Attachment1_ Statement of Work_11242024.pdf

U.S. Customs and Border Protection: Air and Marine Operations (AMO)

Statement of Work (SOW) for Aircraft Support Services

Table of Contents

1. Background:

2. Task Descriptions:

3. AMO Supported Platforms:

4. Labor Categories:

5. Contractor Personnel:

6. Place of Performance and Period of Performance:

7. Governance:

8. General:

a. System Safety

b. Quality Assurance

c. Quality Assurance Surveillance Plans (QASP)

d. Security Management

e. Financial Management

f. Risk Management

9. Program Management Reviews

10. Monthly Meetings

11. Technical Interchange Meetings

12. Kick-Off Meeting

13. Travel

14. Government Furnished Information/Equipment/Property

15. Procurement and Material Support

16. Physical Survey

17. Certification Standards

a. FAA Certification

b. DOD (SRD or NAVAIR) and DHS Certification

18. Integration Support

19. Mission Management System Support

a. JHU APL is the Government provided vendor for development of Minotaur with separate sustainment contracts for software changes

b. The Contractor is not required to establish a contract with JHU but must work with and collaborate with JHU as a CBP team member

c. A Non-Disclosure Agreement (NDA) will be required

20. Data Rights

21. Materials

22. Request for Waivers

23. Technical Reviews:

a. System Requirements Review

b. System Description Document (SDD)

c. Preliminary Design Reviews (PDR)

d. Critical Design Reviews (CDR)

e. Test Readiness Reviews

24. Engineering

a. Engineering Change Proposals (ECP)

b. Initial Engineering Analysis

c. Thermal Load Analysis

d. Electrical Load Analysis

e. Structural and Stress Loads Analysis

f. Electromagnetic Effects Analysis

g. Sensor/Antenna Installation Analysis

h. Human Factors Assessment

i. Ingress and Egress

j. Health Standards

k. Design for Maintainer

l. Warning Labels

m. Subcontractor Engineering Coordination

25. Warranty

26. Weight and Balance

27. Configuration Management (CM)

28. Test Requirements

a. Government Acceptance Tests

b. Contractor Ground Tests

c. EMI/EMC Tests

d. Thermal Tests

e. Airworthiness and Aircraft Performance Tests

f. Mission System Tests

g. Test Operations

h. Test Security

i. Operational T&E Support

29. Government Inspection and Acceptance

30. Technical & Training Support Requirements:

a. Technical Support

b. Post-delivery (Onsite) Service Support

c. Pilot Differences Training

d. Mission System/Sensor Operator (MSO) Differences Training

e. Maintenance Differences Training

31. Aircraft Documentation:

a. Technical Manuals

b. FAA-Approved Flight Manuals and Checklists

c. Vendor Manuals

d. Maintenance Manuals

e. Software/Firmware Configuration Documentation

f. Test Reports

g. Design Drawings

32. Contract Data Requirements List (CDRL)

1. Background:

U.S. Customs and Border Protection (CBP) Air and Marine Operations (AMO) supports a layered enforcement strategy for border security through an integrated and coordinated air and marine force to detect, work with partners to interdict and prevent acts of terrorism arising from unlawful movement of people, illegal drugs, and other contraband across the borders of the United States (U.S.). This requires a fleet of special mission equipped aircraft. AMO fixed and rotary winged assets support CBP and other stakeholders in the detection, identification, and apprehension of targets of interest, both individual and vehicular. AMO assets support other Department of Homeland Security (DHS) and external partners, in their missions including law enforcement support, emergency response support, and providing surveillance for natural disasters.

To provide such support, AMO manages a fleet of approximately 211 aircraft1, spanning 13 aircraft types, equipped with special mission sensors, avionics, radios, and other mission equipment. Over time, both aircraft and mission equipment need alterations and updates, to include such instances as obsolescence.

CBP AMO requires a contract vehicle to support alterations, ad-hoc services, and parts/equipment purchases.

Therefore, CBP AMO is establishing a single award Indefinite Delivery Indefinite Quantity (IDIQ) contract for these services. These services are outside of the current aircraft maintenance contracts, 70B02C20C00000024 (P-3 Aircraft Maintenance and Logistic Services) and 70B02C21C00000005 (National Aircraft and Maintenance Logistics Services).

2. Task Descriptions:

This Statement of Work (SOW) establishes the general scope of work for Contractor-provided aircraft support services for fixed wing and rotary wing aircraft and systems. The Contractor is responsible for providing all labor, tools, transportation, equipment, materials, and supervision in performing the services set forth in this SOW. The work to be performed may include:

• Aircraft Alterations – applicable to both fixed wing and rotary platforms as follows:

o Minor (sensor or communications system upgrade, etc.)

Fabrication, Installation, and Integration Service2

• Avionics Upgrades

• Fabrication for External Alterations o Major (large new system installation, external structural alterations, etc.)

