Attach 01_Performance Work Statement.pdf

PR: FD2060-22-32196 PWS 1

Performance Work Statement for

TH-1H Helicopter Depot Level Maintenance

Purchase Request: FD2060-22-32196

28 June 2023

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Table of Contents

1.0 Description of Services

1.1. Objective(s)

1.2. Benefit to United States Air Force (USAF)

1.3. Background

2.0 Services Summary

3.0 Government Property

3.1. Government Property to be Provided

3.2. Government Furnished Information

3.3. Contractor Responsibility

3.3.1. Contractor Acquired Property (CAP)/Long Lead Items

3.3.2. Replacement of Consumable Maintenance Supplies and Material

3.3.3. Repairable and Replacement Parts

3.3.4. Specialized Tools, Test Equipment, and Support Equipment

3.4. Reporting of Government Property

3.5. Loss of Government Property

3.5.1. Definition of Loss of Government Property

3.5.2. Reporting Loss of Government Property

3.6. Return or Retention of Government Property

4.0 Technical Requirements

4.1. Period and Place of Performance

4.1.1. Contract Period of Performance

4.1.2. Place of Performance

4.2. Contract Data Requirements List(s) (CDRL)

4.2.1. Quality of CDRL Deliverable

4.2.2. Receipt of CDRL Deliverable

4.3. Depot Level Maintenance (DLM) Standards and Requirements

4.3.1. DLM Schedule

4.3.1.1. Fixed Portion

4.3.1.2. Variable Portion

4.3.1.3. Total Flow Days

4.3.1.4. Aircraft Delivery

4.3.2. Sequence of Work

4.3.3. DLM Repair Standards and Defect Classification

4.3.4. Defect Classifications

4.3.4.1. Critical Defect

4.3.4.2. Major Defect

4.3.4.3. Minor Defect

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4.3.4.4. Type of Defect

4.3.5. Defect Correction Criteria

4.3.6. Defects Caused by Depot Facility

4.3.7. Nonstandard Repairs

4.3.8. Over and Above (O&A) Maintenance

4.3.9. Nonstandard Modifications

4.3.10. Special Work Requests

4.3.11. Workmanship and Repair Standards

4.4. Unprogrammed Depot Level Maintenance (UDLM)

4.4.1. Drop-in Maintenance/Depot Field Team (DFT)

4.4.2. Contractor Field Teams (CFT)

4.4.3. Request for Assistance

4.5. Repair

4.5.1. Item Unique Identification (IUID)

4.5.1.1. Marking Requirement

4.5.1.2. Reporting in IUID Registry

4.5.2. Packaging

4.5.3. Counterfeit Electronic Parts

4.6. USAF Technical Orders (TOs)

4.7. Cognizant Field Authority (CFA)/Government Cognizant Field

Representative (CFR)

4.7.1. Cognizant Field Authority (CFA)

4.7.2. Government Cognizant Field Representative (CFR)

4.7.3. Authority

4.7.4. CFA/CFR Maintenance Approval

4.8. Acceptance and Rejection Criteria

4.8.1. Defect Correction

4.8.2. AFTO Form 103

4.8.3. Technical Order System Deficiency Report (AFTO Form 22)

4.8.4. Nondestructive Inspection Technique Change (AFTO Form 242)

4.8.5. Photographs

4.9. DLM Records

4.9.1. Aircraft Records

4.9.2. AFTO Form 95

4.10. Economic Repair, Condemnation, and Replacement of Parts

4.10.1. Economical Repair Determination

4.10.2. Condemnation

4.11. Personnel and Support

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4.11.1. Management of Personnel

