Attachment 02 - Statement of Work -Challenger 600 Series Aircraft Maintenance Programs.pdf

Bombardier Challenger 600 Series Aircraft Maintenance

Programs

Statement of Work Flight Program

Operations

Table of Contents

1.0 Introduction and Overview

2.0 Scope of Work

3.0 Contractor Aircraft Responsibilities

3.1 Program Management Support

3.1.1 Program Management

3.1.2 Reports

3.1.3 Program Management Reviews (PMRs) and Conferences

3.1.3.1 PMR/Conference Agendas

3.1.3.2 PMR/Conference Minutes

3.1.3.3 Travel for Meetings, Reviews or Conferences

3.1.4 Quality Control Plan (QCP)

3.2 Scheduled Maintenance

3.2.1 Airframe

3.2.2 Engines

3.2.2.1 Engine Overhaul Replacement Asset/Equipment Condition and Documentation

3.2.2.2 Time Controlled Engine Parts

3.2.2.3 Engine Components/Parts Replacement and Exchange

3.2.2.4 Engine Core Part Return

3.2.2.5 Disposition of FAA Owned Engine Parts Removed

3.2.2.6 Engine Maintenance Scheduling

3.2.2.7 Engine Configuration and Maintenance Data

3.2.2.8 Contractor Engine Overhaul Maintenance Program

3.2.3 Auxiliary Power Unit (APU)

3.2.4 Avionics

3.2.5 Aircraft Induction

3.3 Unscheduled Maintenance Support

3.4 Aircraft on Ground (AOG)

3.4.1 Airframe

3.4.2 Engines

3.4.3 Auxiliary Power Units

3.4.4 Avionics

3.5 Over and Above Support (O&A)

3.5.1 Over and Above (O&A) Tasks

3.5.2. Over and Above (O&A) Procedures

3.6 Engineering Support

3.7 Logistics/Parts Procurement

3.8 Tool Rental Sourcing Support

3.9 Aircraft Quality Control Inspection

3.9.1 Aircraft Replacement Asset/Equipment Condition and Documentation

4.0 Deliverables

4.1 Monthly Status Report (MSR)

4.2 Engine Tear Down and Evaluation Report

5.0 FAA Acceptance and Inspection

5.1 Aircraft Inspection and Maintenance Documents

5.2 Engine and APU Inspection and Maintenance Documents

6.0 Other Requirements

6.1 Component Warranty

6.2 Contractor Personnel Basic Qualifications

6.3 Subcontractor Requirements

6.4 Contractor Training Requirements

6.5 Workplace Drug Free Program

7.0 Invoicing Instructions

8.0 FAA Responsibilities

9.0 Government Property

10.0 Travel Support

11.0 Period of Performance

12.0 Place of Performance

Appendix A – Sample Monthly Status Report

Appendix B- Sample Engine Tear Down and Evaluation Report

1.0 Introduction and Overview

The Federal Aviation Administration (FAA) Flight Program Operations (AJF) owns and operates three (3) Challenger 601, one (1) Challenger 604, and six (6) Challenger 605 aircraft, for a total fleet of ten (10) Challenger jets. The fleet of Challenger jets are powered by General Electric (GE) CF34‐3A1 and CF34‐3B engines.

The FAA requires contract aircraft maintenance services to support the FAA Challenger fleet. The Contractor must meet all applicable regulations to provide maintenance services under Title 14 of the Code of Federal Regulations (14 CFR) Part 135 and Part 145. FAA requires that each maintenance provider perform all covered work by following Flight Program Operations’ FAA-accepted General Maintenance Manual (GMM) and FAA-approved Continuous Airworthiness Maintenance Program (CAMP). Continued contract support is critical to achieve the FAA missions and strategic goals of ensuring aircraft airworthiness to conduct safe flight operations, executed in accordance with the regulatory standards established by the Flight Program Executive.

The FAA Challenger aircraft are primarily based out of the FAA Mike Monroney Aeronautical Center located at the Will Roger World International Airport in Oklahoma City Airport (KOKC).

However, these aircraft operate worldwide, and maintenance support will be required in both domestic and international airports.

2.0 Scope of Work

FAA Flight Program Operations recognized a need for a single contract for Bombardier Challenger 600 series for aircraft maintenance services. The requirements include scheduled maintenance, unscheduled/Aircraft on Ground (AOG) response, Technical Services, Engineering Support, and parts/tools rental. These services are required to address airframe, CF34‐3A1 and CF34‐3B engines, Auxiliary Power Unit (APU), and avionics. Requirements include options to lease or purchase engines and APUs as necessary.

Flight Program Operations requires discrepancy corrective actions and repair services to be performed, as required, on the FAA fleet of Bombardier Challenger 600 series aircraft over the next five (5) years.

Services required by the Government include obtaining aircraft maintenance and aircraft technical services. The response time for services is critical to return FAA owned aircraft to airworthy and mission capable condition in a timely manner. The availability of aircraft is critical to meet the mission requirements.

The Contractor or any subcontractor performing work under this contract must possess a 14 CFR Part 145 Repair Station Certificate and associated Operations Specifications listing the appropriate ratings and limitations and have access to the original equipment manufacturer (OEM) engineering support.

The Contractor must possess a valid Bombardier, General Electric, and Honeywell service center authorization. The Contractor may be authorized to subcontract for services when an authorized service facility is not available at a site where services are required. Subcontract service providers must comply with applicable regulations.

