering Development Units 2 One (1) set of ProtoFlight Units 3 One (1) Ground Crypto Processor 4 Three (3) sets of Mating Connectors (data and power, not coax) for the EDU hardware 5 Three (3) sets of Mating Connectors (data and power, not coax) for the ProtoFlight hardware

CEI #

Option 1 One (1) set of Flight Units (Flight Spare)

*note: Depending on supplier implementation, “one set” may include a single hardware component that incorporates the functionality described in section 1.3, or “one set” may include multiple components (e.g. 1 transceiver, 1 power amplifier, 1 diplexer, & 1 crypto module) that incorporate the functionality described in section 1.3.

Engineering Development Unit A high fidelity unit that demonstrates critical aspects of the engineering processes involved in the development of the operational unit. Engineering test units are intended to closely resemble the final product (hardware/software) to the maximum extent possible and are built and tested so as to establish confidence that the design will function in the expected environments. In some cases, the engineering unit will become the final product, assuming proper traceability has been exercised over the components and hardware handling.

Protoflight Unit In projects that will not develop a qualification unit, the flight unit may be designated as a protoflight unit and a limited version of qualification test ranges will be applied. This unit will be flown.

Spare Flight Unit The end product that can be flown and has undergone acceptance level testing.

Ground Crypto Processor

a. The contractor shall provide a ground crypto processor for incorporation into NASA test rack

b. The ground crypto processor shall by compatible with the required crypto capacities of the EDU and flight hardware as defined in the VIPER X-Band Comm System Performance Spec.

c. The ground crypto processor shall operate from a 120V power outlet source.

d. The ground crypto processor shall fit in an industry standard 19 inch rack.

e. The ground crypto processor shall be validated for FIPS 140-2 level 1 or better

f. The ground crypto processor shall restrict access to local configuration using the front panel through a physical key lock.

g. The ground crypto processor (with GSE converter if necessary) shall allow key loading via a DS-101 simple key loader.

h. The ground crypto processor shall provide RS-422 interfaces for the plaintext input and the Ciphertext output.

Mating Connectors

a. The contractor shall provide 3 sets of power and data mating connectors for the EDU hardware delivery. Mating connectors for the coax connections are not required.

b. The contractor shall provide 3 sets of power and data mating connectors for the Flight hardware delivery. Mating connectors for the coax connections are not required.

c. For every connector provided, enough contacts shall be provided to fully populate that connector plus an additional 10 contacts.

d. All contacts with the same part number shall be from the same lot

3.2 Customer-Furnished Equipment (CFE)

NASA is not required to provide any CFE for the efforts defined within this SOW except as defined.

3.3 Tooling

The Contractor shall design, manufacture and test any tooling which is required to meet the requirements of this Contract.

3.4 Ground Support Equipment (GSE)

The Contractor shall design (or specify), manufacture (or procure) and test (or calibrate) any electrical (EGSE) and mechanical (MGSE) ground support equipment which is required to meet the requirements of this Contract. The Subcontractor shall identify any and all such EGSE and MGSE, and shall ensure that it is available to meet the requirements of this contract.

3.5 Customer-Furnished Drawings (CFD)

NASA is not required to provide any CFD for the efforts defined within this SOW.

3.6 Services

Subcontractor Services The Contractor shall supply all the test equipment, personnel, and management skills required to perform the tasks identified in this SOW.

Master Schedule The Contractor shall submit to NASA a Gantt chart or other suitable method of planning and schedule control, which identifies the critical schedule path as well as key milestones. These milestones shall include as a minimum the deliverable items required by this SOW, and provide sufficient detail to allow NASA to track hardware status through the performance period of this Contract.

Management of Lower Tier Suppliers The Contractor shall make provisions to allow NASA to participate in the Subcontractor’s review of a sub-tier supplier when a problem is suspected. NASA shall request through the Subcontractor any meetings that are required for resolution of problems.

Design and Analysis All new analyses required to support the requirements delineated within this SOW shall be furnished to NASA. Previously documented design analysis generated in order to substantiate the qualification of the hardware specified herein shall be provided with the Qualification Test Report(s).

The Contractor shall notify NASA of any changes throughout the life of the contract which may affect the qualification status and/or ICD(s).

Fabrication The Contractor shall manufacture or procure all products under this Contract in accordance with the Contractor’s final designs, approved by NASA, and utilize the Contractor’s standard manufacturing processes.

