ATTACH_C_F118_FRONT_FRAME_SOW_Rev3.pdf

Attachment E

File Number: FD2030-17-00680 Page 0

STATEMENT OF WORK (SOW)

For the Remanufacture of the

F118-GE-100 FRONT FRAME

PURCHASE REQUEST NUMBER:

FD2030-17-00680

REV: 3

PREPARATION DATE: 13 May 2019 REVISION DATE: 02 January 2020 REVISION DATE: 06 January 2020 REVISION DATE: 09 March 2020

PREPARING ORGANIZATION:

421st Supply Chain Management Squadron (SCMS)/GUMBA

Air Force Sustainment Center (AFSC) In conjunction with

Air Force Life Cycle Management Center (AFLCMC)/LPSBAB

TINKER AFB, OK 73145-3031

File Number: FD2030-17-00680 Page 1

TABLE OF CONTENT Page 1

SECTION I: SCOPE

1.0 Introduction 2

1.1 General Services and Material 2

1.2 Over & Above 2

1.3 Beyond Economical Repair 3

1.4 Receiving 3

1.5 Remanufacture 4

1.5.1 Disassembly 4

1.5.2 Cleaning 4

1.5.3 Remanufacture Procedures 4

1.5.4 Inspect 6

1.5.5 Testing 6

1.5.6 Assembly 6

1.5.7 Remanufacture Deviations 7

1.6 Reference and Technical Manuals 7

1.7 Deliverables Quality 7

1.8 Deficiency Report (DR) 7

1.9 Condemned Assets 7

1.10 Quality System and Quality Assurance Plan 7

1.11 Reporting 8

1.12 Contract Data Requirement List (CDRL) 8

1.13 Document Storage 9

1.14 Shipping 9

1.15 Packaging and Handling 9

1.16 Preservation 10

1.17 Safety 10

1.18 Contractor Identification to Government Employees 10

SECTION II: GOVERNMENT PROPERTY

2.0 Government Furnished Material (GMF) 11

2.1 Government Furnished Property (GFP) 11

APPENDIX “A”

ACRONYMS 12

File Number: FD2030-17-00680 Page 2

SECTION I: SCOPE

1.0 Introduction

The purpose of this Statement of Work (SOW) is to define the requirements necessary to ensure that the replacement of the Low Observable (LO) Coating for the F118-GE-100 Front Frames are remanufactured as nearly as possible to the original life expectancy consistent with the Air Force (AF) requirements. This SOW applies to the following National Stock Number (NSN) and Part Numbers (P/N):

Input / Output NSN Input P/N Output P/N

2840-01-531-1394LR

9545M13G42 9545M13G44 9545M13G45 9545M13G46

9545M13G42 9545M13G44 9545M13G45 9545M13G46

2840-01-528-4199LR 9545M13G47 9545M13G47

The following instructions stipulated herein provide brief, concise statements providing general requirements for the remanufacture of the F118 Front Frame LO Coating. The Contractor shall maintain a quality system that addresses the elements of ISO 9001-ANSI/ASQC Q9001, quality system model for Quality assurance in Design and Development, Production, Installation, and Servicing to remanufacture the replacement of the LO Coating for the F118 Front Frame; and the Contractor must have the remanufacture capabilities to include appropriate technical data, remanufacture documents, and license agreements, required to accomplish the remanufacture of the Front Frame. The Contractor is responsible for remanufacture and scheduled delivery of a quality product.

1.1 General Services and Material

The Contractor shall provide all materials for the remanufacturing processes required to execute this contract, including the pooling of hardware/material to facilitate the necessary remanufacturing intent of the F118 Front Frame LO Coating remanufacture.

In exchange, in part, for each remanufactured Front Frame LO Coating ordered, the Government will provide, on a one-to-one basis, a degraded or inoperable Front Frame consistent with aircraft engine usage.

These materials shall include “expendable” materials required to facilitate the serviceable rebuild of the F118-100 Front Frame/Frame Assembly following the LO Coating remanufacture; such as, Nuts, Bolts, Washers, Packing (O-Rings), Bushings, Gaskets, and the like.