• Engineering Services to include the following:

o Aircraft Engineering Analysis (structural and systems) o Aircraft Engineering Design and Drawings

• Aircraft Heavy Maintenance (Depot and Maintenance Checks)

• Purchasing of Aircraft Parts and Equipment

1 This number may fluctuate depending on operational needs.

2 These sub-tasks may apply for either minor or major alterations depending on the scope of the project

Alteration services may vary in scope, from minor upgrades to the aircraft through major upgrades to mission capability that impact the aircraft manufacturer’s baseline configuration. See Appendix 2 for relevant definitions and examples.

General maintenance and preservation requirements will be provided at task order SOW level.

Routine organizational level aircraft maintenance is not within scope of this IDIQ contract.

Platforms are represented in two major areas: Fixed Wing and Rotary. The list of platforms is included to provide greater insight into the types of systems and subsystems that will be supported under this contract as well as the complexity and uniqueness of the potential task order (TO) requirements covered by this SOW.

Task orders derived from this SOW shall begin with the identification of the platform type.

Furthermore, task order will provide technical specifications and defined requirements necessary for completion of tasks.

3. AMO Supported Platforms:

AMO aircraft are a mixture of Federal Aviation Agency (FAA) certified and maintained to FAA standards, or Department of Defense (DOD) certified and maintained to DOD standards through either the U.S. Army Systems Readiness Directorate (SRD) or U.S. Naval Air Systems Command

(NAVAIR).

FAA and DOD certified aircraft require approved/acceptable data for alterations. Alterations to FAA certified aircraft require the use of a current or updated FAA Supplemental Type Certificate (STC) or field approval process. Alterations to DOD certified aircraft follow the SRD Airworthiness Release or NAVAIR Flight Clearance processes. AMO may also operate self-certified aircraft and systems.

The Contractor shall obtain/maintain all aircraft applicable manuals and supplements for the duration of the modification. If the Contractor does not have the applicable documents, the Government will attempt to obtain them on behalf of the contractor. Please note that CBP does not own or maintain technical manuals, forms publication, bulletins, directives, specifications and standards. Depending on the situation, subscriptions will need to be obtained outside of the Government, subject to Government review and approval prior to purchase. These costs will be allowable and reimbursed following Government review and approval.

The AMO fleet consists of the following for this requirement:

Fixed Wing Original Equipment Manufacturer B200 King Air Beechcraft B350 Super King Air Beechcraft C12 Huron Beechcraft C206H Cessna DHC-8 (Dash-8) De Havilland PC 12 Pilatus PC12/45 Pilatus P-3 Orion Lockheed Martin

Rotary Original Equipment Manufacturer AS350B A-Star Airbus Helicopters H125 Airbus Helicopters UH60 Black Hawk Lockheed Martin (formerly Sikorsky

Aircraft) UH60A Black Hawk Lockheed Martin (formerly Sikorsky

Aircraft) UH60L Black Hawk Lockheed Martin (formerly Sikorsky

Aircraft) UH60M Black Hawk Lockheed Martin (formerly Sikorsky

Aircraft)

4. Labor Categories:

Labor categories and descriptions are stated in Attachment 3, Aircraft Maintenance Labor Categories. The Labor categories listed are only the Government estimation of likely categories that may be required.

The Government reserves the right to modify the contract to add or remove labor categories that are within the general scope of the contract. If new categories are added, then rate(s) will be negotiated with the awarded Prime Contractor.

5. Contractor Personnel:

The Contractor shall be responsible for the provision of adequate levels of staffing and qualified personnel required to meet this SOW and each follow-on task order. In the performance of this SOW, the Contractor shall meet and exceed all necessary tasks.

There are also two Key Personnel positions for this IDIQ:

1. IDIQ Program Manager (PM)

2. IDIQ Deputy Program Manager (DPM)

The IDIQ Program Manager shall have the following minimum qualifications:

• Bachelor’s degree in business administration, management, or related field from an accredited college or university, OR

• At least ten (10) years’ PM experience managing cost, schedule, and performance for aviation maintenance programs.

The IDIQ Deputy Program Manager shall have the following minimum qualifications:

• Bachelor’s degree in business administration, management, or related field from an accredited college or university, OR

• At least four (4) years’ PM experience managing cost, schedule, and performance for aviation maintenance programs.

The IDIQ Program Manager shall be available to respond to inquiries issued from the Contracting Officer Representative (COR) or Contracting Officer (CO). The Contractor shall notify AMO at least 15 days before placement or replacement of key personnel.

The Contractor is responsible for providing a fully qualified Program Manager who shall provide oversight for all task order work being conducted. If the Program Manager is unable to perform their duties (ex: on leave) then the Deputy Program Manager shall have full supervisory authority during the absences of the primary Program Manager. The Program Manager or Deputy shall be responsible for management and coordination of the contract and shall be the point of contact with Government representatives. The Contractor shall notify the COR or Contracting Officer in writing prior to contract start date of the names of the Program Manager and the designated alternate. The Program Manager and designated alternate must be able to read, write, speak, and understand English.

The Contractor shall assign a Technical Lead for each active task order who shall be present on-site to monitor work being conducted. The Technical Lead may be any labor category currently assigned to work on the task order. The primary purpose of the designated Technical Lead is to be the primary technical point of contact for the Government task order technical lead. If the IDIQ Program Manager is on-site, he or she may also be designated as the Technical Lead.