3.7 Data

Data Deliverables (SDRLs) Deliverable data is summarized in the Subcontractor Data Requirements List of the table below. All deliverable data shall be delivered electronically through appropriate contract channels to be formally acknowledged by NASA.

Approval signifies a contract deliverable item and/or task that must be submitted to NASA for sanction prior to implementation by the Subcontractor.

Review signifies a contract deliverable item and/or task that must be submitted to NASA for evaluation and comment.

Table: Subcontractor Data Requirements List

No. Title Type* Due Date 000 Requirement Compliance Matrix R With Initial Proposal 001 Acceptance Test Plan A 1 week prior to CDR 002 Acceptance Test Procedure R 4 weeks prior to test 003 Acceptance Test Report A 1 week prior to PSR 004 CAD Model R Provided with each ICD submission/update

Certificate of Compliance A 1 week prior to PSR 006 Compliance Verification Matrix A 1 week prior to PDR/CDR 007 Configuration Management Plan A 30 days ARO 008 Contamination Control Plan A 1 week prior to PDR/CDR 009 Critical Design Review Package A 1 week prior to CDR

Critical Items List A 1 week prior to PDR/CDR 011 Derating Analysis A 1 week prior to PDR/CDR 012 Deviation/Waiver Request A As required 013 Drawing Tree R 1 week prior to PDR/CDR 014 End Item Data Package A 1 week prior to PSR

Failure Modes, Effects, Analysis (FMEA) A 1 week prior to PDR/CDR 016 FPGA Development Plan A 1 week prior to PDR 017 FPGA Design Document A 1 week prior to CDR 018 GIDEP/Technical Alert Impact R As required 019 Hazard Analysis A 1 week prior to PDR/CDR

Interface Control Document (ICD) R 30 days ARO, updated as required 021 Master Schedule R 30 days ARO, updated as required 022 Mechanical Analysis A 1 week prior to PDR/CDR 023 Nonconformance Report A As required 024 Non-Standard Parts and Materials Request A As required

Parts Stress Analysis A 1 week prior to PDR/CDR 026 Parts, Material and Process List A 1 week prior to PDR/CDR 027 Preliminary Design Review Package A 1 week prior to PDR 028 Pre-Ship Review Data Package A 1 week prior to PSR 029 Radiation Analysis A 1 week prior to PDR/CDR

Reliability Model & Prediction A 1 week prior to PDR/CDR 031 Structural Model, Stress, and Loads Analysis A 1 week prior to PDR/CDR 032 System Requirement Review Data Package A 1 week prior to SRR 033 Pre-Environment Test Review Data Package A 2 weeks prior to PETR 034 Thermal Analysis A 1 week prior to PDR/CDR

Thermal Model A 1 week prior to PDR/CDR 036 Worst Case Analysis A 1 week prior to PDR/CDR

*Type: “A” = NASA Approval “R” = NASA Review

Requirement Compliance Matrix in Proposal The Contractor shall generate a matrix listing each section in this statement of work and the accompanying Performance Specification reflecting either compliance (plan to meet) or non-compliance (do not plan to meet). Areas of non-compliance shall be further addressed by explaining why the proposed solution will remain non-compliant or identify the proposed equivalent alternative. Contractors are encouraged to note particular cost drivers where a substitution would not impact performance or reliability.

Example Compliance Matrix (alternative supplier formats are acceptable):

Doc Section Description Plan to

Meet Do Not Plan to Meet

Description

Spec 3.1.1 Xmt & Rcv X Spec 3.2.1 Transmit X Spec 3.2.2 Transmit Freq X SOW 9.8.9 Limited Life Items X SOW 9.9 Applicable Docs X All okay, except x. Plan to use y instead.

Data Format

Units Quantitative values (including mass, size, temperature, etc.) in drawings and specifications shall be given in U.S. Customary units unless previously developed and/or currently existing in metric units. Any new drawings developed under this SOW shall use U.S. Customary units with values in metric units in parentheses.

Software Format

All documentation delivered via electronic means to NASA for review or approval shall be generated in Microsoft or Adobe Acrobat software compatible format unless otherwise specified within this SOW. Translation costs (if any) shall be the responsibility of the Contractor.

