Attachment_1_Performance_Work_Statement.pdf

PERFORMANCE WORK STATEMENT (PWS)

For

F100-PW-220 3rd Stage Turbine Vanes

PR: FD2030-19-02811

REV. 2

DATE: 8 November 2022

PREPARING ORGANIZATION:

AFLCMC/LPSEA1

TINKER AFB OK 73145-3030

FD2030-19-02811

TABLE OF CONTENTS Page

Contents

SECTION I

1.1 DATA

1.2 SECURITY

1.3 QUALITY

1.4 DELIVERY SCHEDULES

1.5 CONDEMNATION AND REPAIR

1.6 HANDLING

1.7 INVENTORY

1.8 PRESERVATION

1.9 RECEIPT/HANDLING OF PQDR EXHIBITS

1.10 SAFETY AND HEALTH…………………………………………………………………………………………………………………..8

1.11 ITEM UNIQUE IDENTIFICATION (IUID)…………………………………………………………………………………………9

1.12 GENERAL WORK REQUIREMENTS

1.13 SPECIFIC WORK REQUIREMENTS

1.14 APPICABLE TECHNICAL ORDERS

1.15 APPLICABLE DIRECTIVES

1.16 APPLICABLE DOCUMENTS

1.17 MISSION ESSENTIAL SERVICES

SECTION II

2.1 SERVICE SUMMARY REQUIREMENTS

2.2 CONTRACTOR PERFORMANCE EVALUATION

SECTION III

3.1 GOVERNMENT PROPERTY

APPENDIX 1

A1.1 ACRONYMS

APPENDIX 2

A2.1 NOTES

APPENDIX 3

A3.1 PRODUCT VERIFICATION AUDIT PROCEDURES

A3.2 TERMS EXPLAINED

A3.3 RESPONSIBILITIES

A3.4 AUDIT PROCEDURES

A3.5 AUDIT RESULTS

APPENDIX 4

A4.1 CAV CFM REPORTING REQUIREMENTS

SECTION I

DESCRIPTION OF

SERVICES

This PWS establishes the minimum work requirements to return F100-PW-220 3rd. Stage Turbine Vanes listed below by National Stock Numbers (NSN) and Part Numbers (P/N) to a serviceable but not like new condition. F100-PW-220 3rd. Stage Turbine Vanes received by the contractor, as set forth in this contract shall be overhauled, modified, tested, prepared for storage and shipped in accordance with (IAW) the requirements in this PWS and the contract. 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 correspondence.

NOUN PART

NUMBER

NSN APPLICABLE

REPAIR T.O.

3rd Stage Vane 4084243 2840-01-447-7793 2J-F100-13-9 3rd Stage Vane 4084183 2840-01-445-5773 2J-F100-13-9 3rd Stage Vane 4084233 2840-01-455-8431 2J-F100-13-9

1.1 DATA

1.1.1 Reporting Requirements

1.1.1.1 Product Quality Deficiency Report (PQDR – SF 368): The contractor shall prepare a PQDR on all design and quality control (material) deficiencies found IAW the procedures of TO 00-35D-54. Applicable portions of TO 00-35D-54 relative to quality defects will apply. The contractor shall hold exhibits of reported deficient items pending disposition from the ACO representative.

Report preparation, distribution, holding and tagging of exhibits shall be IAW TO 00-35D-54. The contractor shall furnish an information copy of the SF 368 to USAF F100 Engineering Source Authority listed in TO 2J-F100-13-1, WP 600 00.

1.1.1.2 TO System Publication Improvement Report (AFTO Form 22): The contractor shall prepare a PIR when an error or improvement changes the meaning of the instructions or information contained in technical directives and will prevent the adequate performance intended. The contractor shall accomplish a PIR IAW TO 00-5-1 and submit one copy to AFLCMC/ENR. Minor discrepancies of non-technical nature such as improper sequence of pages, typographical errors, transportation errors, misspelled words, etc., shall not be reported. The contractor shall report omissions of pertinent technical data, correction of overhaul procedures in TOs, or desired changes to TO data shall likewise use the AFTO Form 22.

