2122402B4200RJ031_REPAIR SPECS.docx

BJM_0717

WORK ITEM 1: L3HARRIS TECHNOLOGIES, INC, CASREP OPEN AND INSPECT REPAIR

SCOPE

1.1 Intent. This specification covers the requirements for the repair of electronic equipment and those aspects of the maintenance processes, which are applicable to electronic equipment. It establishes uniform standards and procedures to be used in the repair process, for example, receipt and evaluation, testing, maintenance procedures, selection and use of parts and material, marking, preservation, and packing for shipment.

1.2 Government-Furnished Property.

P/N

CAGE

QTY

(EA.)

ESTIMATED COST

($/UNIT)

PN: 792218-02

CAGE: 1C2N9

*Government-loaned property, which shall be returned to the Coast Guard upon completion of the contract.

1.2.1 Types of equipment/components. The repairs of the following types of equipment/components are included in this specification: Complete assemblies, Equipment subassemblies, Circuit card assemblies, Power supplies, Modules and other components as specified in the solicitation.

1.3 Time of Delivery. (FAR 52.211-8, JUN 1997) The Government requests delivery to be made according to the following schedule. ***IF THIS IS NOT FEASIBLE PLEASE NOTIFY PURCHASE AGENT SO THEY MAY DISCUSS OPTIONS WITH EQUIPMENT SPECIALIST***

RECEIPT OF GOVERNMENT PROPERTY

Contracting Officer. If repairs are Firm Fixed Price (FFP) an Open & Inspect report is not required. If repair costs exceed the quoted FFP, an Open & Inspect Report is required before additional services / costs are approved.

Approval or Non-approval of Estimated Repairs to Begin work

NOTE

If it appears there will be a delay, notify Contracting Officer (KO) or Contracting Specialist (KS) immediately.

REFERENCES

COAST GUARD DRAWINGS

· None

COAST GUARD PUBLICATIONS

· None

OTHER REFERENCES

MIL-PRF-81705E_Amendment-1 Barrier Materials, Flexible, Electrostatic Discharge Protective, Heat-Sealable.

MIL-STD-129P Change 4, Sept 2007 Marking for Shipment and Storage MIL-STD-2073-1E Change 17, January 2011, Standard Practice for Military Packaging (Unless otherwise indicated, copies of the above specifications and standards are available from the Defense Printing Service Detachment Office, Bldg. 4D (NPM-DODSSP), 700 Robbins Avenue, Philadelphia, PA 19111-5094.)

ANSI/ASQC-C1-1996 Specification of General Requirements For a Quality Program (Application for copies should be addressed to the American Society for Quality Control (ASQC), 611 East Wisconsin Avenue, Milwaukee, Wisconsin 53202.)

Original Equipment Manufacturer (OEM) Specifications, latest field changes, modifications, firmware upgrades as listed in OEM service, repair manuals, operator, etc.

REQUIREMENTS

3.1 General.

3.1.1 Government furnished equipment. Defective equipment, modules, or items will be shipped to the Contractor from the Coast Guard Surface Forces Logistics Center or as specified in the procurement documentation (contract).

3.1.2 Defective item lot size. Equipment or items will be shipped as single items or in lots. Lot size will be based on Coast Guard needs.

3.1.3 Upon receipt of equipment at the vendor's repair facility. The contractor shall ensure that all items are complete and of the proper cited part number as specified and/or listed in the contract documentation. Discrepancies shall be reported to the Coast Guard Contracting Officer listed on the contract before further action is taken. See 3.4.1.

3.1.4 Unusually damaged items. Unusually damaged items. Repair requirements do not include equipment or components received which indicate obvious misuse, cannibalization, and severe damage due to mishandling, fire, or submersion. In the event that severely damaged or cannibalized equipment or components are received, the Contractor shall notify the Contracting Officer and submit 1) a description of the condition of the equipment or component as received, 2) include photographs if needed to enhance description, 3) an estimate of the probable cause of the condition, and 4) a written estimate of the cost required to make the repair.