Analyses The Contractor’s format is acceptable but shall include the following as a minimum:

• Summary of the study or analysis

• Description of the original problem

• Detailed analysis or a description of the study

• Supporting charts, tables, references, etc., as applicable

4 Management, Reporting, Documentation and Reviews

4.1 Management and Reporting

The Contractor shall designate a single individual by name who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract; to ensure that all objectives are accomplished within schedule and cost constraints;

and to serve as the interface with the NASA Contractor Officer Representative (COR) for all technical aspects of the Contract.

The Contractor shall generate a list of significant milestones that will enable the NASA/JSC COR to ascertain program progress. The Contractor shall not wait for meetings to report any issues to the COR or seek guidance from the COR: they shall be reported as soon as practical so as to prevent schedule delays.

4.2 Documentation

The Contractor shall ensure the generation and delivery of all documentation as called for in the Contract.

In addition to that documentation specifically called for in the Contract, upon request by the NASA/JSC COR, the Contractor shall make available a copy of any document or data generated during this Contract performance for review. This includes, but is not limited to, schedules, technical reports and memorandums, drawings, schematics, studies, analyses, parts and materials data, test data, alerts, etc.

All hardware and documents provided by the Contractor shall have an export classification.

All documents produced by the Contractor and submitted to NASA shall have an approval signature(s) evident in the document.

4.3 Reviews and Meetings

The meetings required by the Contractor are specified below. After the design is established, the NASA/JSC COR may eliminate reviews/meetings if the design has not evolved sufficiently to warrant a subsequent review.

System Requirements Review (SRR) The Contractor shall organize and present a System Requirements Review at the Contractor’s facility to demonstrate overall conformance with the requirements specified in the VIPER X- Band Communication System Performance Specification and this Statement of Work.

This review shall establish that the baseline requirements are clearly understood, and that system definition is complete. This review shall also provide an opportunity to review drawings and all proposed analyses that are required before the start of fabrication. This review shall cover programmatic, technical, risk, test and verification, and quality assurance topics. A verification plan for each requirement or group of requirements shall be presented.

The SRR shall demonstrate that planning for the remaining project activities is adequate and that there are reasonable expectations that the project will accommodate any imposed constraints and meet its success criteria within the allocated resources.

The Contractor shall provide to NASA/JSC an SRR Presentation Package and all other required deliverable data one week prior to the review.

Review minutes, agenda, attendance lists, action items, action item delegation and due dates shall be captured in an SRR Report following the review. All items shall be in sufficient detail to be self-explanatory. An SRR Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items.

Approval of deliverable data and action item closeout shall serve as authority to proceed with the fabrication process EDUs.

Preliminary Design Review (PDR) The Contractor shall organize and conduct a Preliminary Design Review (PDR) at the Contractor’s facility, unless otherwise agreed to by the Contractor and NASA/JSC COR, on a date defined in the Contract. This review shall demonstrate overall conformance to the requirements specified in this SOW and VIPER X-Band Communication System Performance Specification for the preliminary design. This review shall provide a formal presentation of the architectural design of the VIPER X-Band Communication System, including the mechanical and electrical interfaces. This review shall cover programmatic, technical, risk, test and verification, quality assurance topics, and overall status. This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the fabrication of the Flight Unit hardware following CDR. Early fabrication may be negotiated to reduce schedule risk with concurrence by the Contractor and

NASA/JSC COR.

The Contractor shall provide to NASA/JSC a Preliminary Design Review Presentation Package and all other required deliverable data one week prior to the review.

Review minutes shall be prepared and, as a minimum, shall include attendance, action items, action item accomplishment responsibility and agreements. All items shall be in sufficient detail to be self-explanatory. A Preliminary Design Review Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items.

Critical Design Review (CDR) The Contractor shall organize and conduct a Critical Design Review (CDR) at the Contractor’s facility, unless otherwise agreed to by the Contractor and NASA/JSC COR, before the start of Flight Unit fabrication and on a date defined in the Contract. This review shall demonstrate overall conformance to the requirements specified in this SOW and the Performance Specification. The review shall demonstrate overall conformance of the detailed design using completed drawings and analyses. Drawings and analyses should be released or ready for final review and approval. This review shall define all the thermal, mechanical, and electrical interfaces. This review shall cover programmatic, technical, risk, test and verification, quality assurance topics, and manufacturing and overall status. This review shall provide an opportunity to review drawings, test plans, and non-standard processes before the start of fabrication of the hardware.

The Contractor shall provide to NASA/JSC a Critical Design Review Presentation Package and all other required deliverable data one week prior to the review.