1.2 Over and Above

Over and Above shall be considered for work not covered by the levels of remanufacture for the line items for the basic work under the contract but within the general scope of the contract. The Contractor shall obtain approval from the PCO prior to performing over and above.

Any Government requested remanufacture that is not addressed within the Propulsion Structural

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Integrity Program (PSIP) work scope, defined in the technical data, or in this SOW, shall be considered O&A, and therefore shall require the Contractor to provide a scope and pricing assessment for O&A reporting and quoting. This specific O&A scope and proposed pricing shall be provided to the PCO/ACO and Production Management Specialist (PMS) with the 421 SCMS/GUMBA/AFSC for review and approval prior to any support of the same.

Furthermore, if the Contractor determines any Government Furnished Property (GFP) or asset is beyond the primary remanufacture of the LO Coating, the Contractor shall prepare an O&A report describing the issue(s) and pricing to facilitate the remanufacture. This document shall be provided to the PCO/ACO, and Program Manager (PM) with the 421 SCMS/GUMBA/AFSC.

The PCO/ACO, if delegated, shall provide written disposition along with adequate proposal pricing (i.e. remanufacture the asset via O&A funding, condemnation of the asset, return the asset to the Government in an unserviceable condition, or other disposition unique to the circumstance) within thirty (30) calendar days from the date of receipt of the completed Contractor’s report(s), as referenced above.

Major sub-components; such as, Inlet Guide Vane Flaps, Bearing Housings, or Inlet Guide Vane Actuation System Unison Ring; if determined unserviceable, non-repairable, or missing are to be either Government Furnished Material (GFM) furnished or O&A funding is to be provided to the Contractor to facilitate the needed sub-component replacement. (I.e. Material not already accounted for in the SOW supporting scope and pricing structure.)

The Contractor shall notify the Government, during the remanufacturing process, that it may be necessary to redirect material(s) and/or sub-components of the F118 Front Frame to a sub-contractor/facility to support the remanufacture and/or any required O&A effort. Associated costs, not already accounted for in this SOW for the LO Coating of the Front Frame and its associated pricing, will be identified by the Contractor via the Contractor’s report and submitted as proposed O&A cost to the PCO/ACO, Production Management Specialist (PMS) and Program Manager (PM) with the 421 SCMS/GUMBA/AFSC for review and approval as additional O&A remanufacturing cost.

The Contractor shall not be obligated to induct the asset into the remanufacturing process until written approval is granted by the PCO/ACO and the price is authorized via a contract modification and pricing and funding are provided.

1.3 Beyond Economical Repair (BER)

The Contractor shall, during the incoming receiving inspection, determine if a F118 Front Frame and/or its sub-components, to be BER, report this to the PCO/ACO and return the asset and/or sub-component to the Government, or request written consent to dispose of the subject “components” by the Contractor IAW all regulations and property disposal procedures stated in this SOW and Contract. BER shall be defined as 75% of the replacement cost of the asset or subject sub-component.

1.4 Receiving

The Contractor shall perform a receiving visual inspection upon receipt of each Front Frame

File Number: FD2030-17-00680 Page 4 assembly or bare Front Frame to determine the serviceability and level of remanufacturing required; to include material requirements.

NOTE: Technical Compliance Technical Order (TCTO) 2J-F118-567 will be accomplished at the OC-ALC. Ensure each assembled Front Frame is re-assembled after remanufacture with TCTO assets received with the Front Frame.

In addition, the Contractor shall report in accordance with the Supply Discrepancy Report (SDR), CDRL (A005) and obtain disposition instructions for any received assets which are misidentified, misdirected, have a variation in quantity, non-requisitioned items, lost or damaged parcel post or incorrect shipments. The Contractor shall not destroy reusable shipping containers, and will reuse them for return shipment. The Contractor shall initiate a SDR for such shipments or any assets as described above or received in packaging other than the contracted packaging requirements through WEB SDR.