3.1.5 Obsolete parts/processes. In the event certain parts or processes become obsolete, the Contractor shall notify the Contracting Officer and submit 1) rationale and verification of any obsolete part or process, and 2) a written estimate of the cost required to make the repair. The Contractor shall not proceed until firm fixed price and delivery schedules are negotiated and authorization to proceed is received from the Contracting Officer. See 6.1 for examples of various formats for the Open and Inspection report (OIR).

3.1.5.1 The Contractor shall NOT proceed until a firm, fixed price for repair and a delivery schedule are negotiated and authorization to either proceed with repairs, or disposal instructions have been received from the Contracting Officer. This will be decided upon by the Contracting Officer after submission of the Open and Inspection Report(s) (OIRs) to the Contracting Officer, review and recommendations by the Contracting Officer's Representative (COR)/Equipment Specialist(s) are made, and authorization has been obtained to proceed with repairs from the Contracting Officer.

3.1.5.2 Incoming Inspection Report and/or Open and Inspection Report (OIR). Shall contain the following information for each piece of Equipment repaired.

3.1.5.3 Date of Report, From: (POC: name and phone number), Contract Number, Contract Line Item Number, Nomenclature, Serial Number, OEM Part Number, National Stock Number, Nature of Defect or Problem(s) found, Recommended solution, List of Material/Parts to be replaced for each piece of equipment being repaired, the anticipated material cost, Anticipated Labor hours at Hourly Labor rate, Total Estimated cost to repair this unit, Cost include Open and Inspection Report? Yes ___ No ___, Cost of Packaging, Cost of Marking, Cost of Freight, Delivery Charges.

3.1.6 Limitation of repair. The price in the schedule is the cost of repair unless otherwise authorized under 3.1.5. Repairs will not normally be authorized if the cost of repair exceeds 65% of the acquisition cost of the item. In the event that the repair costs will exceed 65% of the item acquisition cost, the Contractor shall notify the Contracting Officer. The Contracting Officer will make the determination whether to repair the item or will provide disposal instructions after consulting with the Contracting Officer's Representative (COR)/Equipment Specialist(s).

3.2 Level of repair. The contractor shall perform the level of repair required to return the repairable equipment or module to a ready for issue (RFI) condition from a non-ready for issue (NRFI) condition.

3.2.1 Materials. The Contractor shall provide all current technical manuals, all spare parts, discrete components and consumable materials needed for the repair of the items.

3.2.2 Test and diagnostic equipment. The Contractor shall provide all test and diagnostic equipment necessary to create the system mock-up to provide testing for needed repairs, modifications and firmware upgrades.

3.2.3 Parts replacement. Selection of parts and materials for replacement shall be as specified in 3.10. The criteria for parts replacement shall be in accordance with 3.10.

3.2.4 Repair. Electronic equipment shall be processed for the return of unserviceable items to an operational status. This process shall accomplish:

3.2.4.1 Disassembly and cleaning required to facilitate the equipment repairs.

3.2.4.2 Repair of replacement of parts that have failed or are of marginal quality due to wear, deterioration, or damage so as to return the item to ready for issue (RFI) condition. See 3.10.

3.2.4.3 Install all applicable field changes, modifications and firmware upgrades.

3.2.4.4 Re-assembly, alignment, and testing.

3.3 Detailed requirements - repair process.

3.3.1 Technical specifications. Except where otherwise indicated, the Coast Guard will NOT provide the current technical specifications, manuals, or other technical data or diagnostics for repair of the items covered by this specification. The Contractor is responsible for obtaining the required technical manuals or data. This information shall remain the property of the Contractor but must be available for inspection by the Coast Guard.

3.3.2 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.4 Inspections. In the course of repair, three levels of inspection shall be performed as follows.