4.11.1.1. Planned Staffing

4.11.1.2. Unplanned Staffing Changes

4.11.2. Engineering Support Services

4.11.3. Engineering Qualifications

4.11.4. Process Engineering Support

4.11.5. TH-1H Engineering Support

4.11.6. Flight Testing/Engineering Support

4.11.6.1. Test Pilots

4.11.6.2. Flight Mechanics/Crew Chiefs

4.11.7. Pilot Qualification and Currency Training

4.12. Depot Level Maintenance General Maintenance Practices

4.12.1. Policies and Practices

4.12.2. Repair and Replacement of Critical Safety Items (CSIs)

4.12.3. Precision Measuring Equipment (PME)

4.12.4. Aircraft Servicing and Security

4.12.5. Fueling and Defueling

4.12.6. Aircraft Movement or Ground Handling

4.12.7. Aircraft Security

4.12.8. Severe Weather and Hurricane Evacuation

4.12.9. Airfield Requirements

4.12.10. Hazardous Materials

4.12.11. Petroleum, Oils, and Lubricants (POL)

4.12.12. Usage and Handling of Gases

4.12.13. Abrasive Materials

4.12.14. Drawing Configuration Management

4.12.15. Technical Data

4.12.15.1. Technical Drawings

4.12.16. DLM Material Management

4.12.17. Disposition of Repairables and Consumables

4.12.18. Nonconforming Material

4.12.19. Cannibalization of Parts

4.12.20. Substitution of Parts

4.12.21. Measuring and Test Equipment

4.12.22. Components and Parts Segregation

4.13. Quality Requirements

4.14. Inspection Responsibility

4.14.1. Inspection System

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4.14.2. Sampling Inspection

4.14.3. In-Process Inspection

4.14.4. Government Approval

4.15. Documentation, Records, and Corrective Action

4.15.1. Corrective Action

4.15.2. Drawings and Changes

4.15.3. Process Control

4.16. Certification of Personnel, Materials, and Processes

4.17. Indication of Inspection Status

4.18. Nonconforming Material

4.19. Component Reuse

4.20. Standards of Serviceability

4.21. Omissions and Deviations

4.22. Final Acceptance

4.23. Work Requirements

4.23.1. Aircraft PDM Requirements

4.23.2. Engine Removal

4.23.3. Urgent or Immediate Action Time Compliance Technical Orders (TCTOs)

4.23.4. Technical Modifications/Inspections

4.23.5. Technical Modification/Inspection Log and Record

4.24. Nondestructive Inspection (NDI) Requirements

4.24.1. NDI Methods

4.24.2. NDI Personnel Qualifications

4.25. Maintenance and Repair

4.25.1. Findings

4.26. Discrepancies

4.26.1. Structural and Skin Repairs

4.26.2. Replacement Parts and Materials

4.26.3. Primary Structural TO

4.27. Travel

4.28. Meetings, Briefings, and Presentations

4.28.1. Meeting Agendas, Briefings, and Presentations

4.28.2. Meeting Minutes

4.29. Reports and Deliverables

4.29.1. Transition Plans

4.29.1.1. Phase-In Transition Plan

4.29.1.2. Phase-Out Transition Plan

4.29.2. Monthly Status Report (MSR)

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4.29.3. Aircraft Milestone Schedule

4.29.4. Funds and Man-Hours Report

4.29.5. DLM Reports

4.29.5.1. Initial Inspection and Repair Report

4.29.5.2. Rough Order of Magnitude (ROM) Cost Estimate

4.29.5.3. List of Materials (LOM)

4.29.5.4. Final Inspection and Repair Report

4.29.5.5. Contractor Acquired Property (CAP)/Long Lead Inventory Status Report

4.29.6. Weekly Status Report

4.29.7. Engineering Services Reports

4.30. Program Management Reviews (PMRs)/Meetings

4.30.1. 45-Day Induction Meeting

5.0 General Information

5.1. Continuation of Mission-Essential Services During a Crisis

5.2. Security Requirements

5.2.1. Security Regulations

5.2.2. Operations Security (OPSEC)

5.2.3. Security Clearance

5.2.4. Security Incident or Violation

5.2.5. Access to Government System(s)

5.2.6. Access to Government Facility or Military Installation

5.2.7. Common Access Card (CAC)

5.3. Environmental Management System (EMS)

5.4. Agency Affirmative Procurement Programs

5.5. Safety Requirements

5.5.1. Contractor Environmental, Safety, and Occupational Health Compliance

5.5.2. Mishap Notification/Investigation

5.5.3. Voluntary Protection Programs (VPP)

5.5.4. VPP Description

5.5.5. Department of Labor (DoL) Inspection of Contractor Operations

5.6. Inspection of Services

5.7. Service Contract Reporting (SCR)

5.8. Invoicing/Payment and Receipt/Acceptance

5.9. Quality Control Plan/Quality Management System (QMS)

5.10. Trafficking in Persons

6.0 Appendices

6.1. Appendix A – References

6.2. Appendix B – Acronyms

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6.3. Appendix C – Terms and Definitions

6.4. Appendix D – Repairable Items

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1.0 Description of Services

1.1. Objective(s)

This Performance Work Statement (PWS) describes the services required to accomplish Depot Level Maintenance (DLM) capability for the TH-1H model aircraft. The primary purpose of the DLM program is to accomplish Programmed Depot Maintenance (PDM), aircraft structural inspections, and repairs concurrent with zonal inspections at a depth and skill level greater than that available at Organizational maintenance levels. All work performed under this PWS shall be in accordance with (IAW) the publications, technical manuals, and specifications identified herein. The DLM requirements may also include unscheduled maintenance and the deployment of Contractor Field Teams (CFT); however, there is no guarantee that any drop-in maintenance shall be performed. The Contractor shall possess current, direct aircraft maintenance/overhaul and extensive logistics and program management knowledge and experience on light- to medium-lift helicopter platforms greater than 5,000 pounds gross operating weight.

1.2. Benefit to United States Air Force (USAF)

This acquisition will benefit the United States Air Force (USAF) by providing a safe and structurally sound helicopter to facilitate Student Utility Pilot Training while also providing TH-1H aircraft to meet the operational requirements of the USAF pilot training program at Cairns Army Air Field (AAF).

1.3. Background

This is an established requirement to provide services for TH-1H aircraft. The Government has a need to sustain these aircraft in order to support the Flight Training Program.

2.0 Services Summary

The Services Summary (SS) below identifies the Performance Objectives (POs) and Performance Thresholds (PTs) that are significant to ensure the TH-1H aircraft are mission capable. The POs provide the criteria by which the Contractor’s performance will be evaluated during the period of performance indicated in paragraph 4.1.

Performance Objective

PWS

Reference Performance Threshold

Quality of Repair 4.25.1 There shall be zero (0) Category I Major Findings during customer post-PDM/overhaul acceptance inspections for each aircraft.

There shall be no more than one (1) Category II Major finding during customer post-PDM/overhaul acceptance inspections for each aircraft.

There shall be no more than five (5) Category I Minor findings during customer post- PDM/overhaul acceptance inspections for each aircraft.

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Performance Objective

PWS

Reference Performance Threshold

Delivery of Repair 4.3.1.4 Repaired assets shall be delivered in accordance with the schedule defined by the contract/order.

There shall be no more than one (1) late delivery per contract year. The Contractor shall notify the Government if the delivery of any asset will not meet the scheduled delivery date and negotiate a revised delivery date. The late asset shall be delivered by the revised delivery date acceptable to the Government.

Quality of CDRL Deliverable

4.2.1 There shall be no more than one (1) rejection of any

deliverable. There shall be no more than two (2) total rejection(s) of deliverables per quarter. The Government will reject a deliverable if one (1) or more technical errors or five (5) or more minor errors are found within the deliverable.

Receipt of CDRL Deliverable

4.2.2 There shall be no more than one (1) late

submission(s) of deliverables per quarter. The Contractor shall notify the Government if the delivery of any data/document will not meet the scheduled delivery date and negotiate a revised delivery date. The data/document shall be delivered by the revised delivery date acceptable to the Government.