Review minutes shall be prepared and, as a minimum, shall include attendance, action items, action item accomplishment responsibility and agreements. All items shall be in sufficient detail to be self-explanatory. A Critical Design Review Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items.

Pre-Environmental Test Review (PETR) The Contractor shall organize and conduct a Pre-Environmental Test Review (PETR) at the Contractor’s facility, unless otherwise agreed to by the Contractor and NASA/JSC COR, before the environment test program begins and on a date defined in the contract. This review shall demonstrate test methods and procedures are appropriate and sufficient to verify requirements specified in the X-Band Communication System Performance Specification.

This review shall cover programmatic, technical, risk, test and verification, and quality assurance topics. This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the testing of the hardware.

The Contractor shall provide to NASA/JSC a PETR Presentation Package and all other required deliverable data one week prior to the review.

Review minutes shall be prepared and, as a minimum, shall include attendance, action items, action item accomplishment responsibility and agreements. All items shall be in sufficient detail to be self-explanatory. A Pre-Environmental Review Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items.

Pre-Ship Review (PSR)

To be held over teleconference at the completion of verification tests and prior to shipment of the hardware to NASA. A PSR shall be held prior to the delivery of each of the EDU and Flight Unit deliverables. The Acceptance Data Package, per MPCV 70146, shall be reviewed at each flight unit PSR.

Weekly Status Meetings

The Contractor shall hold weekly status meetings over teleconference with NASA. These meetings provide a scheduled time to discuss technical issues, schedule status, action-item dispositions, and any other items related to the Contact. The intent of these meetings is to make sure the teams are touching base at least weekly in an open forum and issues are getting addressed early. These meetings should last no more than 1 hour per week but more can be scheduled as necessary.

4.4 Schedule Milestones

The Contractor shall meet or beat the milestones in the Table below. The Contractor may propose alternate dates in the proposal for the review milestones.

Milestone Date EDU Mating Connectors Mar 1, 2021 EDU Delivery May 28, 2021 Ground Crypto Unit May 28, 2021 Flight Mating Connectors Oct 1, 2021 Flight Unit Delivery Dec 21, 2021

5 Engineering

5.1 General Requirements

The Contractor shall comply with all technical and environmental requirements specified in the VIPER X-Band Communication System SOW and the VIPER X-Band Communication System Performance Specification to ensure compliance and to assemble the documentation necessary to ensure its usability by NASA.

5.2 Engineering Documentation

Unless otherwise noted, contractor preferred format is suitable for all engineering documentation.

5.3 Thermal Analysis

The Contractor shall perform a thermal analysis to assess the thermal design of the X-Band Communication System components and the thermal interfaces. The analysis shall consider the maximum and minimum operating temperatures to which the hardware will be exposed.

The thermal analysis shall show that the device and/or the electronic part junction temperatures are within the EEE parts de-rating guidelines for operation in a vacuum environment. The analysis shall combine the worst-case power dissipation of the components with the worst-case interface temperature. In addition, hot and cold survival temperatures at the interface must be specified and tested by the vendor.

The results of these analyses shall be summarized in a Contractor-format Thermal Analyses Report which shall be provided for review as per the Contract schedule.

The Contractor shall provide a reduced thermal model with approximately 10 nodes. This model shall be delivered in a CRTech Thermal Desktop compatible format.

5.4 Structural Analysis

a. A Structural Analysis shall be performed on the X-Band Communication System structure(s) to ensure the capability to withstand the mission loads environments. The effects of any thermal stresses shall be accounted for in the analyses. The results of these analyses shall be summarized in a Contractor format Structural Analyses that shall be provided for review to NASA per the contract schedule. The Structural

Analysis Report (SAR) shall include bolted joint analysis per NASA-STD-5020A, NASA-STD-5001B, and ARC-STD-8070.1.

b. Venting analysis shall be included in the SAR.

c. A modal survey analysis shall be included in the SAR to confirm that there is no significant modal mass in the coupled loads frequency range

6 Hardware Manufacture

6.1 Long Lead Parts

Long lead parts may be purchased early to reduce schedule risk with concurrence of

NASA/JSC COR.

6.2 Connector Savers

The X-Band Communication System components shall be delivered with connector savers for all connectors to minimize mates and demates to these connectors. The Flight Unit shall be tested with connector savers to minimize mates and demates.