The WEB SDR is located at: https://www.daas.dla.mil/websdr/home.asp.

This system of reporting an SDR has been developed in compliance with DoD Manual 4140.01- V1, Supply Chain Material Management Procedures and 4000.25, Defense Logistics Management System (DLMS), which requires automated SDR processing and IAW Contractor Asset Visibility for the Air Force (CAV AF) Statement of Work (SOW). The prime packaging specialist may authorize exceptions to these requirements.

1.5 Remanufacture

The Contractor shall remanufacture the replacement of the Low Observable (LO) Coating for the F118 Front Frame as follows:

1.5.1 Disassembly

The Contractor shall disassemble the Front Frame to the extent required for remanufacture of the LO Coating of the Front Frame.

1.5.2 Cleaning

All grease, oil, dirt, corrosion, and moisture must be removed prior to inspecting, remanufacturing, or re-assembling the Front Frame.

1.5.3 Remanufacture Procedures

To bring the F118 Front Frame LO Coating to a like new condition the Contractor shall remanufacture by replacing the LO Coating, when required, IAW the Contractor’s established procedures and this SOW. Low Observable Coating is utilized for both original manufacturing, and the restoration of the F118 Front Frame’s LO Coating back to the original life expectancy, or nearly so. Serialized military parts and life limited parts cannot be replaced by remanufactured parts. All tooling and parts required to accomplish the 100% inspection, teardown, and remanufacture of each Front Frame LO Coating shall be Contractor Furnished Material (CFM).

Units of the Front Frame that may potentially have the LO Coating remanufactured:

https://www.daas.dla.mil/websdr/home.asp

File Number: FD2030-17-00680 Page 5

Description Total Quantity per Frame Assembly

Inlet Guide Vane Flap (IGV) 13 Strut 13

Front Frame Outer Flowpath (per one strut to strut sector) 13

Front Frame Inner Flowpath (180 degree sector) 2

Shroud 1 Composite Inlet Translating Lip 1

Localized (LO coating patch repairs to include: edge seal, caulk, and blister repairs - regardless of components)

Defined per the applicable technical data

Remanufacture procedures shall include:

Low Level Remanufacture After inspection and/or teardown, any work to the Front Frame that will only require a total of minor remanufacturing processes to any or all parts of the Front Frame to return the asset to a “like new” condition, or nearly so. Work scope shall include:

• Localized repairs

• Complete strip and recoat of up to three (3), in any combination, of the IGVs, Struts, or

Outer Flowpath sections

Low Level Examples:

1. The Contractor completes fifteen (15) patch repairs and a full strip and recoat of three (3)

IGVs.

2. The Contractor completes no patch repairs and a full strip and recoat of two (2) Struts and one IGV.

3. The Contractor completes twenty (20) patch repairs and a full strip and recoat of one (1)

IGV, one (1) Strut, and one (1) Outer Flowpath section.

NOTE: A full strip and recoat of three (3) IGVs and one (1) Strut is an example that would push the remanufacture into the Medium Level category because the total is now four (4).

Upon completion of coating, the Front Frame will be reassembled and inspected.

Medium Level Remanufacture Work scope shall include Low Level remanufacturing operations and a complete strip and recoat of:

• Up to twelve (12), in any combination, of the IGVs, Struts, and Outer Flowpath sections

• One (1) Shroud

• Up to one (1) Inner Flowpath section

Medium Level Examples:

1. The Contractor completes only one (1) Inner Flowpath – completely stripped and recoated.

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2. The Contractor completes Localized repairs and a complete strip and recoat of four (4) IGVs, four (4) Struts, four (4) Outer Flowpath sections, and one (1) Inner Flowpath section.

NOTE: A full strip and recoat of four (4) IGVs, four (4) Struts, and five (5) Outer Flowpath sections is an example that would push the remanufacture into the High Level category because the total is now thirteen (13). Another example that would push the remanufacture into the High Level category would be if only two (2) Inner Flowpath sections needed a complete strip and recoat.

Upon completion of coating, the Front Frame will be reassembled and inspected.