Request for Assistance 4.4.3 The Contractor shall initially respond to a request for engineering assistance/inquiries within four (4) business hours. Follow-up assistance, if required, shall be provided by the suspense date acceptable to the Government.

Management of Personnel

4.11.1.1, 4.11.1.2

90% of all planned positions defined at contract award shall be filled within 10 business days after award. The remaining 10% of all planned positions defined at contract award shall be filled within 35 business days after award.

Unplanned staffing changes during the contract period due to position vacancy shall not exceed 60 calendar days, with a goal to fill vacancies within 45 calendar days.

Contractor Personnel Qualifications

4.3.11 4.11.3, 4.11.6 4.24.2

Contractor/subcontractor personnel shall meet, at a minimum, the qualifications identified in the PWS.

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Performance Objective

PWS

Reference Performance Threshold

Adherence to Contractor Quality Management System (QMS)

5.9 100% adherence to the QMS is required.

Contractor Quality Assurance Personnel shall maintain compliance with the standards/practices set forth in the Quality Control Manual with no more than two (2) instances of verified noncompliance.

3.0 Government Property

Government property for this effort may include Government Furnished Property (GFP), Government Furnished Equipment (GFE), Government Furnished Material (GFM), and Contractor Acquired Property (CAP)/Long Lead Items. All phase replacement items and items identified in Air Force Technical Order (AFTO) Form 103, Aircraft/Missile Condition Data will be provided by the 23rd Flying Training Squadron (23 FTS).

3.1. Government Property to be Provided

The USAF will provide salvage aircraft hulks to the Contractor as GFP. These aircraft will be cannibalized as a source of supply for customer aircraft undergoing DLM and in support of all TH-1H trainer aircraft. Disposition of GFP will be provided at contract completion.

3.2. Government Furnished Information

Throughout the duration of this contract, the Contractor shall be provided access to USAF engineering and technical data as data rights permit. The Government will provide access to maintenance information systems that shall allow the Contractor to input information on completed tasks. Access to some systems may require the Contractor to complete a DD Form 2875 and a non-disclosure statement. The form must be signed by a government sponsor.

Access to appropriate government legacy sustainment related computer systems shall be provided for the Contractor upon obtaining a Common Access Card (CAC). See paragraph 5.2.7 for procedures to obtain a CAC. The Government shall retain ownership of all data after contract completion.

3.3. Contractor Responsibility

The Contractor shall be responsible for Government property IAW Part 45 of the Federal Acquisition Regulation (FAR), its applicable supplements, and as specified in the clauses of the contract/order. The Contractor shall furnish all repair parts, material, and supplies required for performing the work of this PWS.

3.3.1. Contractor Acquired Property (CAP)/Long Lead Items

The Contractor shall furnish all repair parts, consumables, material, and supplies required for performing the work of this PWS. The Contractor shall receive, store, and account for existing CAP/Long Lead Items, and if necessary, replace materials as recorded on the GFP Attachment in Procurement Integrated Enterprise Environment (PIEE). Upon authorization and receipt of funding, the Contractor shall procure the materials and store them until needed for an individual aircraft. The Contractor shall replace the material when used so that long-lead items are available throughout the term of the contract. An active inventory shall be maintained for tracking and accountability purposes. Upon completion of the contract, the material shall made

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available to the Government, who will coordinate transfer to a follow-on contract or back to the government inventory. Control procedures for this Government property shall include, at a minimum, inspection for completeness, proper type, and damage occurring during shipment, identification and protection from improper use, or disposition. The Contractor shall report to the Cognizant Field Authority (CFA)/Government Cognizant Field Representative (CFR) any damaged equipment or material malfunctioning, or otherwise unsuitable for its intended use.

(CDRL Reference in paragraph 4.2, DI-MGMT-81945, Phase Out Transition Plan)

3.3.2. Replacement of Consumable Maintenance Supplies and Material The Contractor is responsible for obtaining consumable supplies and materials as required to perform maintenance on TH-1H aircraft and accessories as contained in the aircraft parts manual.

Consumable Supplies used on the TH-1H aircraft are found in the applicable Technical Orders (TOs) and the TH‐1H‐23-010-001, Programmed Depot Maintenance Work Specification documents referenced in this PWS.

Note TH‐1H‐23-010-001, Programmed Depot Maintenance Work Specification, is colloquially termed “the PDM Work Specification” in the remainder of this document.

The Contractor shall use the Defense Logistics Agency (DLA) to order consumable parts and material when it is economically feasible. Requests for consumable assets to be provided by the Government will be considered on a case-by-case basis with approval of the System Program Office (SPO).

3.3.3. Repairable and Replacement Parts

The Contractor shall be required to establish a unique Department of Defense Activity Address Code (DoDAAC) to support requirements for repairable items to support the PDM repair line.

Repairable items are identified as National Stock Number (NSN) items authorized for use by the Air Force and Expendability, Repairability, Recoverability Code (ERRC) "T" as identified in WebFLIS. The Contractor shall request these repairable assets through the appropriate Air Logistics Center (ALC) utilizing the approved supply system, to be determined after contract award. The unserviceable carcass repairable asset removed shall be returned to the appropriate ALC within 30 calendar days of receipt of the new/overhauled asset requested. All applicable maintenance, condition tags, and AFTO 95 forms shall accompany each returned component per TO 00-20-3, Maintenance Processing of Reparable Property and the Repair Cycle Asset Control System.

The Contractor shall coordinate with the 23 FTS at Cairns AAF for the repair/disposition of items identified in Appendix D. This listing represents items that are currently supported by the 23 FTS. This list is not all inclusive and is only to be used as a guide.

All other replacement parts listed in the TOs specified in TO 1H-1(T)H-01, List of Applicable Publications -- Technical Manual -- USAF Series TH-1 Helicopters (“the TH-1H LOAP”) and the PDM Work Specification, shall be the responsibility of the Contractor to procure.