7 Field Programmable Gate Array (FPGA) Engineering

7.1 Insight and access

a) The Contractor shall provide NASA with all FPGA products and process tracking information in electronic format.

b) The Contractor shall notify NASA, in the response to this solicitation, as to whether open source cores will be included in code developed for the project.

c) The Contractor shall track all FPGA design changes and non-conformances and provide the data to NASA for review.

7.2 FPGA Process Requirements

a) During FPGA Development Planning, the vendor shall provide an FPGA Development Plan that outlines their approach to:

• Development and Testing Environment

• Quality Management

• Verification & Validation Approach

• Customer Involvement

• Configuration Management Approach

• Product Life Cycle description including integration, delivery and maintenance

• Peer Review/Inspection Processes

• Metrics to be collected

b) During the Design phase, the vendor shall provide an FPGA Design Document.

The FPGA design document shall include:

• Description of cores including algorithms, data structures, and functional decomposition.

• Cores’ input/output description

• Architecture/Interrelationships between cores

• Estimated utilization of FPGA resources

• Identification of new and previously-used code

7.3 FPGA Delivery

a) The Contractor shall deliver EDU and Flight Unit loaded with the latest verified version of the FPGA design unless otherwise specified by NASA COR.

b) The contractor shall update the FPGA load on the EDU, if necessary, to maintain consistency with the FPGA load on the Flight Unit.

c) The Contractor shall deliver FPGA verification artifacts packaged with the hardware verification artifacts.

8 Software Engineering

8.1 NASA software insight and access

a) The Contractor shall notify NASA, in the response to this solicitation, as to whether open source software will be included in code developed for the project.

b) The Contractor shall track all software changes and non-conformances and provide the data to NASA for review.

8.2 Software Process Requirements

a) The vendor shall adhere to the following flight software development process:

• NPR 7150.2 revision C, requirements for Class C software

• The Contractor may substitute its in-house software development processes that have been shown to be equivalent to or better than the intent of the requirements in NPR 7150.2C with the approval of the NASA COR.”.

9 Quality Assurance

9.1 General Requirements

Quality Assurance Manual SAE AS9100D Quality System Certification: The Contractor shall have a quality program that complies with the SAE International Aerospace Standard, AS9100D - Quality Management Systems - Requirements for Aviation, Space and Defense Organizations. If Customer has accepted Supplier's AS9100 registration and Supplier subsequently changes registrars, loses its registration status, or is put on notice of losing its registration status, it shall notify Customer's procuring Component(s) within three days of receiving such notice from its registrar.

a) AS9100 Certification Maintenance: NASA requires flight hardware vendors to have configuration and quality management and controls in place prior to building flight hardware. This task will assure the maintenance of the AS9100 certification so that the Contractor will be capable of producing critical flight hardware at the time of the hardware acquisition. The Contractor shall:

1) Maintain an AS9100 certification schedule including a facility certification and technical training schedule (includes but not limited to other NASA required certifications and training such as ESD certifications and IPC training).

2) Maintain all appropriate quality certifications through the contract’s duration.

3) Maintain certification and pass all audits that pertain to activities undertaken during the period of performance of this contract in order to validate that they met NASA’s requirement to maintain certification.

Software Assurance Requirements For the purposes of this section, the term software shall also include firmware, including hardware definition languages used during the design and programming of FPGAs.

The Contractor shall employ Software Quality Assurance to assure:

a) Standards and procedures for management, software engineering and software assurance activities are defined.

b) All plans (e.g., configuration management, software development plan, etc.) required by the contract are completed and comply with contractual requirements.

c) Standards, design, and code are evaluated for quality and security issues.

d) All software requirements are documented and traceable from system requirements to design, code and test (i.e., a software requirements traceability matrix).

e) Software requirement verification status is updated and maintained via a software requirements verification matrix.

f) Formal and acceptance-level software tests are witnessed.

g) Software products and related documentation (e.g., Version Description Documents and User Guides) have the required content and satisfy their contractual requirements.

h) Reports, schedules and records are reviewed.

Certificate of Compliance (CoC) The Contractor shall provide a certification with each shipment to attest that the parts, assemblies, subassemblies, or detail parts conform to the Order requirements. When applicable, the true manufacturers, lot, heat, batch, date code, and/or serial number must appear on the certification. Certification must contain the following:

a) Customer’s Order number

b) Product name

c) Part and Serial number

d) Name and address of manufacturing or processing location

e) Manufacturer’s lot, heat, batch, date code, and/or serial number (if applicable)

f) Quantity and unit of measurement (each, box, case, gallons, etc.)

g) Be signed and dated by an official of the company

Test Reports The Contractor shall submit test reports with the shipment that certifies test requirements were in accordance with drawings and/or specifications.