1.1.1.3 Teardown Deficiency Report (TDR): A TDR shall be accomplished on any

PQDR exhibit received for investigation. The report shall be completed IAW the procedures established on DD Form 1423 as set forth in the contract.

1.1.2 Other Records, Forms and Reports

1.1.2.1 The contractor shall make available to the appropriate ACO representative the required information to enable him to review and/or verify monthly production status reports on end items and to enable him to complete his records or to complete such other reports as may be required.

1.1.2.2 CAV AF End Item Production Report (End Item Activity Report): The report shall be completed IAW the procedures established on DD Form 1423, as set forth in the contract and the Appendix B.

1.1.2.3 N/A - Note: The F100-PW-220 3rd Stage Turbine Vanes are not serialized tracked parts, and therefore, CEMS reporting is not required in this contract.

1.1.2.4 Completed DD Form 1574 Serviceable Tags are required IAW MIL-STD-129P, paragraph 5.2.21.a.

1.1.2.5 The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

1.1.2.5.1 Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar. Contractors may direct questions to the CMRA help desk.

1.1.3 Technical Data

1.1.3.1 TOs listed in this specification are the basic directives to be used in accomplishing the overhaul requirements of the contract.

1.1.3.2 TO illustrated parts breakdowns (IPBs) listed in this PWS shall be used in the part replacement requirements of the contract. Replacement parts shall conform to the configurations stipulated in the applicable TO IPB as supplemented by other applicable directives and instructions in this PWS. Part replacement shall be confined to those parts determined to be required to produce a serviceable end item.

http://www.ecmra.mil/

1.1.3.3 Directives listed in paragraphs 1.11, 1.12, 1.13 & 1.14 and instructions provided throughout this PWS shall be adhered to, thus obtaining the highest possible quality of workmanship and to maintain acceptable quality standards.

1.1.3.4 Instructions listed in this PWS as “Changes” or “Revisions” to a TO represent publication changes to the Technical Order System and shall be complied with.

The sub-paragraphs contain the location of changes as designated and the deletion, change or addition of technical information to be accomplished.

1.1.3.5 In the event of a conflict between the instructions in this PWS and the applicable technical directive, the following order of override precedence applies (descending order): 1) this PWS, 2) the end item TO, 3) other technical directives..

1.2 SECURITY

1.2.1 Contractor’s Security Controls: Equipment and materials covered by this PWS are not classified.

1.3 QUALITY

1.3.1 The contractor shall provide and utilize an inspection/quality system IAW ISO – 9001.

1.3.2 The contractor shall investigate, take corrective action if necessary, and reply to user initiated PQDR forwarded to them by the ACO. This applies to all PQDRs submitted against products overhauled by the contractor and/or their subcontractor or vendors. Sufficient priority shall be given to PQDR investigation to allow timely corrective action and to meet requirements of TO 00-35D-54 and the CDRL.

1.3.3 No defective parts shall be delivered to the Government.

1.3.4 The Contractor shall allow quality assurance reviews to be conducted at the site of overhaul at the request of the Defense Contract Management Agency (DCMA) throughout the contract period.

1.3.5 The Contractor shall allow a quality acceptance review by the DCMA representative at the site of overhaul for each end item generated under the terms of this contract.

1.3.6 The Contractor shall comply with quality acceptance inspections of each end item IAW DCMA’s latest approved procedure. Quality acceptance will be performed by DCMA at the repair site for each end item generated under the terms of the contract. Quality acceptance documentation for each end-item shall be maintained by the Contractor as part of the item document package.

1.3.7 Ensures the Contractor complies with the requirements of FAR clause 52.222-50(c), (d) and (f) (Combating Trafficking in Persons).