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3.3.4. Specialized Tools, Test Equipment, and Support Equipment The Contractor is responsible for obtaining all the equipment listed in the TOs specified in the TH-1H LOAP and the PDM Work Specification to support the DLM of the TH-1H.

3.4. Reporting of Government Property

The Contractor shall have a system of internal controls to manage (control, use, preserve, protect, repair, and maintain) Government property in its possession IAW FAR 52.245-1, and its property management system shall be adequate to satisfy the requirements of this clause. The Contractor shall record receipt and return of all GFP, as well as the reporting of shipment, consumption, disposal, or transfer to another contract, in the Property Management/GFP Module in PIEE at https://piee.eb.mil, as stipulated by Defense Federal Acquisition Regulation Supplement (DFARS) 252.245-7002. This reporting requirement does not change any liability provisions or other reporting requirements that may exist under the contract. GFP training and guidance is located at the Department of Defense (DoD) Procurement Toolbox at https://dodprocurementtoolbox.com/.

The Contractor shall create and maintain records of all Government property accountable to the contract, including GFP and CAP IAW the FAR and applicable supplements and shall be in compliance with all applicable guidance and clauses listed in the contract. Government property information contained within the Contractor’s database shall be made accessible by the Government upon request. The Contractor shall deliver a report of all GFP and CAP to the SPO annually and no later than (NLT) 30 business days prior to the end of each Period of Performance (PoP). The Government will review and approve or disapprove withing 15 business days of receipt. If disapproved, the Contractor shall incorporate any comments/corrections and resubmit report NLT five (5) business days after receipt. Property records shall enable a complete, current, and auditable record of all transactions.

(CDRL Reference in paragraph 4.2, DI-MGMT-80441D, Government Property Inventory Report)

3.5. Loss of Government Property

3.5.1. Definition of Loss of Government Property

“Loss of Government property” means unintended loss of or damage to Government property, to include property that cannot be found after a reasonable search, loss due to inadequate storage, loss due to lack of security, theft, damage requiring repair to restore the item to usable condition, or damage that renders the property useless for its intended purpose or Beyond Economical Repair (BER). Loss of Government property does not include manufacturing defects, obsolescence, normal wear and tear, or purposeful destructive testing. Unless otherwise stated in the contract/order, loss of Government property does not include normal and reasonable inventory adjustments, i.e., losses of low priority consumable material, such as common hardware, as agreed to by the Contractor and the Government Property Administrator.

3.5.2. Reporting Loss of Government Property

The Contractor shall report loss of Government property in the Property Management/GFP Module located in PIEE at https://piee.eb.mil.

https://piee.eb.mil/ https://dodprocurementtoolbox.com/ https://piee.eb.mil/

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3.6. Return or Retention of Government Property

All property provided by the Government remains the property of the Government and shall be returned to the Government as directed, but NLT completion of the contract/order, unless the Procuring Contracting Officer (PCO) directs the Contractor to retain the property for continued use under a successor contract. All Government property shall be returned to the Government in the condition provided unless approved in advance by the PCO. All material generated under the contract/order becomes the property of the Government and shall be returned to the Government as directed, but NLT completion of the contract/order, unless the PCO directs the Contractor to retain the material for continued use under a successor contract.

4.0 Technical Requirements

4.1. Period and Place of Performance

4.1.1. Contract Period of Performance

The Period of Performance (PoP) for the contract will extend eight (8) years after contract award, assuming all options are exercised, with one (1) base year and seven (7) 12-month option periods.

4.1.2. Place of Performance

These services will be performed at the Contractor’s facility. The facility shall include adequate hangar space to accommodate up to five (5) work-in-progress TH-1H helicopters simultaneously, within a 300-mile radius of Cairns AAF (Ft. Novosel, AL). Other Places of Performance may include Cairns AAF, Robins Air Force Base (AFB), and/or other locations designated by the Program Manager (PM) and PCO to meet mission requirements.

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4.2. Contract Data Requirements List(s) (CDRL)

Document Identifier Base Year

Option Year 1

Option Year 2

Option Year 3

Option Year 4

Option Year 5

Option Year 6

Option Year 7 DID Title PWS

Reference(s)

A001 B001 C001 D001 E001 F001 G001 H001 DI-ADMN-81249C Meeting Agenda 4.28.1 A002 B002 C002 D002 E002 F002 G002 H002 DI-ADMN-81250C Meeting Minutes 4.28.2 A003 B003 C003 D003 E003 F003 G003 H003 DI-ADMN-81373 Presentation Material 4.28.1 A004 B004 C004 D004 E004 F004 G004 H004 DI-MISC-81943 Trip/Travel Report 4.4.2, 4.27 A005 B005 C005 D005 E005 F005 G005 H005 DI-MGMT-80368A/T Status Report 4.29.2, 4.29.6 A006 B006 C006 D006 E006 F006 G006 H006 DI-MISC-80508B Technical Report –

Study/Services 4.29.5.1, 4.29.5.2, 4.29.5.3, 4.29.5.4, 4.29.5.5

A007 B007 C007 D007 E007 F007 G007 H007 DI-MGMT-80441D Government Property Inventory Report

3.4

A008 B008 C008 D008 E008 F008 G008 H008 DI-MGMT-81803A Item Unique Identification (IUID) Marking Plan

4.5.1.1

A009 B009 C009 D009 E009 F009 G009 H009 DI-MGMT-81804A Item Unique Identification (IUID) Marking Activity, Validation and Verification Report

4.5.1.1

A00A B00A C00A D00A E00A F00A G00A H00A DI-MISC-81832 Counterfeit Prevention Plan 4.5.3 A00B B00B C00B D00B E00B F00B G00B H00B DI-SAFT-81563 Accident/Incident Report 5.5.2 A00C B00C C00C D00C E00C F00C G00C H00C DI-QCIC-81794A Quality Assurance Program

Plan 5.9

A00D N/A N/A N/A N/A N/A N/A N/A DI-SESS-82299 Phase-In Transition Plan 4.29.1.1 A00E B00E C00E D00E E00E F00E G00E H00E DI-MGMT-81945 Phase Out Transition Plan 3.3.1,

4.29.1.2 In the event of the exercise of FAR 52.217-8 (Option to Extend Services), the numeration of CDRLs will remain the same as the preceding option period.