Contractor Employees: The Contractor shall provide qualified employees to accomplish all work required.

Contractor Identification on Government locations: The Contractor is responsible for providing employees with any identifiable uniform clothing such as shirts, overalls, hats, etc. to project a professional appearance. Tank tops, cut-off shirts, and/or shorts are not permissible uniforms.

Control of Contractor Employees. Assignment, transfer, and reassignment of Contractor personnel will be the prerogative of the Contractor. The Contractor shall be responsible for employees in performance of Statement of Work and shall comply with the general intent and specific policies set forth in regulations of CBP concerning conduct of employees as referenced herein. The Government is not responsible for any contract employee misconduct.

If work is performed at a government location, then the COR or CO may restrict access of any Contractor employee, or prospective contract employee who is identified as a potential threat to the health, safety, security, general well-being, or operational mission of the site and its population.

6. Place of Performance and Period of Performance:

The primary place of performance shall be at the Contractor provided facility. The Government will transfer aircraft requiring alterations or maintenance from CBP aircraft facilities to the Contractor's place of performance.

Government preference is for aircraft maintenance and alterations to be conducted inside the Contractors’ provided hangar facilities. If the aircraft must be kept outside, then proper preservation procedures shall be required dependent upon aircraft type.

The Government may request work to be performed at a government’s facility, as necessary.

The estimated ordering period will be a five (5) year period from January 2025 through January 2030.

7. Governance:

The Government shall assign a Contracting Officer Representative (COR) for the overall IDIQ. The Government intends for this IDIQ to be utilized through the AMO offices. Therefore, individual task orders may differ in points of contacts. There may be an Alternative Contracting Officer Representative (ACOR) associated with the task orders who will monitor the performance, inspection, and delivery of tasks.

The Contracting Officer (CO) is the only person authorized to approve changes in any of the requirements of this contract. The Contracting Officer shall be the only individual authorized to accept nonconforming work, waive any requirement of the contract, or to modify any term or condition of the contract. The Contracting Officer is the only individual who can legally obligate Government funds. Please refer to the contract clauses for further information regarding the CO’s authority.

8. General:

The Contractor shall establish and execute the following sub-areas as part of their overall performance:

a. System Safety

The Contractor is solely responsible for compliance with all federal, state, and local laws, the Occupational, Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards, OSHA Standards 29 CFR 1910 and 1926, as applicable, and the protection of their employees.

Additionally, the Contractor is responsible for the safety and health of all subcontractor employees and visitors at the Contractor’s facility.

The Contractor shall adhere to their facility safety regulations and procedures.

The Contractor shall report to the Government safety and injury incidents that occur to personnel in the performance of their duties under this contract.

b. Quality Assurance

The Contractor shall hold current applicable quality management certifications related to the aerospace industry.

c. Quality Assurance Surveillance Plans (QASP)

A QASP may be required at the task order level dependent on the scope of work. The QASP is based on the premise that the Government desires to maintain a quality standard for required services. This plan is primarily focused on what the Government must do to ensure that the Contractor has performed in accordance with performance standards.

d. Security Management

Access to classified information is not required for the performance of this effort. Contractor aircraft maintenance and integration support personnel will not require a security clearance but may require cleared escorts at a government facility.

e. Financial Management

For cost type task orders (TO), the Contractor shall notify the Contracting Officer in writing whenever it has reason to believe that the costs it expects to incur under any TO, when added to all costs previously incurred, will exceed 75 percent of the total amount so far allotted to the TO by the Government. The notice shall state the estimated amount of additional funds required to continue performance for the period specified in the Schedule.

f. Risk Management

Contractor shall employ an industry standard risk management strategy to ensure risks are identified early, tracked, and action is taken to mitigate or avoid those risks. Identified risks and their mitigation strategies shall be documented in the IDIQ Monthly Status Reports (MSR) (CDRL A001) (See Section 10).

9. Program Management Reviews

The Contractor shall prepare and conduct PMRs at the Contractor’s facility when directed by the Government PM, providing at least 14 calendar days’ notification. The Contractor shall provide the proposed agenda to the COR via email for the PMR at least one business week before the review and submit the minutes and action items of the PMR to the COR for approval within five business days after the review.

During the PMRs, the Contractor shall present accomplishments, program status (including technical, cost and schedule performance, issues, and risks), plans for accomplishing project milestones, etc. The Contractor shall use the PMR to provide the Government with the information necessary to assess the Contractor’s progress and performance against the task order requirements.

10. Monthly Meetings

The prime Contractor shall establish an overall IDIQ level monthly program meeting (Teams preferred) with the AMO IDIQ Program Management Office (PMO) to discuss at minimum: upcoming requirements from AMO, open action items, and review of the prime contractor IDIQ MSR (CDRL A001). Monthly meetings shall be conducted within 5 business days after receipt of the IDIQ Monthly Status Report.

Additional meetings or status reporting may be required between the Contractor and respective AMO requirement offices at the task order level.