3.4.1 Incoming inspection. This inspection shall be performed at the point of receipt of the repair material to detect damage in transit. The items shall be inspected for completeness, for model type per contract or work order, and for obvious flaws and defects. If the equipment or module is received incomplete or damaged in transit, the Contracting Officer shall be immediately notified of the discrepancy. The Contractor shall identify and record the damaged property by its nomenclature; serial number (if applicable), National Stock Number (NSN), manufacturer's part number, date of receipt, quantity, number inspected, number defective or damaged, contract number, nature of the defect, circumstances of discovery, and estimated repair cost.

3.4.2 In-process inspections. These inspections shall be performed during repair in order to ensure completeness of repair and conformance to equipment technical requirements. Examples of such inspections are 1) adherence to fault isolation and test procedures, 2) proper application of coatings and treatments, and 3) proper mounting and connection of piece parts.

NOTE

The results of all in process inspections shall be recorded and submitted to the Contract Officer upon request. See 3.4.1 for the required information and 3.12.

3.4.3 Final inspection. This inspection shall consist of 1) a visual inspection of workmanship, assembly and fit, mechanical and electrical safety and marking, materials, parts, and finish, and, treatment for prevention of corrosion and 2) verification of all operations specified in the equipment technical requirements.

NOTE

All final inspection observations and measurements shall be recorded and certified. A copy of the final inspection shall be placed with the repaired unit or item with it in the packing.

3.5 Testing. In the course of repair, the Contractor will perform two types of testing.

3.5.1 Operational tests. These tests shall be for the purpose of verifying operation and to identify areas requiring fault isolation.

3.5.2 Final performance and acceptance testing. A dynamic test will be conducted to confirm acceptability of alignment and function. This must be accomplished using a fully operational equipment mock-up, or the use of Automated Test Equipment (ATE) with the ability to emulate live circuit conditions. The qualifying performance standard for the equipment shall be the test criteria contained in the equipment technical requirements. A copy of this final performance and acceptance test shall be packed with each item. See 3.4.3.

3.6 Repair diagnostics. The Contractor shall develop repair diagnostics and test procedures to effectively troubleshoot problems with the components and repair the components to meet the requirements of this specification. The diagnostics and test procedures shall be in accordance with current technical specifications. See 3.3.1.

3.7 Fault isolation. Troubleshooting of electronic equipment and modules shall recognize the fault symptom, identify the circuit responsible, and isolate the defective component(s) or sub assembly. After a fault has been localized, but prior to corrective action, ascertain that the specific fault is actually the cause of the malfunction rather than a symptom of some other malfunction. The Contractor shall be responsive to the troubleshooting procedures as indicated in the applicable technical documentation or established test procedures.

3.8 Disassembly. The degree of disassembly on any equipment or module processed by the Contractor shall be commensurate with the level of repair required.

3.9 Cleaning. Items requiring cleaning during repair shall be cleaned prior to or during the pre-induction inspection and disassembly, whichever is deemed more practical by the Contractor. Final cleaning shall be conducted to ensure the component is free of obvious defects and corrosion, soil, grease, residue, fingerprints, perspiration, or other acid or alkali residues.

NOTE

All temporary markings and tags, to include the CG-5236 or DD-1577-2 Serviceable/Unserviceable Tag shall be removed.

3.10 Selection of parts and materials.

NOTE

The Contractor shall utilize parts and materials specified in the latest design specifications. Original equipment manufacturers (OEM) parts or parts that equal or exceed the performance and tolerance characteristics of the OEM parts must be used on all component part replacements.

CAUTION

Any part which would change the form, fit, and/or function of the equipment or module shall not be used. Requests to utilize nonstandard (non-OEM or direct equivalent) parts shall be submitted to the Contracting Officer for approval.

3.11 Marking.

3.11.1 Contractor identification.

NOTE

The Contractor shall affix a permanent vendor identification decal that is traceable by the Coast Guard to the Contractor, date of repair and the contract under which the repair was accomplished.

3.12 Documentation. All rework performed and parts replaced on each item shall be documented. The record sheet shall contain all operations, including; inspection, initial testing, probable cause of failure, repair, alignment, cleaning, final testing, and inspection that have been performed.