High Level Remanufacture Work scope shall include Medium Level remanufacturing operations and a complete strip and recoat of:

• Up to twenty-four (24), in any combination, of the IGVs, Struts, and Outer Flowpath sections

• Up to two (2) Inner Flowpath sections

NOTE: A full strip and recoat of eight (8) IGVs, eight (8) Struts, and nine (9) Outer Flowpath sections is an example that would push the remanufacture into the High-Plus Level category because the total is now twenty-five (25).

Upon completion of coating, the Front Frame will be reassembled and inspected.

High-Plus Level Remanufacture Work scope shall include High Level remanufacturing operations and a complete strip and recoat of:

• Up to thirty-nine (39), in any combination, of the IGVs, Struts, and Outer Flowpath sections

• Up to one (1) Translating Lip

Upon completion of coating, the Front Frame will be reassembled and inspected.

1.5.4 Inspect

Each Front Frame shall be inspected to ensure that all operational and performance requirements are met per the Contractor’s required technical data before returning to service.

1.5.5 Testing

Each Front Frame shall be tested to ensure that all operational and performance requirements are met per the required applicable technical data. When the Front Frame passes all tests, the Contractor shall ensure that all assembly is complete (including safety wire) before returning to service.

1.5.6 Assembly

Assembly of the Front Frame shall be IAW the appropriate technical procedures.

File Number: FD2030-17-00680 Page 7

NOTE: Technical Compliance Technical Order (TCTO) 2J-F118-567 will be accomplished at the OC-ALC. Ensure each assembled Front Frame is re-assembled after remanufacture with TCTO assets received with the Front Frame.

1.5.7 Remanufacture Deviations

Prior to the remanufacturing of any Front Frame, the Contractor shall obtain written approval from the PCO for any deviations from the processes, materials, material processes, or procedures and must show that the intent of the process, materials, material process or procedures conform to processes required by the Contractor’s established procedures and this Statement of Work.

The F118 cognizant engineer reserves the right to approve or disapprove any processes or procedures when they fail to meet the intended requirements of the Front Frame.

1.6 Reference & Technical Manuals

In execution of this SOW, all remanufactured items must meet the inspection criteria, and the Contractor shall apply manufacturing processes, tools, and products as prescribed in FAR 22.1003-6(a) (1) (iv) and the Contractor’s established procedures.

1.7 Deliverables Quality

The Contractor shall ensure that materials, parts, and accessories used in remanufactured components are restored to original life expectancy or nearly so, and are interchangeable without alterations.

1.8 Deficiency Report (DR) Investigation

The Contractor shall investigate and submit findings to include root causes and a corrective action against all DRs submitted against reported defective items remanufactured by this contract. Each DR will be processed IAW T.O. 00-35-D-54 using SF Form 368, USAF Material Deficiency Reporting System, in a timely manner to meet suspense dates assigned by the action agency IAW Deficiency Reporting (CDRL A004).

1.9 Condemned Assets

Any Front Frame or component parts that exceed present remanufacture and inspection limits shall be condemned at the Contractor’s facility and processed through Plant Clearance Automated Reutilization Screening System (PCARSS). The Contractor shall not utilize serviceable parts from condemned assets. The Contractor will be allowed to move components among repairable end items to expedite the remanufacture of replacing the LO Coating of the Front Frame, versus maintaining serial number integrity.

Condemned assets shall not count toward production and be reported to the Production Management Specialist (PMS) with the 421 SCMS/GUMBA/AFSC to establish usage rates and cost planning. The Contactor shall report all condemned parts via CDRLs Commercial Asset Visibility Air Force (CAV AF) System (CDRL A002) and Contract Depot Maintenance Production Report (CDRL A001).

1.10 Quality System and Quality Assurance Plan

Each Front Frame identified as serviceable shall be delivered to the Government free of defects as it relates to the applicable technical data.

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The Contractor shall maintain a quality system that addresses and adheres to the elements of ISO 9001-ANSI/ASQC Q9001, Quality System Model for Quality Assurance in Design and Development, Production, Installation, and Servicing.