Services Centers provide AOG support throughout the United States and worldwide. The Contractor must perform heavy maintenance and engine overhauls at an authorized service center.

The FAA will provide heavy maintenance work cards prior to aircraft induction. At the completion of each maintenance event, the Contractor must clean the inside and outside of the aircraft. This includes washing and polishing the aircraft to maintain appearance and condition equal to the condition of the aircraft when first delivered to the contractor for services.

3.0 Contractor Aircraft Responsibilities

3.1 Program Management Support

3.1.1 Program Management.

The Contractor must provide program management direction to ensure its contractor employees perform the identified tasks efficiently, accurately, on time, and in compliance with the requirements. The Contractor must assign a Program Manager (PM) to serve as the lead communicator with the FAA Contracting Officer (CO) and Contracting Officer’s Representative (COR) and must participate as a member of a government-led team as requested by the COR. The Contractor’s PM must provide a Kick-Off meeting with the FAA, COR, and Contractor to review Statement of Work (SOW) requirements and to understand work scope and deliverables. The Contractor’s PM must prepare and submit meeting minutes to the FAA that capture the discussions and understandings from the Kick-Off meeting.

3.1.2 Reports.

The Contractor must provide a monthly Project Scheduling and Monthly Status Reports (MSRs) by the 5th day of each month via email to the COR and authorized FAA Representatives as designated by the CO.

3.1.3 Program Management Reviews (PMRs) and Conferences

If determined necessary, the FAA will request, host, and participate in a post award conference and program review meetings with representatives of the Contractor to coordinate the Maintenance and Overhaul program effort. If determined necessary, the FAA or Contractor may request formal PMR’s. The PMR location will be determined and identified in response to the request. Informal meetings and reviews may be held on an “as-needed” basis to resolve problems.

3.1.3.1 PMR/Conference Agendas

An agenda, in Contractor format, is required for each PMR and must be transmitted by email the COR and other authorized FAA Representatives as designated by the CO. The agenda must include the following:

1. Purpose and objectives of the meeting.

2. Date, and time duration.

3. Chronological listing of each major topic to be discussed and the time scheduled for each topic.

4. Name of FAA and Contractor Co-Chairpersons and a list of attendees and their organization.

5. List of all documentation to be available for review.

6. Status of action items or problems identified at previous meetings.

3.1.3.2 PMR/Conference Minutes

Minutes of each program management review and conference must be prepared in Contractor format and must include, as a minimum, the following:

1. Tile page containing the following.

a. Contract name and number

b. Type of meeting and date

c. Name of the Contractor and address to which the Contracting Officer should send acknowledgments of receipt and comments.

2. Purpose and objectives of the conference

3. Location of the conference

4. Summary of the discussions, decisions, agreements reached, and directions.

5. List of attendees by name, position, organization represented, and phone number.

6. Copy of action items. Format of the action item sheets must be as specified by the

FAA. The Contractor must update the status of formal open action items weekly by email.

7. Updated conference agenda reflecting the actual agenda as conducted.

8. Copy of all briefing/presentation materials

3.1.3.3 Travel for Meetings, Reviews or Conferences

The Contractor travel costs for meetings, reviews, or conferences, when determined necessary by the FAA will be in accordance with (IAW) FAA Acquisition Management System (AMS) policies.

3.1.4 Quality Control Plan (QCP)

The Contractor must provide adequate quality control during the performance of all maintenance on FAA Flight Program aircraft. Quality control will be strictly exercised while the Bombardier Challenger 600 series aircraft is being maintained and repaired. This includes:

• Continuous monitoring of technicians and work in progress to ensure technical data is being followed, and ensuring all work is completed in accordance with the Flight Program Operations’ 14 CFR Part 145 FAA-approved CAMP, applicable 14 CFR parts, and in a safe and thorough manner.

• Competently performing complete records research of Airworthiness Directives and Service Bulletins, as well as preparing proper documentation of compliance in permanent aircraft logbook.

• Approve Bombardier Challenger 600 series aircraft for return to service in accordance with Flight Program Operations’ 14 CFR Part 145 FAA-approved CAMP.

• The FAA will have a Quality Assurance (QA) on site to oversee scheduled and non-routine maintenance tasks. All maintenance will be performed in accordance with Bombardier Challenger 600 series aircraft maintenance manuals and FAA-accepted and/or approved aircraft maintenance manuals.

3.2 Scheduled Maintenance

The Contractor must have adequate facilities, approved tooling, equipment, parts, and material to perform scheduled maintenance inspections in accordance with Flight Program Operations CAMP.

The Contractor must provide available dates and manpower, for requested scheduled maintenance inspections within seven (7) days of the request. The FAA will submit request for scheduled maintenance within at least 60 days prior the required induction date.

All maintenance inspections, repairs or alterations must be documented in accordance with Flight Program Operations’ General Maintenance Manual.

All scheduled Maintenance Inspection down times will be agreed upon by the Contractor and Government based on the work scope requirements prior to the induction date of the Scheduled inspection. Inspections will be performed as required by scheduled periodicity of Time Limited Work for the Challenger 601, 604, and 605. Up to fifteen (15) days is the standard performance period unless a discrepancy is found that drives a longer return to service date. Additional unscheduled maintenance or Over and Above (O&A) may cause this schedule to be extended. The Contractor must provide this information to the COR and CO to negotiate a longer period of performance on these scheduled inspections.