11. Technical Interchange Meetings

The Contractor shall conduct Technical Interchange Meetings (TIMs) to discuss the status of specific technical task order activities, including studies, design or production status and issues, associated recommended solutions, cost and schedule impacts, test plans and procedures, test results, technical performance, implementation, and technical guidance to ensure continued Government visibility into the technical progress of the contract. The Contractor shall develop a mutually agreed-on TIM agenda and provide it to the COR and the PM via email at least three (3) business days before the TIM. The Contractor shall conduct the TIM at a location and on a date mutually agreed on with the Government.

12. Kick-Off Meeting

No later than 30 calendar days after receipt of IDIQ award, a kick-off meeting will be held with key stakeholders of the Contractor’s staff who will be assigned major responsibility for carrying out the tasks of the contract shall meet with the Contracting Officer, Contracting Officer Representative (COR) and other interested Government personnel within CBP at a location to be determined following IDIQ award.

This meeting will ensure the Contractor, and the Government have a common understanding; in addition, they will discuss the IDIQ program objectives, planned course of action, deliverables, and resolve any differences between the CBP technical requirements and the Contractor’s approach. The Contractor shall provide a briefing describing the firm’s planned approach per their final proposal. The Contractor shall be prepared with appropriate briefing materials.

13. Travel

Travel may be required in accordance with task order requirements. Arrangements for and costs of all travel, transportation, meals, lodging, and incidentals are the responsibility of the Contractor. Travel costs shall be incurred and billed in accordance with the Federal Travel Regulations (FTR). Costs for these expenses will be reviewed, certified, and approved by the COR. All travel and transportation shall utilize commercial sources and carriers. The Government will not pay for business class or first-class travel. Lodging and meals shall be reimbursed in accordance with regulations defined in the FTR.

The Government does not anticipate the prime contractor to travel to USG locations. However, the Government expects the prime Contractor to monitor their subcontractors. If travel is required to subcontractor locations, then it will be approved, subject to properly followed procedure as identified above.

14. Government Furnished Information/Equipment/Property

The Contractor may receive Government Furnished Information (GFI) or Government Furnished Equipment/Property (GFE/GFP) necessary to execute a task order. Any GFI/GFE/GFP made available to the Contractor shall be used only for the purpose of carrying out the requirements of the TO and shall not be divulged or made known to any persons except as necessary in the performance of the TO. The Contractor may be requested to sign non-disclosure statements (NDS). All Government furnished information must be protected to the degree and extent required by local rules, regulations, and procedures.

The task order shall define the applicable Government-furnished equipment (GFE) and property (GFP) for each requested alteration in addition to any required hold-harmless agreements. If any GFE or GFP (including aircraft) does not meet required configuration standards or specifications for the successful execution of the task order, the Contractor shall request, in writing, no later than 15 calendar days from the receipt of the GFE/GFP, the disposition of the item from the CO and COR.

On a case-by-case basis, the Government may provide small specialty tools to accomplish task order requirements. However, large items such as GSE and P-3 depot equipment will not be provided.

Upon receipt, GFE/GFP shall be entered into the Contractor’s asset control process for inventory control before delivery. GFE/GFP will be made available to the Contractor based on an agreed-on schedule with the AMO platform PMs and as detailed in the task orders.

There is no requirement for a warehouse. However, if GFE is provided then storage of those items is required at the Contractor's facility.

15. Procurement and Material Support

The Contractor shall be responsible for purchasing or manufacturing all materials and parts required for each task order execution.

The Government may also require the Contractor to purchase a stand-alone part(s), such as a sensor, to be delivered directly to the Government.

16. Physical Survey

The Contractor shall conduct a physical aircraft survey and inspection of aircraft documents before start of any alterations to ensure the platform is suitable for alteration and immediate recovery to flight operations on completion of work. The Contractor shall immediately notify the CO and COR of any discrepancies recorded with the Government-furnished aircraft via email and then follow up by phone as soon as all parties’ schedules allow (but no more than 7 business days).

17. Certification Standards

The overall IDIQ contract and follow on task orders requiring installations of equipment shall comply with the design and installation standards contained in FAA Advisory Circular No. AC 23.1309-1E. The Contractor shall produce and maintain FAA equivalent certifications in accordance with FAR Part 23 for the purposes of aircraft historical records.

To mitigate risk, the Contractor should utilize existing Supplemental Type Certificates (STC) and parts manufacturing approval (PMA) components and other methods of compliance such as parts manufactured to DOD or industry standards, parts manufactured under technical standard order authorizations (TSOs), original equipment manufacturer (OEM) certified parts, and field approvals.

The Contractor shall develop the fabrication, installation, and alteration data in accordance with FAA or DOD airworthiness certification standards and submit properly substantiated engineering data to the Program Management Office (PMO) for review. Technical data packages (TDPs) for avionics modifications or minor alterations and prototyping of parts and kit development for multiple aircraft installations will be developed.

a. FAA Certification

Major alterations affecting an aircraft’s airworthiness certification shall be covered by modification to existing or new STCs issued by the FAA.