The Contractor’s system shall be certified to ISO 9001 by an approved ISO 9001 International registrar. The Government reserves the right to assess the Contractor’s compliance to its documented quality system. The quality system procedures, planning, and all other documentation that comprise the quality system, shall be made available to the Government for their review. The Government shall reserve the right to accept any non-conforming supplies and also, reserves the right to disapprove of the quality system, or portions thereof, when it fails to meet the intended objectives.

1.11 Reporting

The Contractor shall provide completed Certificate of Conformance documentation with each Front Frame that have been remanufactured with the intent of returning the part to a serviceable condition. This documentation shall have the part number, serial number, level of work accomplished, and Service Bulletins complied with on a serviceable tag, DD Form 1574. Also,

1.12 Contract Data Requirement List (CDRL)

The Contractor shall ensure that all reporting as specified under the following Contract Data Requirement List (CDRL) are accomplished:

A001: Contract Depot Maintenance (CDM) Production Report

The Contractor shall prepare the report using Table I in DID DI-PSSS-81995 as of the last working day of the month and forward to the PMS or original mail service NLT the fifth working day of the month during which the contracts assets are received. Reports will continue to be forwarded unless contract is terminated and the last report will be annotated as “Final Report”. The Contractor’s format with the same data elements as found on the CDM report may be accepted if approved by the PCO and IAW CDRL DD Form 1423-1.

A002: Commercial Asset Visibility Air Force (CAV AF) Reporting

The Contractor shall report End Item transactional data through electronic submission in CAV AF using the CAV AF website IAW the referenced DID and/or IAW the CAV AF SOW and shall not be waived. The transactions and data will be submitted by the Contractor daily IAW CAV AF User Guide, Version 8.0.1 or higher. For CAV AF reporting, the Contractor shall submit SDRs when required and IAW CDRL Form 1423- 1.

A003: Comprehensive Engine Management System (CEMS) Reporting

The Contractor shall provide the following information for each remanufactured F118 Front Frame on Air Force (AF) Form 1534:

a) Configured Item Identifier (CII) Designation

b) Serial Number (S/N)

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c) Date work was accomplished

d) Stock Record Account Number (SRAN)

e) Part Number (P/N)

f) Type of Transaction

g) Time on Front Frame

The AF Form 1534 is required to be submitted by close of business of the business day following the occurrence of the reportable event.

(An example of the AF Form 1534 may be provided to use as a guide.)

For verification of part numbers and serial numbers for NSN: 2840-01-531-1394LR and 2840-01528-4199LR (CII: HF11820) the Contractor shall contact the F118 Technical Equipment Specialist with the Air Force Life Cycle Management Center.

A004: Deficiency Report (DR)

Deficiency Reporting is initiated on the occurrence when deficient Government assets are received by the Contractor. Contractor shall refer to T.O. 00-35D-54 using SF Form 368 or equivalent and IAW CDRL DD Form 1423-1.

A005: Shipping and Packaging Discrepancy Report (Supply Discrepancy Report) The

Contractor shall notify the Government within five (5) working days of discovery or discrepancy when freight contents do not agree with the shipping documents and IAW CDRL Form 1423-1.

The Contractor shall use WEBSDR to submit an electronic SF-364 (Standard Form) IAW T.O. 00-35D-54 or a paper SF 364s until access to WEBSDR is attained, upon discovery of discrepancies for items of supply received for: overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damage, and/or improperly packaged shipment.

1.13 Document Storage

All records and reports outlined in this SOW shall be prepared for each part and a copy kept on file by the Contractor for three (3) years. The Government’s technical representative reserves the right to request and view any records at any time.

1.14 Shipping

The Contractor shall meet the delivery schedule. The Contractor shall ship or transport applicable assets as appropriate in order to have the assets available to support the customer’s operational requirements and in accordance with the contract’s delivery schedule. The Contractor shall not destroy reusable shipping containers, and will reuse them for return shipment.