3.2.1 Airframe

As required, the Contractor is responsible for performing aircraft scheduled maintenance inspections at their facility. Scheduled maintenance will consist of 12M, 24M, 36M, 48M, 60M, 240M, 240-120M, 400H, 800H, 1200H, 1600H, 2400H, 3200H, 4800H inspections and Time Limited Work (TLW) items.

• Scheduled Maintenance- The Contractor will be required to perform scheduled maintenance checks on the Challenger 601, 604, and 605 series aircraft.

• Aircraft TLW: Reoccurring work orders for the Challenger 601, 604, and 605. TLW includes providing associated life limited parts and labor associated with required component overhauls, inspections and lubes.

• Challenger 601 Hourly and Monthly Scheduled Maintenance Checks for three aircraft.

• Challenger 604 Hourly and Monthly Scheduled Maintenance Checks for one aircraft.

• Challenger 605 Hourly and Monthly Scheduled Maintenance Checks for six aircraft.

The table below provides a breakdown of the frequency of these checks during the period of performance of the contract.

601 Aircraft Monthly Airframe Check

604 Aircraft Monthly Airframe Check

605 Aircraft Monthly Airframe Check

Airframe Checks

Frequency per aircraft over 5 years Airframe Checks

Frequency per aircraft over 5 years Airframe Checks

Frequency per aircraft over 5 years 12M 5 12M 5 3M 20 24M 2 2M 2 6M 10 36M 1 36M 1 12M 5 48M 1 48M 1 24M 2 60M 1 96M 1 36M 1 *120M 0 48M 1 *240M 0 96M 1

3.2.2 Engines

The Contractor will be required to perform maintenance, hot section inspections and overhauls on GE CF-34-3A1, and CF34-3B engines. The Contractor may be required to provide spare engines for rent or lease to minimize aircraft downtime. The Contractor may be required to provide spare engines as an option for purchase. The Contractor will be required to perform Challenger 600 Series Engine Inspections.

The Contractor will be required to perform Challenger Hourly and Monthly Scheduled Engine Maintenance Checks. The table below provides a breakdown of the frequency of these checks during the period of performance of the contract.

CF34-3A1 Aircraft Engine MX CF34-3B Aircraft Engine MX

Engine Checks Frequency per aircraft over 5 years Engine Checks

Frequency per aircraft over 5 years 30 day (100 HR Chip Detector) 60 30 day (100 HR

Chip Detector) 60

400H E 12 100 HR (Fuel Filter Inspection) 48

800H E 6 400H E (Engine Wash Only) 12

1600H E 3 600H E 8 3200H E 2 800H E 6

3200 HSI 1200H E 4

6000 Hour Overhaul 2400H E 2

3200H E 2

3200 HSI 2

6400-hour overhauls

The Contractor must provide an engine overhaul services for up to (8) CF34‐3A1, and up to fourteen (14) GE CF34‐3B Challenger engines. The overhaul services must provide coverage for the cost of unscheduled engine maintenance including parts, labor, engine removal and install and other tasks as described in this SOW. The Contractor must also provide for the removal, packing, transportation (e.g., shipping), and re-installation of the engine(s). The Contractor must provide that availability of a leased engine to minimize aircraft down time. The Contractor will be expected to provide engines to be leased and installed within five calendar day. However, the FAA recognizes that some engines may need longer lead times due to market conditions. When this is the case, the Contractor must provide updates as to when the next engine will be available.

Scheduled maintenance and inspections on the Challenger 600 Series Engine will include:

preventive maintenance, phase inspections, special inspections required by the manufacturer, corrosion control, overhaul and/or replacement of components, and modifications to aircraft system(s). Scheduled items include Service Bulletins issued by the manufacturer, Airworthiness Directives (AD) issued by the FAA, as well as Maintenance Alert Directives (MAD) issued by Flight Program Operations. All scheduled work to be performed will be preceded with a budgetary quote/proposal for the known items of work to be completed.

Scheduled work will not commence until the work package has been approved in writing by the CO or the COR, as the designated representative of the CO. The scope of the work to be performed as part of this effort is specified in Section 2 of this SOW.

The Contractor must have the approved tooling and equipment to provide regularly scheduled maintenance for the GE CF-34-3A1, and CF34-3B engines.

As required, the Contractor will be responsible for performing engine scheduled maintenance inspections at their facility. Scheduled maintenance will consist of, 400H engine, 800H engine, 1600H engine, 3200H engine and 6000 hours overhaul and 6400 hours overhaul and time limited work items.

The Contractor must have adequate facilities, approved tooling, equipment, parts, and material to perform scheduled maintenance inspections in accordance with Flight Program Operations CAMP.

The Contractor must provide available dates and manpower for requested scheduled maintenance inspections within seven (7) days of the request.

All maintenance inspections, repairs or alterations must be documented in accordance with Flight Program Operations’ General Maintenance Manual.

3.2.2.1 Engine Overhaul Replacement Asset/Equipment Condition and Documentation

Any parts required to accomplish the overhaul or to correct discrepancies discovered during the performance of overhaul may be procured or purchased by the contractor with prior authorization from the FAA CO or COR. Any asset(s) required to replace existing component(s) necessary for the accomplishment of the contracted work must meet the following requirements:

Reasonable Parts Handling markup/surcharge fees will be negotiated by the CO and Contractor prior to contract being awarded. The proposed parts markup should include a sliding scale whereby higher cost parts have a lower markup. All shop fees must be included in the overhaul/unscheduled maintenance as not separately priced, which will be considered over and above tasks.