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4.2.1. Quality of CDRL Deliverable

The Contractor shall deliver all data/reports associated with all CDRLs, with no more than one

(1) rejection of any deliverable. There shall be no more than two (2) total rejection(s) of deliverables per quarter. The Government will reject a deliverable if one (1) or more technical errors or five (5) or more minor errors are found within the deliverable. A technical error is defined as the format not being IAW the CDRL or the content not being accurate and complete IAW the CDRL, PWS, or contract. A minor error is exemplified by a typographical error, a grammatical error, etc. The rejected deliverable shall be corrected and resubmitted within five

(5) business days of notification of Government rejection IAW the associated DD Form 1423 instructions/requirements.

4.2.2. Receipt of CDRL Deliverable

CDRL deliverables shall be submitted via Wide Area WorkFlow (WAWF) and submitted directly to the Government representative identified on the CDRL. There shall be no more than one (1) late submission(s) of deliverables per quarter. The Contractor shall notify the Government if the delivery of any data/document will not meet the scheduled delivery date and negotiate a revised delivery date. The data/document shall be delivered by the revised delivery date acceptable to the Government.

4.3. Depot Level Maintenance (DLM) Standards and Requirements

4.3.1. DLM Schedule

The schedule shall consist of a total of all work accomplished IAW this PWS. The intent of this effort is broken down into two task categories – Fixed and Variable Portions.

4.3.1.1. Fixed Portion

The fixed portion of the PDM is the completion of the standard recurring work as directed in the PDM Work Specification.

4.3.1.2. Variable Portion

The variable portion of the PDM is the Over and Above (O&A) repair and defect corrections performed, which are unique from aircraft to aircraft. The variable portion shall be adjusted based upon the evaluation of the aircraft and the number of man-hours required to complete the additional O&A work as documented on the Initial Inspection and Repair Report and as negotiated and approved IAW paragraphs 4.29.5.1 through 4.29.5.4.

4.3.1.3. Total Flow Days

The total PDM flow days are a combination of the fixed and variable work requirement and shall be negotiated at the 45-Day Induction Meeting based upon number of manhours required to complete the PDM work. The contractor shall complete all work within 260 calendar days from induction.

4.3.1.4. Aircraft Delivery

Repaired assets shall be delivered IAW the negotiated and Government-approved schedule accomplished at the 45-Day Induction Meeting. Delivery delays are governed by Air Force Materiel Command Instruction (AFMCI) 21-118, Aircraft Maintenance Production/Compression Report (AMREP). There shall be no more than one (1) late delivery per contract year.

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4.3.2. Sequence of Work

The contractor shall provide fuselage and tailboom fixtures in order to ensure proper alignment of the airframe IAW the PDM Work Specification paragraph 3.3.1.1. Further, the contractor shall provide full aircraft strip/paint capability in order to meet the requirements of the PDM Work Specification paragraphs 3.2.3 and 3.4.4. The typical DLM repair process is outlined in Figure 1. This is a generalization from delivery to the DLM facility up to final acceptance check flight and receipt by the custodian.

Figure 1. Typical DLM Process Flow

4.3.3. DLM Repair Standards and Defect Classification

A fundamental task associated with the DLM process includes objectively classifying defects in order to determine if a defect requires correction during the DLM process. The following paragraphs outline the methods for classifying defects discovered during the repair process to determine if the defects require maintenance under the DLM program and to establish a general level of expectation as to the quality of repair.

4.3.4. Defect Classifications

A defect (synonymous with discrepancy) is defined as any deviation, disagreement, difference, or inconsistency, physical or otherwise, of an aircraft part or assembly from the design specification, usage, or operation. All defects are subject to the validation of the CFA/CFR. A

PREPARATION FOR INDUCTION

(PDM WORK SPEC PARA 2.1.1)

AIRCRAFT INDUCTION

(PDM WORK SPEC PARA 2.1.2)

INSPECTION/REPAIR

MANDATORY REPAIRS

-FIXED TASKS-

(PDM WORK SPEC PARA 2.1.3)

MAINTENANCE/REPAIR

OVER AND ABOVE

-VARIABLE TASKS-

(PDM WORK SPEC PARA 2.1.4)

PREPARATION FOR DELIVERY

(PDM WORK SPEC PARA 2.1.5)

AIRCRAFT DELIVERY

(PDM WORK SPEC PARA 2.1.6)

INITIAL INSPECTION

AND REPAIR REPORT

FINAL INSPECTION

AND REPAIR REPORT

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defect classification decision tree is provided in Figure 2. Defects shall be classified by the failure effect of the defect, not overall end item criticality (e.g., though the main rotor grip is a Critical Safety Item, light surface corrosion would be classified as Minor while a crack in the blade bolt tang would be classified as Critical).

4.3.4.1. Critical Defect

A critical defect is a defect that is likely to result in hazardous or unsafe conditions for individuals operating or maintaining the aircraft, system, or component.

4.3.4.2. Major Defect

A major defect is a defect other than critical that is likely to result in failure, or to materially reduce the usability of an aircraft system or component from its intended purpose. All primary airframe structural cracks shall be classified as major defects at a minimum.