3.12.1 Test data record sheet. A record of the data obtained during tests performed (see 3.5) shall be made on a test data record sheet. The Contractor is responsible for preparing and maintaining the documents.

NOTE

A copy of the Final performance and acceptance testing data record shall be included with each item. See 3.4.3 and 3.5.2.

QUALITY ASSURANCE

4.1 General. The Contractor shall maintain an inspection system in accordance with ANSI/ASQC-C1, which shall insure each item that is offered to the procuring activity for acceptance or approval conforms to contract requirements. The inspection system shall be documented and available for review and approval by the procuring activity.

4.2 Responsibility for inspection. Unless otherwise specified in the contract or purchase order, the Contractor is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified, the Contractor may use his own or any commercial facilities acceptable to the Government.

4.2.1 Records. The Contractor shall maintain records of all inspections and tests. These records shall be available for viewing upon request.

4.3 Calibration. Test equipment utilized during repair shall be calibrated in accordance with ANSI/ASQC-C1-1996 using standards traceable to the National Bureau of Standards.

4.4 Submission of test plans. If the equipment is being repaired by other than an OEM authorized / certified repair facility, Test Plans shall be submitted for review by the Equipment Specialist(s) prior to the award of the repair contract via the Contracting Officer.

PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 Preservation.

5.1.1 Electrostatic protection. Electronic parts susceptible to damage by environmental field forces.

5.1.1.1 Sensitive electronic devices and other items susceptible to environmental field force damage (electrostatic fields, electromagnetic fields, or magnetic fields, or combinations of these fields) shall be protected in accordance with MIL-STD-2073-1E with Change 17, January 2011. See paragraph 3.7, 5.2.4.1 and table J-Ia.

5.1.1.2 See MIL-PRF-81705E_AMENDMENT-1 Barrier Materials, Flexible, Electrostatic Discharge Protective, Heat-Sealable. This specification explains the need for using this specification of electrostatic/vapor barrier material.

5.2 Military packing. Packing shall comply with MIL-STD-2073-1E with Change 1 to provide the military preservation and packing that a given item requires to ensure that it is not degraded during shipment and storage.

5.2.1 Intermediate and exterior packing. Application of materials and/or methods designed to protect an item during shipment, handling, indeterminate storage and distribution to consignees worldwide.

5.2.2 Unit pack. All items repaired shall be individually packaged per MIL-STD-2073-1E w/Change 1 7 January 2011, APPENDIX B, B.3.1 and returned in the same container that it was received in prior to induction. Multiple parts which when assembled equal one (1) unit will all be packed within the same outer box.

5.2.3 Damage to or loss of original container. In the event of damage to or loss of the original container, the Contractor must provide an equal replacement container.

NOTE

Remove any old markings and if applicable the CUA stickers from the containers prior to applying the new markings.

NOTE

A copy of the Final performance and acceptance testing data record sheet shall be included in the container. See 3.4.3 and 3.5.2.

5.3 Marking. In addition to any special markings required by the contract or order, all interior packages and shipping containers shall be marked in accordance with MIL-STD-129P w/Change 4. See 6.2 for example.

5.4 Shipping. Unless otherwise directed by the Contracting Officer, the contractor shall return repaired electronic equipment/units to:

NOTE

Normal deliver hours at the warehouse are Monday through Friday 07301300. If delivery is needed to be made outside that delivery window the Contractor shall notify the Contracting Officer.