Any asset(s) required to replace existing component(s) necessary for the accomplishment of the contracted work must meet the following requirements:

Components offered as “New” must:

• Have zero (0) hours and zero (0) cycles in service since time of manufacture, and the internal components must have (0) hours and zero (0) cycles in service since time of manufacture.

• Have documentation that provides full traceability of parts and assemblies, if applicable, and a copy of the original shipping invoice from the Production Approval Holder (PAH) to the supplier providing evidence that the origin of the part is from a FAA PAH or that the original acquisition was from a FAA-approved source.

• Have documentation that identifies assembly internal components that are required to be tracked for traceability in accordance with the OEM manuals. Documents must identify part number and serial number.

Components offered as “Overhauled/Repaired/Serviceable” must:

• Be restored by an FAA-approved 14 CFR Part 145 Repair Station in accordance with the OEM manual requirements.

• Be restored after January 1, 2011 and have zero (0) time and zero (0) cycles in service since time of restoration.

• Have documentation that identifies all assemblies and assembly components meet the OEM one hundred twenty (120) month restoration requirement.

• Have documentation that identifies assembly internal components that are required to be tracked for traceability in accordance with the OEM manuals. Documents must identify part number, serial number, and times/cycles/landings since new or overhaul.

All components must:

• Be properly identified as an approved aeronautical part in accordance with 14 CFR Part 21 and 14 CFR Part 45.

• Have a shipping invoice from the contractor to the FAA identifying part numbers and serial numbers.

3.2.2.2 Time Controlled Engine Parts

Time controlled parts are parts where time has expired and must be replaced with new or overhauled parts. When time-controlled parts have failed, but time has not expired, they may be repaired and used on the FAA CF-34-3A1 and CF-34-3B engine engines provided the part have sufficient life to achieve its next major scheduled event where access to such part is permitted.

3.2.2.3 Engine Components/Parts Replacement and Exchange

Engine components/parts that are removed and exchanged during maintenance of the FAA engines will no longer be the property or responsibility of the FAA. The replacement of newly embodied engine components/parts will become the property of the FAA. All exchange components/parts removed from engines during maintenance by FAA personnel will be returned to the Contractor or their designated supplier in an “as‐is condition”.

3.2.2.4 Engine Core Part Return

In those instances when a simultaneous exchange of parts is not feasible, the Contractor must allow the FAA to return the core part within a fourteen (14) day period. If the FAA does not return the part within the fourteen (14) day period, the Contractor must provide notification to the FAA of the past due core. If the FAA is unable to return the core part due to the Contractor, the part may be deemed lost. The Contractor will provide the FAA the value of the part. Upon approval of the FAA, the Contractor may invoice the FAA for the value of the part using the O&A procedure.

3.2.2.5 Disposition of FAA Owned Engine Parts Removed

Each part removed by the Contractor from a FAA owned engine, not reinstalled therein, or is not replaced or exchanged by the contractor is the property of the FAA. Such parts must be identified with a tag attached to each part that identifies “FAA Property”, part number, component serial number, cause for removal, and serviceability if known. The parts must be returned to the FAA’s designated maintenance program manager and must include shipping document that lists each part and quantity.

3.2.2.6 Engine Maintenance Scheduling

The FAA will schedule GE CF-34-3A1 and CF-34-3B engine maintenance to comply with requirements IAW Bombardier, GE manuals, advisories, and technical specifications as applicable. The FAA will notify the Contractor of scheduled engine overhaul requirements at least thirty (30) days prior to them becoming due.

3.2.2.7 Engine Configuration and Maintenance Data

The FAA will provide engine configuration and maintenance data upon the Contractor’s request. The data provided will be from the FAA tracking systems database and/or from the GE CF-34-3A1 and CF-34-3B engine logbooks.

3.2.2.8 Contractor Engine Overhaul Maintenance Program

The Contractor must provide GE CF-34-3A1 and CF-34-3B engine overhaul maintenances services consisting of teardowns, evaluations, and inspections. All maintenance performed under this contract will be performed by experienced GE CF-34-3A1 and CF-34-3B approved overhaul and repair facilities that are properly certified under the CFR Part 145.

Engine parts and components used to complete the overhauls of the CF-34-3A1and CF-34- 3B, and engines must have a valid certification required by CFR, Title 14. All facilities and parts used in support of this contract will be subject to surveillance and acceptance by the FAA Flight Program Operations Quality Assurance Representative.

The Contractor must provide a teardown and evaluation report for the CF-34-3A1, and CF34-3B engine. This teardown and evaluation report must include time and materials. A copy of the maintenance service report must be part of the recertification documents (8130-

3) packet that must be provided to the FAA’s designated maintenance program manager when the overhaul is complete.

After receipt of the teardown and evaluation report, the price of the overhaul will be negotiated and finalized with the CO. No overhaul work shall begin until the price is finalized unless specifically authorized by the CO.

The Contractor must be responsible for the freight cost of shipping engines to and from the overhaul facility. The Contractor will provide CF-34-3A1 and CF-34-3B engines approved shipping containers when needed. The Contractor will provide labor necessary to perform engine removals and installations when needed.

3.2.3 Auxiliary Power Unit (APU)

The Contractor will be required to perform scheduled maintenance on APUs. The Contractor may be required to provide spare APU’s for rent or lease to avoid aircraft downtime. The Contractor may be required to provide spare APU’s as an option for purchase.

The Contractor will be required to perform maintenance and overhaul on GTCP36-150RJ and GTCP36-150CL APUs. The Contractor may be required to provide spare APU for lease to minimize aircraft downtime.