1.15 Packaging and Handling

The Contractor shall be responsible for the preservation and packaging of the Front Frame IAW the Special Packaging Instructions (SPI) specified on AFMC Form 158. The Contractor shall

File Number: FD2030-17-00680 Page 10 place a serviceable tag, DD Form 1574, inside the package along with the assembly as well as outside the package.

In addition, all markings and labeling of units and shipping containers shall be packed IAW T.O. 00-85B-3, using Special Packaging Instruction (SPI) F 01-296-9470 or MIL-STD-129, Rev R, Department of Defense Standard Practice, Military Marking for Shipment and Storage.

The Contractor shall use additional guidance for preparation and shipment IAW T.O. 00-20-1, T.O. 00-20-3, MIL-STD-2073-1, MIL-STD-129, AFPAM24-237, and AFMAN 24-206. This contract does not allow for commercial packaging.

The Contractor shall meet the delivery schedule IAW the contract. The Contractor shall ship or transport applicable assets as appropriate in order to have the assets available to support the customer’s operational requirements and IAW the contract.

1.16 Preservation

The Contractor shall be responsible for the preservation and packaging of the Front Frame IAW the Special Packaging Instructions specified on AFMC Form 158. The Contractor shall place a serviceable tag, Department of Defense (DD) Form 1574, inside the package along with the assembly as well as outside the package.

The Contractor shall not destroy reusable shipping containers, and will reuse them for return shipment. Units shall be packed IAW with T.O. 00-85B-3 using Special Packaging Instruction (SPI). In addition, the Contractor agrees to the use of the crate that the Government sends the asset in, in order to return the asset to the Government in a serviceable condition.

In the case that a crate is received by the Contractor in an unserviceable condition, the Contractor shall notify the PCO, in writing, the proposed cost to repair the crate or negotiate the price for a replacement crate . The Contractor shall not destroy any reusable containers.

1.17 Safety

The Contractor shall maintain and execute a safety program using MIL-STD-882D, AFI 91- 301 and AFI 91-204 as guides. The Contractor shall comply with all safety provisions and technical specifications listed in the Contractor’s established procedures, along with any outstanding FAA Airworthiness Directives. All Contractor personnel and technicians shall comply with system safety engineering principles during all levels of remanufacturing.

While performing work under this contract the Contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health.

1.18 Contractor Identification to Government Employees

Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishing badges or other visible identification for meetings with Government personnel. In addition, Contractor personnel shall appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence.

File Number: FD2030-17-00680 Page 11

SECTION II: GOVERNMENT PROPERTY

2.0 Government Furnished Material (GFM)

NONE. All parts and components required to accomplish the intent of the T.O., SOW, or SBs shall be Contractor furnished material. Contractor furnished material and parts used for replacement shall be parts specified in T.O. 6J3-4-113-4, SBs or as written approval from the AFLCMC/LPSEB and/or AFLCMC/LPSBA in writing through the PCO.

2.1 Government Furnished Property (GFP)

All items to be remanufactured will be shipped to the Contractor. This is only GFP that will be applicable to this contract.

File Number: FD2030-17-00680 Page 12

APPENDIX “A”

ACRONYMS

ACO Administrative Contracting Officer ACSS Air Combat Sustainment Squadron AF Air Force AFMC Air Force Materiel Command CAVAF Commercial Asset Visibility Air Force CDRL Contract Data Requirements List CMM Commercial Maintenance Manual DD Department of Defense DER Designated Engineering Representative DR Deficiency Report ESM Engine Shop Manual GFM Government Furnished Material GFP Government Furnished Property IAW In Accordance With ISO International Standards Organization LO Low Observable NSN National Stock Number OC-ALC Oklahoma City Air Logistics Center PCO Procurement Contracting Officer PCARSS Plant Clearance Automated Reutilization Screening System P/N Part Number PMS Production Management Specialist SB Service Bulletin SDR Supply Discrepancy Report S/N Serial Number SOW Statement of Work

SRU S

SS Service Summary USAF United States Air Force