4.3.4.3. Minor Defect

A minor defect exceeds negligible limits, however, is not likely to materially reduce the usability of a system or component for its intended purpose or is a departure from established standards having no significant bearing on the effective use or operation of the system or component. For an organizational-level minor defect that does not materially degrade ability of aircraft to meet mission requirements, but has action recommended to prevent future failures, Contractor may request defect to be "Noted but Not Corrected" (NBNC). NBNC defects shall be captured and reported IAW paragraph 4.29.5.1. NBNC defects are not authorized to be corrected and shall be identified by type, location, and description for appropriate action by the gaining custodian. For an organizational level minor defect that does not materially degrade ability of aircraft to meet mission requirements and no future repair action is recommended, Contractor may request defect be categorized as "Use As Is" (UAI). UAI defects are not required to be recorded as NBNC.

Final NBNC and UAI determinations shall be approved by CFA/CFR.

4.3.4.4. Type of Defect

Defects will be identified by type to include but not limited to:

• Corrosion

• Crack

• Gouge/nick/scratch out-of-limits

• Loose fasteners

• Missing fasteners

• Damaged fasteners

• Delamination

• Chaffing

• Burned wires

• Loose bundles

• Damaged electrical connectors

• Security

• Interim repair

• Buckled/oil canned

• Deteriorated

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4.3.5. Defect Correction Criteria

Defect classification determines whether a defect shall be corrected. A decision tree is provided in Figure 3 to determine defect correction disposition. Defect corrective actions taken as a result of criteria met in paragraphs 4.3.4 and 4.3.8 shall receive CFA/CFR final approval for adequacy to applicable maintenance standards.

4.3.6. Defects Caused by Depot Facility

All defects caused by the depot facility shall be corrected at no cost to the Government.

4.3.7. Nonstandard Repairs

Any nonstandard repair discovered during the DLM process shall be considered a defect. Any previous repair that is not authorized by, or does not meet the standards of quality, security, or strength of the applicable maintenance references shall be considered a defect. The depot facility should submit an AFMC Form 202 for engineering evaluation and disposition.

Figure 2. Defect Classification & Disposition

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Figure 3. Defect Correction Disposition

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4.3.8. Over and Above (O&A) Maintenance

The PDM Work Specification defines required maintenance actions, inspections, and mandatory part replacements during the PDM process. Any DLM maintenance task that is not specifically required or mandated by the PDM Work Specification shall be considered O&A maintenance.

This is to include but not limited to any repairs, replacements, or maintenance not directed by the PDM Work Specification. All O&A maintenance shall be negotiated at the 45-Day Induction Meeting and must be approved by the CFA/CFR prior to correction.

4.3.9. Nonstandard Modifications

Any airframe or structural modification that is intended to be temporary and is discovered during the DLM process shall not automatically be considered a defect. The depot facility shall notify the CFA/CFR prior to correction of any nonstandard modification. The Contractor shall provide an evaluation and/or solution for the correction of any nonstandard modifications and submit to WIUE for approval via the automated process for AFMC Form 202.

4.3.10. Special Work Requests

A Special Work Request, which includes AFTO Form 103, contains inspection or maintenance actions that are not considered part of the DLM process. These are considered O&A maintenance requirements that must be negotiated separately between the Contractor and the CFA or CFR. Owning activities shall submit these Special Work Requests in sufficient time to permit an evaluation by the Contractor, and approval and funding by the Government. Special Work Requests must be submitted to the CFA via the appropriate chain of command IAW TO 00-25-4, Depot Maintenance of Aerospace Vehicles and Training Equipment. A Special Work Request shall be accomplished only if agreed upon by the repair activity and approved and funded by the Government.

4.3.11. Workmanship and Repair Standards

All repairs shall be performed under the direct supervision of aircraft mechanics licensed by the Federal Aviation Administration (FAA) to perform safety of flight maintenance on rotary-wing aircraft.

4.4. Unprogrammed Depot Level Maintenance (UDLM)

4.4.1. Drop-in Maintenance/Depot Field Team (DFT)

Drop-in maintenance shall be performed on aircraft received from the using activity that require maintenance at a depth and skill level greater than that available at Organizational maintenance levels. The Contractor shall accomplish inspection, correction, and repair of Unprogrammed Depot Level Maintenance (UDLM) IAW TO 00-25-107, Maintenance Assistance, and AF electronic Technical Assistance Request (TAR) system as well as the accompanying Statement of Work (SOW). Aircraft shall be estimated, negotiated, and charged to the contract IAW the O&A procedures. The Contractor shall accomplish repair of aircraft at no additional charge to the PDM Aircraft (A/C) and with no delay to delivery schedule of the PDM repair line.

Technical inspection of the completed work shall be accomplished by the CFR. Examples of drop-in maintenance include, but are not limited to:

• Mishap repair

• Damage to primary structural elements

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• Maintenance-induced damage

• Corrosion damage repair/parts replacement

• Hard Landing Assessments

4.4.2. Contractor Field Teams (CFT)

CFTs shall be responsible for performing all maintenance related tasks as defined by Air Force Life Cycle Management Center (AFLCMC)/WIUE’s engineering disposition IAW TO 00-25- 107, and AF electronic TAR system as well as the accompanying SOW. Labor shall be estimated, negotiated, and charged to the contract IAW the O&A procedures. Travel related to CFT shall be IAW paragraph 4.27.

(CDRL Reference in paragraph 4.2, DI-MISC-81943, Trip/Travel Report)

4.4.3. Request for Assistance

The Contractor shall initially respond to a request for engineering assistance/inquiries within four

(4) business hours. Follow-up assistance, if required, shall be provided by the suspense date acceptable to the Government.

4.5. Repair

4.5.1. Item Unique Identification (IUID)

4.5.1.1. Marking Requirement

Item Unique Identification (IUID) is required for all items to be delivered to the DoD that meet the criteria established by the FAR.