Calibration System The Contractor shall have a documented calibration system that meets the requirements of American National Standard Institute (ANSI)/National Conference of Standards Laboratories (NCSL) Z540-3, Requirements for the Calibration of Measuring and Test Equipment.

Processes and Products The Contractor shall notify the customer of proposed changes in process definition and will obtain approval from the customer prior to implementing the change. Changes affecting processes, production equipment, tools and programs shall be documented. Procedures shall be available to control their implementation. This statement shall also apply to Supplier designated “critical processes” that have been subcontracted.

Quality Requirements for Lower Tier Suppliers The Contractor shall assure that applicable requirements of this order are applied to any lower tier suppliers.

Government Source Inspection

a) All work on this purchase contract is subject to inspection and test by the Government at any time and any place. Government inspection is required on this order prior to shipment from Contractor’s facility. Government inspections performed will be determined by a NASA Government inspection representative and may be conducted during processing, fabrication, or final inspection. Upon receipt of this purchase contract, promptly notify the Government representative who normally services your plant, i.e., Defense Contract Management Agency (DCMA) representative, so that appropriate Government inspection planning can be accomplished. If the contractor’s facility is not serviced by DCMA for Government source inspection, the contractor shall immediately notify the NASA Government representative.

b) The Government’s request for source inspection shall specify the period and method for the advance notification and the Government representative to whom it shall be furnished. The Contractor shall notify the DCMA Government representative 48 hours in advance of the time articles are ready for test or inspection when the DCMA government representative is resident in the Contractor’s plant/facility. Requests shall require at least 7 workdays advance notification to the Government representative if not resident in the contractor’s plant/facility.

c) The contractor shall not proceed with fabrication/assembly processing until Government mandatory inspection points (GMIPs) are added to contractor’s manufacturing instructions/procedures. GMIPs shall not be by-passed unless authorized in writing by the NASA Government inspection representative.

d) The contractor, without additional charge to the contract, shall provide all reasonably required facilities and assistance (applicable drawings, specifications, change orders, inspection and/or test equipment) for the Government representative to perform their duties.

e) The Contractor shall ensure that Government inspection acceptance is evident for every individual GMIP and that completion of Government inspection is evident on Contractor’s shipping document/packing list/DD250/DD1149. Evidence may be the signature of Government inspection representative with printed name and office, or application of the representative's stamp.

f) The Government will accept or reject supplies as promptly as practical after delivery, unless otherwise provided in the contract. Government failure to inspect and accept or reject the supplies shall not relieve the Contractor from responsibility, nor impose liability on the Government, for nonconforming supplies.

g) When manufacturing processes are affected by GMIPs and subcontracted by Contractor, the provisions of this requirement shall be included in the Supplier's Purchase Order verbatim.

h) The Government has the right to inspect any and all of the work included in this order at the supplier’s facility.

i) For activities performed onsite at JSC, supplier shall comply with the JSC Quality Management System.

Contractor Source Inspection The Contractor shall ensure that its Contract or subcontract documents impose the applicable requirements on subcontractors and other suppliers. The subcontractor and other suppliers shall in turn impose the requirements on their procurement sources.

The Contractor shall perform source inspection at the subcontractor's or supplier's facilities in accordance with the Contract or subcontract documentation or when one or more of the following conditions exist:

• In process, end item controls, or tests that are destructive in nature prevent the developer from verifying quality after delivery to the developer's facility.

• It is not feasible or economical for the Contractor to determine the quality of procured articles solely by inspections or tests performed at the Contractor’s facility.

• Qualification tests are to be performed by the subcontractor or supplier.

• Products are shipped directly from the source to NASA, by-passing the Contractor's inspection facilities.