1.3.8 Combating Trafficking in Persons. IAW DFARS PGI 222.17, the COR shall pursue, as appropriate, the following methods of monitoring the contractor's performance regarding trafficking in persons such that non-compliances with FAR clause 52.222- 50 are brought to the immediate attention of the

1.3.9 Contracting Officer:

a. Keep the lines of communication open with the contractor. At the Post-Award conference, remind the contractor of his contractual responsibilities to notify the government if the contractor receives notification of any alleged violations to this policy or if actions have been taken against the contractor employees, subcontractors or subcontractor employees pursuant to the clause.

b. When appropriate, encourage contractor to complete Human Trafficking Awareness Training.

c. Encourage the contractor to take steps to investigate and eliminate slavery and human trafficking in their supply chains and to publish information for consumer awareness.

d. Periodically access the Department of State's Trafficking in Person (TIP) website for updates and to view the latest reports. http://www.state.gov/g/tip.emergency

1.4 DELIVERY SCHEDULES

1.4.1 The delivery schedules shall be IAW the contract delivery schedules.

1.4.2 DoD FEDMall is prohibited for use by non DoD entities. The contractor shall ensure they have viable sources of supply to enable them to meet the government’s delivery schedules.

1.5 CONDEMNATION AND OVERHAUL

1.5.1 Contractor’s Scrap Procedures: The contractor shall prepare and submit to the Government Property Administrator (GPA) for approval, a written plan that sets forth procedures for handling scrap materials. These procedures shall include the requirements stipulated in the Federal Acquisition Regulation (FAR) 45.1, titled “General”. Disposition of condemned parts containing critical alloys and/or precious metals shall by IAW TO 00-25-113, 00-25-113-F100-ENG and FAR 45.6 titled “Reporting, Reutilization, and Disposal”.

1.5.2 Condemnation: The contractor without written approval of the ACO or his representative shall not condemn End Items.

1.5.2.1 End Items determined by the contractor and verified by the ACO to be beyond economical overhaul shall be disposed of as directed by the ACO in writing.

1.5.2.2 Parts, which have been condemned as a result of NDI methods, other inspection methods, or for other reasons, shall be mutilated to the extent necessary to ensure that purchasers of scrap are unable to repair the item for possible resale or reuse.

All documents and tags pertinent to such condemned parts authorized for transfer to disposal shall bear a certificate to the effect that all required mutilation has been accomplished and meets DEMIL directive requirements.

1.5.2.3 The serial number and part number of any life-limited item, which is condemned, must be transmitted to F100 Engineering Source Authority listed in TO 2J-F100-

53-1, WP 600 00.

1.5.3 Overhaul: End Items determined to be beyond economical overhaul shall not be overhauled by the contractor unless authorized in writing by the ACO.

1.6 HANDLING

1.6.1 The contractor shall have physical custody of end items and parts received at their facility and shall be responsible for their constant care during such custody.

1.6.1.1 N/A - Note: The F100-PW-220 3rd Stage Turbine Vanes are not serialized tracked parts, and therefore, CEMS reporting is not required in this contract.

1.7 INVENTORY

1.7.1 Each end item shall be inspected by the contractor upon receipt to determine its condition and to ensure that its item identification corresponds to that shown on the contract schedule. Non-conforming end items shall be reported to the appropriate ACO representative.

1.8 PRESERVATION

1.8.1 Preservation inspection of end items is not required upon receipt. Adequacy of preservation will be determined when the item is placed in work and if found deficient shall be reported to the appropriate ACO representative.

1.8.2 All Government assets shall be stored in an enclosed and covered area and shall be adequately protected against loss by fire, theft, and physical damage by the elements.

Government owned items and parts shall not be co-mingled with non-Government owned property. Government owned items and parts shall not be co-mingled with non- Government owned property.