(CDRL Reference in paragraph 4.2, DI-MGMT-81803A, IUID Marking Plan) (CDRL Reference in paragraph 4.2, DI-MGMT-81804A, IUID Marking Activity, Validation and Verification Report)

4.5.1.2. Reporting in IUID Registry

4.3.1.2.1 Transmission of Government property must be recorded in the IUID Registry.

The Government is required to record the transfer of GFP to the Contractor. The Contractor is required to record the receipt of GFP from the Government. The Contractor is required to record the return of GFP to the Government.

4.3.1.2.2 The Government or contractor/subcontractor personnel responsible for causing a “life cycle event” (i.e., abandoned, consumed, destroyed by accident, destroyed by combat, donated, exchanged – repair, exchanged – sold, exchanged – warranty, expended – experimental/target, expended – normal use, leased, loaned, lost, reintroduced, retired, scrapped, sold – foreign government, sold – historic, sold – nongovernment, sold – other federal, sold – state/local, and stolen) will update the item record in the IUID Registry.

4.5.2. Packaging

The Contractor shall package and mark material IAW the contract/order Air Force Materiel Command (AFMC) Form 158, Packaging, Handling, Storage, and Transportation Acquisition and Sustainment Product Support Instruction, and applicable Government regulations. The Contractor shall ensure that classified material is packaged, marked, and delivered IAW DoD 5220.22-M, National Industrial Security Program Operating Manual (NISPOM). The

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Contractor shall package and mark material IAW other applicable Government regulations including, but not limited to, those regarding security, safety, and environmental concerns.

4.5.3. Counterfeit Electronic Parts

The Contractor shall establish and maintain a counterfeit electronic part detection and avoidance system to mitigate the risk of counterfeit electronic parts being installed in end items or otherwise entering the USAF/DoD inventory. The system shall incorporate processes/procedures to address the requirements listed IAW the FAR and applicable supplements and shall be in compliance with all applicable guidance and clauses listed in the contract. The Government's review of the Contractor’s system shall be accomplished as part of the evaluation of the Contractor’s purchasing system IAW the FAR and applicable supplements and shall be in compliance with all applicable guidance and clauses listed in the contract.

(CDRL Reference in paragraph 4.2, DI-MISC-81832, Counterfeit Prevention Plan)

4.6. USAF Technical Orders (TOs)

The use of USAF TOs/Manuals to perform Depot maintenance is mandatory. Use of other sources of technical data, to include but not limited to technical manuals, maintenance manuals, component repair and overhaul and structural repair manuals by either the Original Equipment Manufacturer (OEM), FAA or other sources shall require prior approval from USAF SPO Engineering using an AFMC Form 202. It is acceptable for the Contractor to develop separate “Work Instructions” per the Contractor’s local processes, provided the Contractor Work Instructions developed and used are 100% in compliance with the latest revision of USAF TOs.

Contractor Work Instructions shall be approved for use and are subject to periodic review. All revisions to USAF TOs or formally approved alternate technical data that occur during this work effort shall be reviewed and included and the Contractor Work Instruction shall be updated to reflect the revision as applicable.

4.7. Cognizant Field Authority (CFA)/Government Cognizant Field Representative

(CFR)

4.7.1. Cognizant Field Authority (CFA)

The CFA is responsible for ensuring all Government interests are met and all requirements of the DLM contract are accomplished. The CFA is also assigned the responsibility and the authority to approve all or portions of in-service engineering functions, to determine logistic requirements, to review budgeting, and to coordinate necessary program and material management to support the DLM effort. In addition, the CFA is responsible for monitoring and evaluating the maintenance effort. The CFA shall determine effectiveness and efficiency of the depot facility in accomplishing the required DLM tasks, in maintaining acceptable quality standards, and in meeting required delivery schedules. The designated USAF CFA is listed below:

Department of the Air Force Special Operations Forces (SOF)/Personnel Recovery (PR) Rotary Branch

AFLCMC/WIU

370 Richard Ray Blvd.

Robins AFB GA 31098-1670

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4.7.2. Government Cognizant Field Representative (CFR)

The CFR is the on-site Defense Contract Management Agency (DCMA) Government representative for the CFA at the depot facility. CFR responsibilities and authority are delegated by the CFA and are partly defined by this PWS. The CFR is responsible for on-site monitoring of the DLM process to ensure proper compliance and execution by the depot facility of the requirements stated herein. The CFR is also responsible for accomplishing CFR tasks assigned in the PWS and as directed by the CFA. In addition, the CFR is the Contractor facility’s direct point of contact for addressing DLM implementation issues.

4.7.3. Authority

This DLM PWS has been reviewed and approved by the CFA for the USAF and is authorized for use on all USAF TH-1H aircraft. Program management of the DLM process is the responsibility of the CFA. Execution of the DLM requirements shall be monitored by the CFR.

4.7.4. CFA/CFR Maintenance Approval

Maintenance actions beyond those required in the PDM Work Specification (such as modifications or special inspections) require CFA/CFR approval for O&A work.

4.8. Acceptance and Rejection Criteria

4.8.1. Defect Correction

The CFA or CFR shall judge whether defects have been corrected satisfactorily (per paragraph 4.25.1) and that applicable maintenance standards have been met with respect to materials, workmanship, design, construction, cleanliness, quality, and documentation. The CFA/CFR shall have final approval on determining if the aircraft has been delivered in acceptable condition and that all applicable quality control standards have been met.

4.8.2. AFTO Form 103

Areas of the aircraft that are beyond the capability of the Unit and need to be worked during the DLM process shall be submitted by the owing activity on an AFTO Form 103, IAW TO 00-25-4.

Organizational maintenance, inspections, and Time Compliance Technical Orders (TCTOs) may be identified for negotiations. If a TCTO is dependent on a kit, the Unit shall supply it within 10 business days of aircraft induction. Supplemental AFTO Form 103s shall be utilized for new requirements after primary aircraft AFTO Form 103 has been signed/approved.