Government Right of Access

a) The Government has the right to inspect and test all supplies called for by the contract, to the extent practicable, at all places and times, including the period of manufacture, and in any event before acceptance. The Government will perform inspections and tests in a manner that will not unduly delay the work. The Government assumes no contractual obligation to perform any inspection and test for the benefit of the Contractor unless specifically set forth elsewhere in this Contract.

b) If the Government performs inspection or test on the premises of the Contractor or a subcontractor, the Contractor shall furnish, and shall require subcontractors to furnish, at no increase in Contract price, all reasonable facilities and assistance for the safe and convenient performance of these duties. Except as otherwise provided in the Contract, the Government will bear the expense of Government inspections or tests made at other than the Contractor’s or sub-tier Contractor’s premises; provided, that in case of rejection, the Government will not be liable for any reduction in the value of inspection or test samples.

Government Mandatory Inspection Points (MIPs) The government or its representative will perform the following MIPs listed below. The government may request additional MIPs if a specific process prohibits inspection at a later time. MIP’s are reviewed during the normal reviews and meetings of the Contract and are mutually agreed upon prior to production under this contract.

• Pre-Ship Inspection / Data Review

Configuration Management The Contractor shall be responsible for controlling/tracking changes to parts and components manufactured to ensure that the end product meets specified design functional and physical characteristic requirements. This includes any part or component manufactured to Customers’ or vendors’ drawings, specifications, or special process procedures. With each shipment, the Contractor shall submit “configuration documents”, which define the requirements, designs, build/production and verification for a configuration controlled item.

This record shall be signed and dated by an official of the Supplier’s Quality Assurance department. In addition to the aforementioned required information, record shall include the following minimum requirements:

a) Supplier’s Contract/Purchase Order number including any change orders

b) Line item number

c) Part number

d) Serial number (traceability as applicable)

e) Lot number (traceability as applicable)

f) Drawing number

g) Revision level (baseline configuration)

h) Revision level (as built)

i) Engineering order(s) (if applicable)

For products and services that do not require an extensive configuration management system, the above noted clause should be used to define minimum configuration management requirements. Examples where this clause might be used in lieu of ISO 10007 guidance include prototype parts, non-critical/non flight hardware/software, COTS hardware/software, products/services provided by small suppliers.

Software Configuration Management For the purposes of this section, the term software shall also include firmware.

The developer shall develop and implement a Software Configuration Management (SCM) system that provides baseline management and control of software requirements, design, source code, data, and documentation. Class 1 change shall be forwarded to the NASA CO for approval. Class I changes are defined as those which affect:

• System requirements.

• Software requirements.

• Software safety.

• Software reliability.

• Cost.

• Schedule.

• External interfaces.

Any changes classified as Class II shall be forwarded to NASA for review

Record Retention

a) Supplier and supplier's subcontractors shall maintain verifiable objective evidence of all inspections and tests performed, results obtained and dispositions of non-conforming articles. These records shall be identified to associated articles, including heat and lot number of materials, unit or lot serialization and made available to Customer and/or Government Representatives upon request and shall be retained in a safe, accessible location for a period of ten (10) years after date of delivery as defined in the Contract.

b) Supplier's records associated with the manufacture of serialized or lot controlled articles will provide for continued traceability of serial numbers or lot number identification through all phases of manufacture, commencing with the raw material and continuing through final acceptance of the end item.

c) Records held for the required retention period ten (10) years shall not be destroyed without Customer's written concurrence.

Anomaly Reporting Reporting of software failures shall begin no later than the start of formal Flight Unit testing, which commences with the first power application of acceptance testing. The Contractor shall report all Flight Unit hardware rework and failures to the NASA COR within 24 hours of failure occurrence.

The Contractor’s processes for review, disposition and approval of anomaly reports shall be described in their quality plan/manual or provided as a supplement document. In addition, the Contractor’s anomaly reporting document shall describe the members of the Material Review Board (MRB) and Failure Review Board (FRB). The MRB and FRB shall include VIPER participation. The Contractor’s failure reporting process shall ensure that positive corrective action has been taken to preclude recurrence and that appropriate audits and tests are performed to verify the implementation of the corrective action.

The Contractor shall routinely inform the VIPER Project of MRB and FRB meeting schedules and agendas with sufficient notice to permit VIPER Project participation if desired by VIPER Project.

At the Contractor’s facility, NASA/Government representatives may participate in MRB/FRB activities as deemed appropriate by Government management or contract.

The NASA/JSC COR reserves disapproval rights on MRB and FRB decisions. To assure process consistency, the Contractor shall provide the VIPER Project on-line access to their VIPER anomaly-reporting database.