Minor alterations, including temporary installs associated with a specific aircraft mission configuration, shall be covered under the Contractor’s FAA repair station license with independent, designated engineering representative approval (where required) and approved data and drawings defining the alteration.

The Contractor shall be responsible for obtaining, filing, and processing all certification plans, certification testing, flight test, reports and substantiating data, for final FAA evaluation, inspection, and approval.

All installations of equipment shall comply with the design and installation standards contained in FAA Advisory Circular No. AC 23.1309-1E. The vendor shall produce and maintain FAA equivalent certifications in accordance with FAR Part 23 for aircraft historical records.

The altered aircraft shall remain certificated for day and night operations in both U.S. national and international airspace under FAA FAR Part 91 and International Civil Aviation Organization (ICAO) visual and instrument flight rules in the air traffic control environment.

Copies of alterations documentation (including installation instructions, data, drawings, and diagrams associated with certification(s), and the STC where applicable) shall be provided to the Government upon aircraft acceptance.

b. DOD Public-Use type aircraft

The Contractor shall be responsible for development of an Airworthiness Qualification Plan, certification testing, flight test, reports and substantiating data, and support for final evaluation and inspections by

CBP.

The Airworthiness Qualification Plan shall state the vendors plan to document the modification, change, etc. to ensure they have complied with all related requirements per task order. The Contractor shall be responsible for producing documentation to maintain airworthiness status (Configuration Management log-set records), acceptable to be incorporated into the aircraft official logbook.

Alterations to AMO non-FAA certified aircraft shall by covered by the development of a comprehensive airworthiness qualification plan to accommodate the installation of new parts or mission equipment.

Military mission equipment not subject to FAA certification shall comply with the design and installation standards referenced in the data supporting the SRD airworthiness release.

Copies of alteration documentation (including installation instructions, data, drawings, and diagrams associated with obtaining an airworthiness release or flight clearance) shall be provided to the Government upon aircraft acceptance.

18. Integration Support

The Contractor shall provide a Designated Engineering Representative (DER) to support all TOs requiring testing, detail required inspections, and to perform required reporting.

19. Mission Management System Support

The task order will define support for the Government’s mission management system (Minotaur). If required by the task order, the Contractor will be provided with Minotaur as GFE. The technical design authority for Minotaur is Johns Hopkins University Applied Physics Laboratory (JHU APL).

The Contractor shall work with the technical design authority for the Government’s mission management system (Minotaur) to ensure the effective integration with aircraft mission hardware and software.

a) JHU APL is the Government provided vendor for development of Minotaur with separate sustainment contracts for software changes.

b) The Contractor is not required to establish a contract with JHU but must work with and collaborate with JHU as a CBP team member.

c) A Non-Disclosure Agreement (NDA) will be required.

20. Data Rights

The Contractor shall pass all data rights relating to alterations (including deliverable reports, drawings, interface control documents (ICDs), and STC packages) to the Government.

For newly generated STCs obtained under the task orders, the COR shall direct whether the STCs shall be held by and issued to the Government or held by and issued to the Contractor with the Government’s retaining unlimited rights.

21. Materials

The Contractor shall select materials, parts, and processes that meet or exceed FAA or DOD aviation standards for certification (due at delivery). The determination of whether the Contractor meets or exceeds those standards will be identified by the COR and/or the PM. The Contractor may present the proposed materials, parts, and processes before delivery to ensure that they meet the requirements.

22. Request for Waivers

For noncompliance to the task order requirements, the Contractor must submit a Request for Waiver (RFW) documenting the noncompliance together with a mitigation plan, workaround, or plan for remedy. The RFW shall be submitted to the COR via email before delivery and acceptance of the modified aircraft or mission system by the Government, and the COR and CO shall approve or deny the RFW within 10 working days of receipt.

23. Technical Reviews:

The Contractor shall conduct the following formal program reviews for each applicable task order:

• System requirements review (SRR)

• Preliminary design review (PDR)

• Critical design review (CDR)

• Test readiness reviews (TRRs)

The technical reviews shall provide the task order PMs and CO with the information necessary to assess the progress and performance of the Contractor with respect to the requirements stated in the IDIQ task orders for the designated aircraft or mission system.

a. System Requirements Review

SRRs shall be conducted at the Contractor’s facility in accordance with task order requirements. The purpose of the requirements review shall be to allow the Contractor to baseline the alteration requirements and to present derived requirements and methods for test and verification.

b. System Description Document (SDD)

The Contractor shall prepare an SDD that describes the alteration hardware, integration and software, architectures, and designs that meet the task order requirements.