NOTES

6.1 Open and inspection report examples.

FIGURE 1. OIR Example Inspection Report (OIR)

Date: __________________________ From: (POC: name and phone number):___________________________________________________ Contract Number: ______________________________________________ Line Item: _____________

REPAIR:

Nomenclature: ____________________________________________ S/N: ________________________ OEM P/N:_________________________________ NIIN/NSN: _________________________________ Revision: ________________ Problem(s) found:

Recommended solution: List Material/Parts: _______________________________________________ Anticipated Material Cost: __________________________________ Anticipated Labor Hrs:_________________ At Hourly Labor rate of: ______________ Total Estimated Repair Cost: ______________________________________________ Cost includes Open/Inspect fee? YES ______ NO _______ Cost of Packaging:__________________________________________ Cost of Marking:___________________________________________ Cost of Freight:_____________________________________________ Delivery charges:____________________________________________

Or

BER:

Nomenclature: ____________________________________________ S/N: ________________________ P/N:_________________________________ NIIN/NSN: ______________________________________ Revision: ________________ Problem(s) found:

Recommended solution: List Material/Parts: _______________________________________________ Anticipated Material Cost: __________________________________ Anticipated Labor Hrs:_________________ At Hourly Labor rate of: ______________ Total Anticipated Repair Cost: ______________________________________________ Cost includes Open/Inspect fee? YES ______ NO _______ Cost of Packaging: __________________________________________ Cost of Marking: ___________________________________________ Cost of Freight: _____________________________________________ Delivery charges: ____________________________________________Obsolete Material/Parts: __________________________________________________________________

Or

NO FAULT FOUND:

Nomenclature: ____________________________________________ S/N: ________________________ P/N:_________________________________ NIIN/NSN: ______________________________________ Revision: ________________ Problem(s) found:

Recommended solution: List Material/Parts: _______________________________________________ Anticipated Material Cost: __________________________________ Anticipated Labor Hrs: _________________ At Hourly Labor rate of: ______________ Total Anticipated Repair Cost: ______________________________________________ Cost includes Open/Inspect fee? YES ______ NO _______ Cost of Packaging: __________________________________________ Cost of Marking: ___________________________________________ Cost of Freight: _____________________________________________ Delivery charges: ____________________________________________ FIGURE 2. OIR Example Inspection Report (OIR) Date: _________ From: (POC: name and phone number)

_______________________________ REPAIR:

Contract Number: HSCG40-___________________________ Line Item: ________________ Nomenclature: ________________________________ S/N: _____________________

NIIN/NSN: ___________________________

P/N: _______________________________ Revision: _________ Problem(s) found: ________________________________________________________ Recommended solution (List Material/Parts): __________________________________ Anticipated Material Cost: ___________Anticipated Labor Hrs: ___________ Total Anticipated Repair Cost: _____________ Cost includes Open/Inspect fee? YES NO Cost of Packaging: __________________________________________ Cost of Marking: ___________________________________________ Cost of Freight: _____________________________________________ Delivery charges: ____________________________________________

OR

BEYOND ECONOMICAL REPAIR (BER):

Contract Number: HSCG40-___________________________ Line Item: ________________ Nomenclature: ________________________________ S/N: _____________________

NIIN/NSN: ___________________________

P/N: _______________________________ Revision: _________ Problem(s) found: ________________________________________________________ Recommended solution (List Material/Parts/Replacement): _______________________ Obsolete Material/Parts: __________________________________________________________________ Labor Hrs: ______ Cost (if any): __________ Cost includes Open/Inspect fee? YES NO Cost of Packaging: __________________________________________ Cost of Marking: ___________________________________________ Cost of Freight: _____________________________________________ Delivery charges: ____________________________________________

OR

NO FAULT FOUND:

Contract Number: HSCG40-___________________________ Line Item: ________________ Nomenclature: ________________________________ S/N: _____________________

NIIN/NSN: ___________________________

P/N: _______________________________ Revision: _________ Effort made to determine the item was operational (Include any programming, alignment, set-up or material changes):

Labor Hours: ______ Cost (if any):_________ Cost includes Open/Inspect fee? YES NO Cost of Packaging: __________________________________________ Cost of Marking: ___________________________________________ Cost of Freight: _____________________________________________ Delivery charges:____________________________________________

6.2 Military marking example.

FIGURE 1. MILITARY MARKING EXAMPLE

Example of unit pack, intermediate and exterior container identification markings (**Barcoding is no longer used or required by our warehouse. All barcoding requirements referenced within this document are waived from our required packaing specs**).

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