4.8.3. Technical Order System Deficiency Report (AFTO Form 22) When a deficiency exists in official USAF publications, deficiencies shall be reported. An AFTO Form 22, Technical Manual (TM) Change Recommendation and Reply, shall be submitted with the suggested technical data change IAW TO 00-5-1, Air Force Technical Order System.

Technical data errors relating to work stoppage shall be submitted to AFLCMC/WIUE for immediate resolution.

4.8.4. Nondestructive Inspection Technique Change (AFTO Form 242) If any inspection contained in TO 1H-1(U)N-36, Nondestructive Inspection, USAF Series UH-1N/UH-1H/TH-1H Helicopters is found to be deficient, AFLCMC/WIUE shall be contacted for clarification and procedures to correct the deficiency. If required, the Contactor shall prepare

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and submit an AFTO Form 242, Nondestructive Inspection Data, IAW TO 33B-1-1, Non- Destructive Inspection Methods, Basic Theory.

4.8.5. Photographs

Copies of any photographs taken to illustrate or better depict major defects shall be submitted to AFLCMC/WIUBC and WIUE. Each photograph shall be marked to show discrepancy location/orientation, identified by aircraft serial number, part number (P/N), and TO 1H-1(U)N- 36, inspection number (if applicable). The series of photographs shall begin at a broad level and zoom in to the defect so that the defect location can be easily identified.

4.9. DLM Records

The Contractor shall participate in all reporting functions required to ensure technical accuracy, quality, timeliness, effectiveness, efficiency, and safety of the DLM process.

4.9.1. Aircraft Records

The Contractor shall maintain records of work accomplished on DLM aircraft. Records are considered Government-owned data. Upon request, AFLCMC/WIUBC shall have access to all Contractor’s depot facility records of any DLM aircraft. The Contractor shall ensure that all aircraft records and documentation are updated and accompany the aircraft when returned to the customer. The Contractor shall maintain archives of all maintenance performed IAW depot facility instructions.

4.9.2. AFTO Form 95

A notation shall be made in the "Significant Historical Data” column of the airframe AFTO Form 95, Significant Historical Data, indicating day, month, year, and aircraft time that PDM was accomplished IAW TO 00-20 series, Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures. Annotate “PDM complied with”. As DLM is completed and prior to AF acceptance, the Contractor shall inventory all components with AFTO Form 95 records and verify the correct match of serial numbers between forms and components.

AFTO Form 95 discrepancies shall be immediately reported to AFLCMC/WIUE. No aircraft shall be released until all such discrepancies have been corrected.

4.10. Economic Repair, Condemnation, and Replacement of Parts

4.10.1. Economical Repair Determination

The economic repair limits for items shall be determined by the criteria of TO 00-20-3. Items BER or non-repairable items shall be replaced with a serviceable item from Government supply.

Items BER shall be repaired or manufactured only when authorized by AFLCMC/WIUE via the automated process of AFMC Form 202.

4.10.2. Condemnation

The Contractor shall not repair items where the cost of parts and labor exceeds 75% of the replacement cost of the item unless authorized by AFLCMC/WIUE due to the criticality of the item. Parts, components, subassemblies, or assemblies found worn or defective beyond economic repair shall be condemned and disposed of IAW applicable maintenance manual. The Contractor shall not condemn repairable items without prior approval by AFLCMC/WIUE.

Reference TO 00-20-3.

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4.11. Personnel and Support

4.11.1. Management of Personnel

4.11.1.1. Planned Staffing

The Contractor shall fill 90% of all planned positions defined at contract award within 10 business days of award. The remaining 10% of all planned positions defined at contract award shall be filled within 35 business days of award.

4.11.1.2. Unplanned Staffing Changes

Unplanned staffing changes during the contract period due to position vacancy shall not exceed 60 calendar days, with a goal to fill vacancies within 45 calendar days.

4.11.2. Engineering Support Services

The Contractor shall provide engineering support services to resolve technical and engineering issues that may arise.

4.11.3. Engineering Qualifications

Engineers directly responsible for developing the disposition of aircraft related discrepancies shall have either a bachelor’s degree in Engineering (preferably Mechanical, Aerospace or equivalent) from an Accreditation Board for Engineering and Technology (ABET) accredited school and a minimum of three (3) years of aircraft engineering support experience, or a bachelor's degree in Engineering Technology with a minimum of five (5) years of aircraft engineering support experience.

4.11.4. Process Engineering Support

The Contractor shall provide engineering support to resolve engineering and technical process issues that may arise during the DLM, including continuous surveillance of the processes, solving problems, and developing procedures, processes, or repairs not provided by applicable technical publications. Contractor shall present repair methods for consideration that mitigate any lack of tech data issues for review and approval by Government engineering. Evaluate and notify the CFA/CFR of any waiver or deviation to a required process or procedure.

4.11.5. TH-1H Engineering Support

The Contractor shall provide engineering capability necessary for the DLM support of inspection and repair requirements for the TH-1H aircraft structure, aircraft systems, mission systems, and aircraft components. Any repair deemed a major structural repair (see the PDM Work Specification for definition of major structural repair) not covered by applicable USAF TOs must be approved by the WIUE Engineering via an AFMC Form 202. The Contractor engineering support shall provide a repair solution or engineering disposition for correction of the defect or problem. Engineering solutions provided by the contractor shall contain a detailed justification of the disposition, to include any engineering analysis. Prior to any repair disposition decision, a judgment shall be made by the Contractor that the repair shall be cost-effective relative to other repair disposition alternatives. The contractor’s engineering support shall be responsible for developing and/or designing repair solutions and or deviations that are not currently supported by USAF TOs using best engineering practices to ensure airworthiness of all repairs developed or designed to support the PDM repair phase. The contractor shall gain and maintain access to the AF automated 202 system (AutoTAR or future systems) and use that system to submit repair

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solutions via AFMC Form 202. AF engineering, AFLCMC/WIUE will…