As applicable to the task order, the SDD shall address changes in aircraft and mission system configuration and function to the following:

• Aircraft characteristics

• Performance

• Stability

• Control design information

• Structural design

• Propulsion systems and subsystems

• DC and AC electrical power systems and subsystems

• Flight controls

• Environmental control systems and subsystems

• Emergency equipment

• Survival equipment

• Smoke alarms

• Communication, navigation, surveillance equipment (including integration)

• Equipment racks and operator workstations/consoles

• Aircraft structural illustrations and drawings, showing cockpit and cabin dimensions and layout, crew vision range and lines, cockpit and cabin instrument panels, mass properties, electrical loads

• Size, weight, and power consumption (SWaP-C)

• Thermal management

• Mission systems equipment (e.g., sensors, communications, displays)

• Outer mold line (e.g., Radomes and external antennas)

c. Preliminary Design Reviews (PDR)

PDRs shall be conducted at the Contractor’s facility in accordance with task order requirements. The Contractor shall present the preliminary alteration drawings, including technical issues, aircraft and mission system interfaces, and safety items.

d. Critical Design Reviews (CDR)

CDRs shall be conducted at the Contractor’s facility in accordance with task order requirements. The Contractor shall present the final drawings for the alterations design and the engineering approach for installation and integration, including any mutually agreed-on changes identified at the PDR. ICDs, engineering analyses, material and process specifications, and acceptance and verification plans (including inspection and test) shall also be complete at this time.

The approved results of the CDR shall be the final requirements for design, performance, and test.

e. Test Readiness Reviews

TRRs shall be conducted at the Contractor’s facility in accordance with task order requirements to demonstrate the readiness of each modified aircraft or mission system to enter test and evaluation. The purpose of the TRR is to permit the Government to formally review the Contractor’s acceptance test plan, approach, and procedures and to discuss build-related activities associated with the modified aircraft equipment, line replaceable units (LRUs), or mission systems.

24. Engineering

Engineering requirements for a task order will be specified and outlined fully in a follow on TO SOW.

a. Engineering Change Proposals (ECP)

Requirement changes after the CDR shall require ECPs.

The Contractor shall submit ECPs, along with impacts to cost and schedule, to the COR via email for review and approval before implementation and incorporation of a change to the baselined requirements.

The Contractor shall submit a detailed change description for each document that would be changed if that ECP were approved. The Contractor shall include in each change description the exact proposed changes by citing the words/information to be changed from the baseline documentation contents. ECP life cycles, from initiation to approval, shall take less than 30 calendar days (including Government review) and will amend the task order under mutually agreeable terms.

For minor task order changes, which can support an expedited life cycle of less than five business days, the Contractor shall recommend to the Government an agile change process that is tailored to the nature of the task.

b. Initial Engineering Analysis

The Contractor shall provide an initial engineering analysis where the aircraft alteration or installation of mission equipment may present complex integration challenges. This analysis will allow AMO to mitigate the risk of actual alterations, identify resources, and understand the route to a final certified capability.

c. Thermal Load Analysis

The Contractor shall provide a thermal analysis for the aircraft in missionized configuration with all equipment operating and personnel on board (including passengers and/or cargo as noted in the task order), if applicable.

d. Electrical Load Analysis

The Contractor shall undertake an electrical load analysis that reflects changes made by the alterations.

AC 23.1311-1C (FAR Part 23) practices shall be used as a guide for preparing the electrical load analysis supplement.

Task orders that modify aircraft or mission equipment electrical systems shall include an electrical load analysis of both AC and DC power to the modified aircraft and/or mission equipment. This includes updating the electrical placard.

e. Structural and Stress Loads Analysis

The Contractor shall provide a structural and mechanical loads analysis for the aircraft alterations. Stress analysis of all alterations shall also be accomplished to the extent required to obtain FAA certification for the alterations.

f. Electromagnetic Effects Analysis

The Contractor shall ensure that aircraft alterations or mission equipment installations are not sources of detrimental conducted or radiated interference. Conducted or radiated interference from other equipment or systems installed in the airplane should not adversely affect new aircraft of mission equipment. The contract shall use design practices as outlined in AC 23.1311-1C or MIL-STD-464C, as applicable, as a guide to minimize electromagnetic compatibility/interference (EMC/EMI) adverse impacts.

An electromagnetic environmental effects (E3) analysis shall document how E3 controls are applied to the aircraft systems and mission equipment and verified.

g. Sensor/Antenna Installation Analysis

The Contractor shall conduct a sensor/antenna location and interference analysis for any aircraft and mission system alteration that require the removal, relocation, or installation of new sensors/antennas. The analysis shall update the aircraft’s antenna map and detail the required sensor/antenna patterns and methods employed to meet the performance requirements for new sensor/antennas, to meet the expected performance characteristics, and/or to address any concerns associated with potential for interference that would affect either function or performance.

h. Human Factors Assessment

Human factors engineering shall be in accordance with guidelines of DOD Design Criteria Standard:

Human Engineering (MIL-STD-1472H) or FAA Human Factors Design Standard (HF-STD-001B).