The Contractor will be responsible for providing parts and labor for APU Scheduled Maintenance such as detailed Hot Section Inspections (HSI). APU maintenance must be accomplished by an authorized Maintenance Service Plan (MSP) Service Center and includes gaining access to removal and replacement of APUs and Line Replaceable Units (LRUs).

For standard maintenance all insurance, transportation and repair logistic expenses related to on-site maintenance activities, such as mobile repair units, personnel and equipment charges, and all expenses related thereto, incident to the repair, exchange, or loan of APUs will be provided by the contractor when the Aircraft cannot be relocated to an Authorized Service Center due to an APU being in an Unserviceable condition.

3.2.4 Avionics

The FAA requires the Contractor to be an Authorized Service Facility for Rockwell Collins, Universal and Honeywell to provide aircraft avionics maintenance and troubleshooting support during scheduled maintenance events.

The Contractor must have approved tooling, equipment, parts, and material to adequately repair all avionics systems on the Challenger 600 Series aircraft. The Contractor must also have extensive experience on performing preventative maintenance, modifications, and repairs for the avionics systems.

3.2.5 Aircraft Induction

Upon the arrival of the aircraft, before any work commences, the Contractor and the COR or Quality Assurance Representative must inspect the aircraft exterior and interior to confirm the configuration and condition of the aircraft. Any irregularities should be documented, and a copy will be provided to the COR.

Any repair and/or non-routine discrepancy tasks must be completed prior to release of the aircraft for flight. A post-maintenance inspection will be performed to ensure airworthiness, inspect for damage, and verify completeness.

All maintenance inspections, repairs or alterations must be documented in accordance with Flight Program Operations’ General Maintenance Manual.

3.3 Unscheduled Maintenance Support

The definition of unscheduled maintenance is any maintenance that has a fixed priced before an aircraft goes into depot for scheduled maintenance. This would also include any service bulletins, Air Worthiness Directives and other modifications to the aircraft. Fuel cell maintenance and repairs, if required, are considered unscheduled maintenance. If fuel cell maintenance is subcontracted, the subcontractor performing work under this contract must hold a 14 CFR Part 145 Repair Station Certificate and associated Operations Specifications listing the appropriate ratings and limitations.

3.4 Aircraft on Ground (AOG)

AOG items cover pilot in-flight, pre and post flight discrepancies. These activities are not a part of the scheduled maintenance.

The FAA CO will request a proposal, based on a work package, for any AOG work to include a firm fixed price and induction schedule. When possible, the FAA will combine as many scheduled and unscheduled maintenance efforts to reduce aircraft downtime. AOG work will not commence until the work package has been approved in writing by the CO or the COR, as the designated representative of the CO.

AOG Services: The contractor is required to correct pilot in-flight, pre and post flight inspection discrepancies. The contractor will be required to perform a return to service release in accordance with FAA Flight Program Operations’ approved General Maintenance Manual (GMM).

3.4.1 Airframe

As required, the Contractor will be responsible for performing aircraft repairs remotely or at their facility. The Contractor must provide AOG / Mobile Repair Team (MRT) services for AOG when aircraft cannot be relocated. The MRT request must be acknowledged within four (4) hours and technicians must be dispatched in an expedited manner.

The Contractor must provide technical experience and troubleshooting support 24 hours/day, 7 days/week, including holidays, for the Bombardier Challenger 600 series airframe when experiencing operating discrepancies and abnormalities.

The aircraft may be flown to the contractor’s facility under Minimum Equipment List (MEL) or a Special Flight Permit for repair. Under this scenario, the repair service must commence within 24 hours of aircraft arrival/delivery.

The Contractor must have approved tooling, equipment, parts, and material to adequately repair all Bombardier Challenger 600 series aircraft systems. The Contractor must also have extensive experience on performing preventive maintenance, inspections, modifications, and repairs on airframe and engine (GE CF-34-3A1 and CF- 34-3B engines) for Bombardier Challenger 600 series aircraft.

At the completion of each repair, the Contractor must ensure the aircraft maintenance logs (AML) are properly completed in accordance with Flight Program Operation’s Maintenance Control Instructions.

The Contractor must hold a 14 CFR Part 145 Repair Station Certificate and associated Operations Specifications listing the appropriate ratings and limitations, have access to the original equipment manufacturer (OEM) engineering support, an Authorized Bombardier Service Center is desired. Contractor must have the ability to provide AOG support throughout the United States and worldwide.

Due to the AOG nature, the contractor must complete most repairs within 48 hours of notification, or within 24 hours of a pre-established return to service (RTS).

3.4.2 Engines

The Contractor must provide technical experience and troubleshooting support 24 hours/day, 7 days/week, including holidays, for GE CF-34-3A1 and CF-34-3B engines when experiencing operating discrepancies and abnormalities.

The Contractor must have approved tooling, equipment, parts, and material to adequately repair all General Electric CF-34-3A1 and CF-34-3B engines. The Contractor must also have extensive experience on performing preventive maintenance, inspections, and repairs on the GE CF-34-3A1 and CF-34-3B engines for Bombardier Challenger 600 series aircraft.

3.4.3 Auxiliary Power Units

As required, the Contractor will be responsible for all parts and labor for Unscheduled Maintenance. Unscheduled Maintenance will be performed by an Authorized Service Center. Spare APUs will be available for rent or purchase at the time of extended Unscheduled Maintenance. The work includes troubleshooting, gaining access to, and the removal and replacement of APUs and Line Replaceable Unit (LRUs).