The Contractor shall provide, as part of the weekly status meetings, a list of all open anomaly reports and a separate list of the anomaly reports closed during the week. For each reported anomaly or nonconformance, there shall be a report that documents the investigation and engineering analysis needed to determine the cause and corrective actions to disposition the nonconformance, and identify any closed problem reports that do not have a definitive cause or corrective action. Reports shall be submitted to the NASA/JSC COR for review and approval of the disposition.

The supplier shall establish and maintain documented procedures to ensure product that does not conform to specific requirements is prevented from unintended use or installation. This control shall provide for identification, documentation, evaluation, segregation (when practical), disposition of nonconforming product, and for notification to the functions concerned.

Non-Conforming Material

a) Per this requirement the Government grants no authority to disposition product or process non-conformances to the Contractor or its sub-tier contractors. Repair is not allowed unless signed off by NASA COR.

b) The controls and related responsibilities for dealing with nonconforming product shall be defined in a documented procedure. The Contractor’s documented procedure shall also define the responsibility for review and authority for the disposition of nonconforming product and the process for approving personnel making these decisions.

c) When a nonconformance is discovered, a review process shall be initiated with the identification and documentation of the nonconformance. This review shall be the initial step performed by the Contractor to determine if the nonconformance needs to be reported to the customer (see below), and to determine if the nonconformance is minor and can be re-worked to a condition that completely conforms to the drawing or specification requirements.

d) This review does not negate the requirement to identify, segregate, document, report and disposition non-conformances.

e) Non-conformances shall be reported to the customer as soon as it is detected and determined not to be re-workable and may be salvageable. When notification is required, notification shall be within 3 working days after the nonconformance is discovered. This requirement applies to all procurements.

f) Any nonconformance discovered by the Contractor, on products in their control, shall be documented by the Contractors’ approved method of nonconformance reporting.

This shall include a detailed description of the nonconformance; location (by drawing reference point, hardware reference point, clock location, etc.) and exact callout of the violation by drawing or specification requirement (including sub-paragraph or illustration number). It shall also list what type of inspection revealed the discrepant condition, and what, if any, subsequent actions were taken prior to disclosure.

Dimensional violations shall include “should be” and “is” dimensions, and tool(s) calibration traceability numbers.

g) The Contractor shall ensure that product, which does not conform to product requirements, is identified and controlled to prevent its unintended use or delivery until dispositioned or scrapped after review.

h) Nonconformance Approval: Any deviation from drawings, specifications, SOW’s, or other requirements specified on the purchase order, must be approved by the customer in writing. If approved, a copy of the nonconformance report shall accompany the shipment.

9.2 System Safety Requirements

The Contractor shall supply detailed descriptions of the design, test, operation, and inspection requirements for all flight hardware and materials, ground support equipment, and their interfaces necessary for a valid identification, assessment, control and mitigation of documented hazards. This includes technical information concerning hazardous and safety critical equipment, systems, operations, handling and materials. For all identified hazards, the Contractor shall also document hazard controls, verifications and tracking methods.

The Contractor shall provide technical data for safety working group and technical meetings as necessary.

9.3 Reliability Requirements

The Contractor shall prepare and conduct the following set of reliability analyses.

Failure Modes and Effects Analysis The Contractor shall perform a Failure Modes and Effects Analysis (FMEA) in accordance with MPCV 70043, MPCV Program Failure Modes and Effects Analysis/Critical Items List (FMEA/CIL) Requirements. The FMEA shall identify failures at the functional level, including external interfaces, and address attendant consequences. This analysis shall be provided to the NASA/JSC COR for review.

EEE Parts Stress Analyses The Contractor shall perform a parts stress analyses on Electrical, Electronic, and Electromechanical (EEE) parts and devices as employed in the circuit designs of the Flight Units to certify conformance with the de-rating requirements of EEE parts. The analyses shall be documented, and justification shall be included for all applications that do not meet the de-rating criteria. The Contractor should use guidelines of NASA document, VIPER Mission EEE Parts Plan. Contractor de-rating guidelines may be considered in place of the VIPER guidelines but shall be submitted for approval. The analysis results and Contractor-specific guidelines shall be provided to the NASA/JSC COR for review and approval.

Worst Case Analyses The Contractor shall perform worst-case parameter analysis of the Flight Unit design on performance critical or functional critical components for which excessive operating variations could compromise mission performance. The analyses shall validate timing parameters and functionality over combined worst-case radiation effects, temperature, and supply voltage. This should include a signal integrity analysis for each board and for the box as a whole.