Any system that is altered/modified under the task orders shall have a human factors assessment.

i. Ingress and Egress

The altered/modified aircraft shall not hinder ingress/egress through existing emergency exits, hatches, and passageways for all crewmembers. Aircraft seating shall not occlude egress/ingress through aircraft exits, hatches, and passageways. Crewmembers shall not be required to adjust any of the seats in order to execute an emergency egress.

j. Health Standards

The aircraft and mission system alterations shall control noise health hazards in accordance with 14 CFR Part 36 Noise Standards: Aircraft Type and Airworthiness Certification or DOD Design Criteria Standard: Noise Limits (MIL-STD-1474E). Alterations to cabin ventilation and cooling systems shall control air quality health hazards in accordance with 14 CFR Part 25.831.

k. Design for Maintainer

The aircraft and mission system alterations (including the physical interfaces for the kits, sensor packages, and racks) shall comply with MIL-STD-1472H in the following areas:

• Maintenance accessibility (Section 5.9.6)

• Mounting of items (Section 5.9.2)

• Adjustment of controls (Section 5.9.5)

• Access and accessibility (Section 5.9.6) (note: applies also to equipment racks)

• Fasteners (Section 5.9.11)

• Design for efficient handling (Section 5.9.4)

• Mounting (Section 5.9.3)

• Conductors (Section 5.9.14)

• Connectors (Section 5.9.14)

l. Warning Labels

The aircraft shall prominently display warning labels to warn personnel of hazards to people or equipment in accordance with MIL-STD-1472H.

m. Subcontractor Engineering Coordination

The Contractor shall provide engineering liaison with all subcontractors/vendors during the design, fabrication, assembly, installation, test, and acceptance phases. The Contractor shall be responsible for managing all subcontractor nonrecurring engineering, technical activities, and expenditures.

25. Warranty

The Contractor shall warrant that each modified aircraft will be free from defects related to design and craftsmanship. The Contractor shall repair or replace those defects for a period of 180 days from the date of aircraft acceptance by the Government if both parties agree that the defect is related to the Contractor’s design or craftsmanship. This warranty excludes component equipment where separate individual manufacturing warranties provide coverage for the defect. The Contractor shall pass on any warranties for subcontractor modification work, and equipment installed on the modified aircraft. These warranties shall start at aircraft acceptance. The Contractor shall correct any failure of equipment or software due to inadequate design, improper integration, or testing without cost to the Government for this warranty period. Warranty work will be conducted at the Contractor’s facility unless agreed otherwise by both the Contractor and the Government. The Contractor shall submit the warranties (CDRL A002) per SOW Section 32, IDIQ Contract Deliverables Report List.

26. Weight and Balance

With all mission systems installed, the altered aircraft shall meet all operational requirements of the performance specification without exceeding the maximum takeoff weight or basic empty weight when operating within all other flight manual limitations.

The Contractor shall ensure that the installation of equipment defined in the task order does not adversely affect the center of gravity of the aircraft.

All aircraft shall be weighed upon completion of major alterations or installation activity. A new weight and balance chart shall be created for each aircraft.

27. Configuration Management (CM)

The Contractor shall provide a configuration management plan or process and maintain a list of all items under configuration control IAW task order requirements.

28. Test Requirements

If required, the task order will identify the level of aircraft testing necessary based on type of alteration.

The task order will identify the lead organization for test planning and execution. Some tests shall be Contractor led; others will be under an AMO test and evaluation (T&E) lead. All test plans will have AMO T&E oversight and approval.

The Contractor shall prepare ground and flight test plans that outline the tests to be conducted and submit them to the COR no later than 90 calendar days before the scheduled aircraft acceptance test. The COR shall notify the Contractor via email of approval or disapproval within 30 calendar days after receipt of those test plans.

Aircraft tests shall be thorough enough to demonstrate capability, verify performance, and ensure that no degradation of other avionics and/or electronic equipment performance has been caused by inadequate manufacturing or installation techniques, power instabilities, or heating/cooling deficiencies.

a. Government Acceptance Tests

Acceptance shall include all ground, and flight tests of installed or modified equipment in accordance with the specified test plans and procedures to be developed by the Contractor and approved by AMO T&E and the CBP COR. Except for Contractor Ground Integration Testing, all formal testing for purposes of Government Acceptance shall be conducted with Government participation, unless waived by the COR.

b. Contractor Ground Tests

The Contractor shall develop ground test plans sufficient to demonstrate that the aircraft, aircraft alterations, and all mission system installations and alterations meet or exceed all requirements identified in the task orders and FAA/SRD/NAVAIR criteria required for airworthiness certification.

The PM and COR shall determine if the plans meet or exceed requirements.

Aircraft ground testing shall be performed in accordance with any applicable technical or vendors’ manuals, including where required by the nature of the integration and participation from the technical design authority for the Government’s mission management system (Minotaur).

c. EMI/EMC Tests

As required by the task orders, the Contractor shall perform an electrical bonding test and an intra-system EMC test in accordance with a Contractor-developed test procedure to verify that there is no degradation of aircraft avionics, radios, or other electronic equipment performance. EMC tests shall be completed, and results documented, before commencement of acceptance flight testing.

d. Thermal Tests

As required by the task orders, the Contractor shall perform thermal testing at the lowest and highest altitudes used by the aircraft operationally (low altitudes tend to be the worst case for cabin overheating with high altitudes typically the worst case for electronics cooling as air mass flow rates are reduced).

Test altitudes shall be maintained long enough to establish steady-state cabin temperatures and normal mission equipment function.