As required, the contractor will be responsible for APU Alert and Recommended Service Bulletins: All parts and labor for APU Alert and Recommended Service Bulletins will be accomplished in conjunction with other covered maintenance and in accordance with the instructions of the Service Bulletin.

As required, the Contractor will be responsible for periodic APU Inspections. Inspections will be performed at Authorized Service Center.

APUs are an on-condition removal item and are only removed due to failure or when the performance deteriorates below an acceptable limit.

The Contractor must provide technical experience and troubleshooting support 24 hours/day, 7 days/week, including holidays, for GTCP36-150RJ and GTCP36-150CL APUs when experiencing operating discrepancies and abnormalities.

The Contractor must have approved tooling, equipment, parts, and material to adequately repair all GTCP36-150RJ and GTCP36-150CL APUs. The Contractor must also have extensive experience on performing preventive maintenance, inspections, and repairs on the GTCP36-150RJ and GTCP36-150CL APUs for Bombardier Challenger 600 series aircraft.

3.4.4 Avionics

The Contractor must be an Authorized Service Provider with Rockwell Collins, Universal, and Honeywell to provide AOG support. The Contractor must provide technical experience and troubleshooting support 24 hours/day, 7 days/week, including holidays, for Rockwell Collins, Honeywell and Universal when experiencing operating discrepancies and abnormalities.

The Contractor must have approved tooling, equipment, parts, and material to adequately repair all Rockwell Collins, Honeywell, and Universal avionics systems. The Contractor must also have extensive experience on performing troubleshooting, preventive maintenance, modifications, inspections, and repairs on these avionics systems.

3.5 Over and Above Support (O&A)

(O&A) support is any non-routine discrepancy that is found during a scheduled maintenance event on the aircraft other than AOG. Either the FAA or the Contractor may initiate an O&A action depending on the circumstances. All non-routine discrepancies that need to be corrected will be submitted promptly to the COR for approval prior to commencement of work. The Contractor is required to provide maintenance services, parts, and support tasks associated with an O&A effort.

Any pilot reported discrepancy upon induction of a scheduled maintenance event would be considered non-routine and should be billed as O&A.

3.5.1 Over and Above (O&A) Tasks

The O&A tasks include but are not limited to the following:

1. Parts – Necessary engine parts or components not fixed priced in the pricing matrix or negotiated after teardown, test, and evaluation may be paid for via the O&A (a.k.a. Unscheduled Maintenance) CLIN. Note that O&A is linked to a T&M CLIN and that parts are supplied at cost plus a reasonable handling fee as defined in Section 5.4

2. Labor – Labor, or “Time,” that is not allocable to a separate CLIN on a fixed price or cost reimbursable basis, may be allocated and paid for via O&A.

3. Foreign Object Damage (FOD) – Repair of damage to the engines resulting from foreign object damage, i.e., hail, bird strikes, rocks, or other debris.

4. Damage/Loss –Repair/replacement of parts or components either damaged or lost because of negligence or accident on the part of the FAA.

5. Theft – Replacement of parts because of theft of parts or components from engines other than when in control of the contractor.

6. Acts of GOD – Repairs due to flood, earthquake, volcanic ash, lightning strikes, tornadoes, hurricanes, other local emergencies, etc.

7. Corrosion, Erosion, or Sulphation – Component repair or replacement costs attributable to damage caused by corrosion, erosion or sulphation.

8. Support Equipment, Materials, Manuals, Technical Support – Cost of support equipment rentals, materials, manuals, technical support, etc. that is not covered by the cost per engine operating hour Engine Management Program.

9. Spares Parts Purchases – Purchase of spare parts less discount for FAA stock.

3.5.2. Over and Above (O&A) Procedures

Either the FAA or the Contractor may initiate the O&A action that meets the criteria. If the FAA determines an O&A action is required, the CO or COR will request a quote for the O&A action. Upon approval of the quote, the COR will ensure sufficient funding is available on the O&A (a.k.a. Unscheduled Maintenance) CLIN.

O&A actions must be billed on a separate Contract Line-Item Number (CLIN)—the O&A Maintenance Support” CLIN. The Contractor must receive prior authorization from the CO or their designated representatives, Contracting Officer Representative (COR), before providing O&A maintenance, parts, or support tasks.

The CO must approve all obligations. If the FAA determines an O&A action is required, the CO or COR will request a price quote. Upon approval of the price quote, the COR will ensure sufficient funding is available on the O&A CLIN. The CO or COR will provide approval to the contractor by issuing a Notice to Proceed (NTP) in FAA format or written notification by electronic mail.

When the Contractor discovers or determines an O&A action is required, the Contractor must notify the CO and COR via email no later than one calendar day after the discovery.

The communication must include a description of the required action, and an explanation as to why it is considered an O&A action.

The Contractor must submit a Not‐To‐ Exceed (NTE) price, as soon as practical. The NTE request should include estimated labor hours and a material listing with projected pricing.

This must be done by electronic mail.

The COR will review the contractor O&A request with the appropriate FAA personnel and provide a recommendation of approval or disapproval to the CO. In addition, the COR will validate that sufficient funding is available on the Over and Above Maintenance Support CLIN and provide this information to the CO. The CO will provide formal approval to the contractor via electronic mail or designate in writing the COR may provide this approval.

At a minimum, all O&A actions and quotes must identify the requested maintenance or support action, and include all pertinent information (e.g., aircraft system, engine serial number, part numbers, tool, rental fee) with supporting documentation. The contractor must provide a NTE or Firm-Fixed Price (FFP).

3.6 Engineering Support

The Contractor will be responsible for providing engineering support for AOG/Unscheduled;

scheduled; and non-routine discrepancies to include aircraft, engine, APU and avionics support. The Contractor must provide technical experience and troubleshooting support 24 hours/day, 7 days/week, including holidays.

Engineering support responsibilities include technical support for modifications, structural and electrical repairs.

3.7 Logistics/Parts Procurement

The Contractor will be responsible to provide logistical support for AOG; Unscheduled;

scheduled; and non-routine discrepancies to include aircraft, engine, APU and avionics support. The Contractor must provide logistical and parts sourcing support 24 hours/day, 7 days/week, including holidays.

3.8 Tool Rental Sourcing Support

The Contractor will be responsible to provide tool rental sourcing support to support AOG;

Unscheduled; scheduled; and non-routine discrepancies to include aircraft, engine, APU and avionics support. The Contractor must provide tool rental sourcing support 24 hours/day, 7 days/week, including holidays.

3.9 Aircraft Quality Control Inspection

The Contractor must provide adequate quality control during the performance of all repairs on FAA Flight Program Operations aircraft. Quality control will be strictly exercised while the aircraft is being maintained and repaired. This includes:

• Continuous monitoring of technicians and work in progress to ensure technical data is being followed, and ensuring all work is completed in accordance with the Flight Program Operations’ CAMP.

• Approve aircraft for return to service in accordance with Flight Program Operations’ 14 CFR Part 145 FAA-approved CAMP.

• The COR will identify to the contractor the name of a Flight Program Operations Quality

Control Representative to oversee scheduled and non-routine maintenance tasks. The Contractor is responsible for annotating all discrepancies and submitting the documentation to the Flight Program Operations Quality Control Representative/COR prior to starting work. All maintenance will be performed in accordance with Challenger 600 series aircraft maintenance manuals and FAA-accepted and/or approved aircraft maintenance manuals.

• Performing all repair and/or maintenance actions in accordance with Bombardier

Challenger 600 series aircraft maintenance manuals along with any technical instructions (i.e., Airworthiness Directive (AD), OEM Service Bulletin (SB), Engineering Order (EO), Maintenance Action Directive (MAD) or Fleet Campaign Instructions).

3.9.1 Aircraft Replacement Asset/Equipment Condition and Documentation

A pre-draw parts kit or Materials Requirement Listing (MRL) will be provided by the Federal Aviation Administration, all parts contained in the MRL should be used prior to contractor purchasing parts.

Any part required to accomplish scheduled inspections or to correct discrepancies discovered during the performance of scheduled inspection may be procured or purchased by the contractor with prior authorization from the FAA CO or COR.

Any asset(s) required to replace existing component(s) necessary for the accomplishment of the contracted work must meet the following requirements:

• Reasonable Parts Handling markup/surcharge fees will be negotiated by Federal

Aviation Administration and Contractor prior to the contract being awarded. All shop fees must be included in the scheduled maintenance/inspection price and not separately priced.

Any asset(s) required to replace existing component(s) necessary for the accomplishment of the contracted work must meet the following requirements:

Components offered as “New” must:

• Have zero (0) hours and zero (0) cycles in service since time of manufacture, and the initial components must have (0) hours and zero (0) cycles in service since time of manufacture.

• Have documentation that provides full traceability of parts and assemblies, along with documentation to establish proper certification for type design in accordance with the Bombardier Challenger 600 series illustrated parts catalog or Flight Program Operations Instructions for continued airworthiness.

• Have documentation that identifies assembly internal components that are required to be tracked for traceability in accordance with the OEM manuals.

Documents must identify part number and serial number.

Components offered as “Repaired/Overhauled/Serviceable” must:

• Be restored by an FAA-approved 14 CFR Part 145 Repair Station in accordance with the OEM manual requirements.

• Be restored in the last five years and have zero (0) time and zero (0) cycles in service time of restoration.

• Have FAA form 8130-3 Airworthiness Approval Form.

• Have Identification documentation for all life limited subassemblies.

Consumable components must:

• Have proper acceptable documentation in accordance with the Flight

Program Operations General Maintenance Manual.

4.0 Deliverables

4.1 Monthly Status Report (MSR)

The Contractor’s Program Manager must provide an MSR that documents the activities of the previous month and identifies planned activities for the following month. The Contractor must deliver the reports to the COR. The reports must include, at a minimum, the following information, see Appendix A –Sample Monthly Status Report:

Overview of work completed, work in progress, and work planned for each task.

Hours expended by task, labor category, and personnel.

Status of individual deliverables.

Identification of risk areas with recommended remedial actions.

Status of all outstanding risks identified in previous MSRs.

Summary of expenditures by resource and labor category for the monthly reporting period, as well as cumulative year-to-date totals for the performance.

Travel Request and status.

Any additional information pertinent to the Government in administering the performance of this effort when directed by the COR.

Financial information to include:

• CLINs used during month.

• Cost/hours funded or apportioned by CLIN.

• Cost/hours used by CLIN.

• Projected date when 75% of funds are spent.

• Projected date when funds are exhausted.

• Funds/hours remaining by CLIN.

• Other direct costs (ODCs) estimated, used, and remaining by month.

• Summary of expenditures by resource and labor category for the monthly reporting period, as well as cumulative year-to-date totals for the performance period.