Thermal tests shall be completed, and results documented, before completion of acceptance flight testing.

e. Airworthiness and Aircraft Performance Tests

The Contractor shall demonstrate to the Government that aircraft altered/modified under each task order shall satisfactorily meet all of the criteria required for FAA/DOD/DHS airworthiness approval, including verifying flight manual supplements.

The Contractor shall satisfactorily demonstrate mission profiles under the conditions outlined in the task order to confirm there is no adverse effect on the operational use of the aircraft in its intended environment.

Airworthiness and aircraft performance tests results shall be in accordance with Government-approved flight test plans.

f. Mission System Tests

The Contractor shall demonstrate to the Government that the aircraft modified under each task order will satisfactorily perform the mission requirements for any new, modified, or disturbed systems installed during the period of the task order.

Mission system tests and results reporting shall be in accordance with Government-approved flight test plans.

g. Test Operations

Before final acceptance, the airworthiness, aircraft performance, and mission system flight testing shall be accomplished at the Contractor’s facility or at an alternate facility specified in writing by the COR.

The Contractor shall provide pre-flight and post-flight support of the modified aircraft and mission systems including aircraft fuel and servicing consumables.

Test support requirements shall be presented to the COR via email for review and approval no later than 60 calendar days before the first flight of the modified aircraft.

h. Test Security

Aircraft mission systems test data shall be marked as directed by the task order requirements.

i. Operational T&E Support

In accordance with the task order, the Contractor may be tasked to support an operational test and evaluation (OT&E) of the alterations.

29. Government Inspection and Acceptance

The Government may perform the following actions during inspection and acceptance testing:

• Witness Contractor testing.

• Review Contractor quality assurance inspection documentation and sign off.

• Conduct physical inventory at the LRU level of items added/removed as part of the alteration.

• Arrange for support from the Johns Hopkins University Applied Physics Laboratory during acceptance testing.

30. Technical & Training Support Requirements:

The Contractor shall provide program, technical, manufacturing, and engineering liaison management.

Access to Contractor facilities shall be granted to Government representatives in accordance with the contract terms and conditions or upon agreement of both parties.

After delivery of an altered/ modified aircraft to the Government, the Contractor shall provide telephonic and, as needed, onsite technical and logistical support during the warranty period of the contract to any of the sites where the aircraft are fielded. The Contractor shall coordinate with the COR for access to aircraft maintenance facilities and records. The Government personnel authorized to place requests for support services shall be determined by the COR and designated in writing to the Contractor by the CO.

a. Technical Support

After contract award and during the warranty period, the Contractor shall supply the COR via email with its support service phone number. The support service phone line must be staffed and answered by the Contractor at least eight continuous hours per day (local time to the Contractor’s support facility), five days per week excluding federal holidays. The Contractor shall also supply the COR with a 24-hour support service phone number for emergencies that arise outside of normal working hours.

b. Post-delivery (Onsite) Service Support

If required by the task order, the Contractor shall provide field service representatives (FSRs) to be available on as needed basis and in accordance with the support period identified in the task order SOW.

FSR support visits shall be conducted within two calendar days of Government authorization.

Contractor personnel shall coordinate with the COR and comply with any applicable security, badge, or other access regulations and requirements specific to a facility where onsite services are required.

c. Pilot Differences Training

As required by the task order, the Contractor shall provide an updated flight training syllabus and initial classroom training to qualify AMO pilots on differences to operate the altered/modified aircraft and mission systems. The flight training syllabus shall meet applicable FAA guidance and/or regulations concerning the development of flight training manuals. Location, duration, daily training hours, etc., shall be identified by the Contractor and submitted to the Government.

The Contractor shall also provide an updated syllabus if significant software changes have taken place that impact pilot use. The proposed training syllabus shall be provided to the COR for review and approval no later than 60 calendar days before the delivery of the first modified aircraft or mission system.

d. Mission System/Sensor Operator (MSO) Differences Training

As required by the task order, the Contractor shall provide classroom-based MSO differences training and documentation for the operation of mission equipment that has been installed or modified under the task order. Location, duration, daily training hours, etc., shall be identified by the Contractor and submitted to the Government.

The Contractor shall also provide an updated syllabus on the operation of mission equipment if significant hardware changes have taken place, including diagnosis of faults and procedures for configuring the equipment. The proposed training syllabus shall be provided to the COR for review and approval no later than 60 calendar days before the delivery of the first modified aircraft or mission system.

e. Maintenance Differences Training

As required by the task order, the Contractor shall provide a maintenance training syllabus and initial classroom training to qualify designated maintenance personnel to maintain aircraft and mission systems modified under the task order. Location, duration, daily training hours, etc., shall be identified by the Contractor and submitted to the Government. The maintenance training syllabus shall meet applicable FAA guidance and/or regulations concerning the development of maintenance training manuals. The proposed training syllabus shall be provided to the COR for review and approval no later than 60 calendar days before the delivery of the first modified aircraft or mission system.

Areas of training shall include, but not be limited to, any changes to the following:

• Engines and/or generators

• Sensors and related systems

• Mission system equipment

• Aircraft avionics

• Aircraft and/or mission equipment electrical…