4.2 Engine Tear Down and Evaluation Report

The Contractor’s Program Manager must provide an Engine Tear Down and Evaluation

Report that documents engine inspection results for replaced material, or material requiring repair due to Inspection findings. The reports must include, at a minimum, the following information, see Appendix B – Engine Tear Down and Evaluation:

Contract Number

Task Order Number

Period

Work Order

Engine Model

Engine S/N

Prepared for/Prepared by

Engine Specifics to include ESN, TSN and CSN with reason for removal.

Inspection findings Summary

Inspection findings-Material for Replacement detailing the following:

• Removed P/N

• S/N

• Description

• Qty

• Comments

5.0 FAA Acceptance and Inspection

5.1 Aircraft Inspection and Maintenance Documents

The FAA will conduct a receiving inspection on all aircraft after maintenance, IAW Technical Inspection (TI) 4100.24, General Maintenance Manual. Any parts received in a damaged condition or without proper certification documentation will be recorded and identified to the Contractor for resolution. Should the engines or parts require return shipment to the Contractor it will be at the Contractor’s expense.

5.2 Engine and APU Inspection and Maintenance Documents

Upon completion of engine or APU inspections, maintenance, and repair the Contractor must provide all certification documents including full copy of work order that describe all details of inspections performed, maintenance performed, components repaired or replaced, and problem areas corrected. The Contractor must enter in the historical records (engine or APU logbooks) all FAA airworthiness directives, manufacturers’ service bulletins or other modifications, and all other significant maintenance actions accomplished. In addition, the

Contractor must record all previously complied with modifications found to be previously accomplished, but not recorded. The Contractor must indicate in the historical records the nomenclature, part number, location, total time, and total cycles, accumulated for all replacement life limited parts (LLP) installed. Any LLP parts that are repaired, reworked, or modified that extend or reduce life will be identified with new limits in the historical records.

6.0 Other Requirements

6.1 Component Warranty

The Contractor must provide a written statement of warranty for the work performed for the FAA. The warranty statement must identify what is covered under warranty and the warranty duration.

6.2 Contractor Personnel Basic Qualifications

The Contractor must provide personnel who possess the required qualifications under 14 CFR, as well as the necessary skills and training to effectively accomplish the requirements of this SOW. The skills must include technical support for all applicable aircraft maintenance tasks, engine and airframe troubleshooting, parts support required for airframe and engine maintenance/inspection, field support for airframe and engine repairs, engine change, and accounting support for invoicing as described in this SOW.

6.3 Subcontractor Requirements

Whether maintenance is subcontracted domestically or overseas, subcontractors must hold a 14 CFR Part 145 Repair Station Certificate and associated Operations Specifications listing the appropriate ratings and limitations. The subcontractor must have access to the OEM engineering support.

The Contractor must establish agreements with the OEMs and subcontractors that allow the Contractor to obtain the approved data and technical support necessary to maintain the Bombardier Challenger 600 series aircraft airframes, engines, accessories, and systems to ensure the FAA airworthiness certification is not compromised.

The Contractor must ensure the agreements are in effect at the start of the full-scale period of performance. The Contractor must ensure mission capability and departure reliability requirements are not impacted because of the inability to obtain data or support from the OEMs. The Contractor must ensure subcontractors comply with all FAA, Quality Assurance (QA), Safety and contractual requirements.

Subcontractor actions that do not directly apply to other CLINs in this SOW may be billed on the “Subcontract Maintenance Supplies and Labor” CLIN.

6.4 Contractor Training Requirements

The Contractor must provide adequate staff of current (valid) FAA Airframe and Powerplant

Certificate technicians with aircraft familiarization (FAM) certified training.

The Contractor technician must have a current (valid) FAA Airframe and Powerplant Certificate 14 CFR part 65 and proof of the OEM aircraft FAM certified training.

6.5 Workplace Drug Free Program

The Contractor must ensure each contractor employee working on this contract is drug and alcohol free as set forth in Title 14 CFR Part 120. The FAA Guidance for random drug and alcohol testing that implements this CFR is IAW the Department of Transportation (DOT) Office of Drug & Alcohol Policy & Compliance that requires mandatory drug testing of each employee who performs a safety-sensitive function.

7.0 Invoicing Instructions

The Contractor must submit an invoice for the services and approved O&A actions within thirty

(30) days of any maintenance activities being completed. Each invoice must be numbered in contractor format and include the program contract number and task order number. The invoice must detail the work being billed for each CLIN. The invoice should be accompanied by the MSR detailed in SOW section 4.1; the financial information should match the information detailed on the invoice. Each invoice must have appropriate supporting documentation which may include but is not limited to travel authorizations, over and above NTP, and parts receipts.

The CO or COR may request additional supporting information when needed.

8.0 FAA Responsibilities

If required, the FAA will ferry aircraft from the place of disablement to a service center for repair work to be performed.

The FAA will provide the Contractor with a shipping address or location for services requested.

The FAA will provide a discrepancy, squawk, work scope, description, etc. of required aircraft maintenance or technical services when required.

The FAA may provide replacement parts or materials based on availability and when required for the Contractor to perform aircraft maintenance actions. The provisions for Government supplied material(s) are at the discretion of the Government.

The FAA will provide the contractor with all applicable supplemental manuals, technical manuals, custom Work Content Documents, the FAA GMM, and the FAA-approved CAMP.

A pre-draw parts kit or MRL will be provided by the Federal Aviation Administration. All parts contained in the MRL must be used prior to contractor purchasing parts. The only parts that may be supplied by the FAA are time limit or high-cost items.

9.0…