1.9 RECEIPT/HANDLING OF PQDR EXHIBITS

1.9.1 Any exhibit received for the purpose of an investigation into the cause of a material or a quality deficiency shall be kept separated from normal repair assets until the investigation is completed. The contractor shall provide the exhibit receipt date through the ACO with the F100 Engineering Source Authority listed in TO 2J-F100- 53-1, WP 600 00.

1.10 SAFETY AND HEALTH

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

The contractor shall notify the Government Representative (GR), within eight (8) hours of any damage to government property where the dollar value exceeds $500,000.00 and within two workdays, for any damage to government property less than $500,000.00 during the execution of the contract.

1.10.1.1 Mishap notifications shall contain, as a minimum, the following information:

1.10.1.1.1 Contract, Contract Number, Name and Title of Person(s) Reporting

1.10.1.1.2 Date, Time and exact location of accident/incident

1.10.1.1.3 Brief Narrative of accident/incident (Events leading to accident/incident)

1.10.1.1.4 Cause of accident/incident, if known

1.10.1.1.5 Estimated cost of accident/incident (material and labor to repair/replace)

1.10.1.1.6 Nomenclature of equipment and personnel involved in accident/incident

1.10.1.1.7 Corrective actions (taken or proposed)

1.10.1.1.8 Other pertinent information

1.10.2 If requested by the designated GR, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office

1.11 ITEM UNIQUE IDENTIFICATION (IUID)

1.11.1 Repair contracts that result in the delivery of tangible personal property to the Government shall follow the latest DoD instructions to install IUID compliant marks in accordance with policy as stated in DFARS 211.274. IUID requirements for the J85 MISTR components have not been identified at this time. When directed by the PCO, the contractor shall follow the latest DoD instructions to install IUID compliant marks.

TOs and drawings will be complied with for any component where direction is currently called out in the TO or drawings.

1.12 GENERAL WORK REQUIREMENTS

1.12.1 The instructions for the repair of items stipulated in this PWS shall be performed IAW the applicable TO’s and the below exceptions.

1.12.1.1 The contractor is authorized to use its own tooling, which is similar to OEM

(Original Equipment Manufacturer) tooling.

1.12.1.2 The contractor is authorized to inspect per part drawing and part QAD (Quality Assurance Document).

1.12.2 The contractor shall use protective equipment to protect items from damage as they are processed through the plant. Special protection shall be placed over the machined surfaces of end items.

1.12.3 The contractor shall inspect the various disassembled components or part of the end item to determine if further repair or overhaul is needed. Subsequent overhaul shall be accomplished IAW the applicable portion of the applicable overhaul technical order and supplementary instructions specified herein.

1.12.4 The contractor shall rework all reparable parts so that they are capable of meeting the serviceable requirements of this PWS.

1.12.5 The contractor shall continue to use all parts and assemblies determined serviceable and appropriate as a result of inspections and checks, except as specified in this PWS.

1.12.6 The contractor shall replace condemned parts of the end item with like serviceable parts listed in the applicable technical order IPB unless otherwise specified in or within this PWS.

1.12.7 When overhaul kits are available for the overhaul of an end item, such kits shall be used IAW the applicable technical order and changes thereto or the specific instructions contained in this PWS.

1.12.8 Where the contractor is directed to hold an item for OC-ALC disposition by any cited publication herein or by any statement made within this PWS, such items shall be reported to the ACO through the GPA for disposition.

1.12.9 Overhaul, to the maximum extent, is desired when such overhaul is economically feasible. The contractor is encouraged to submit new or improved overhaul procedures to the Government whenever practical. Procedures may be submitted on an AFTO Form 22 as specified in this PWS or by any other means authorized under this contract. This does not preclude the contractor’s submission of overhaul procedures, which are not economically feasible, when such overhauls are advantageous to the Government.

1.12.10 All of the contractor’s operators of special processes; such as, X-ray radiography machines, Fluorescent Penetrate and Magnetic Particle Inspection Equipment, as well as welders and inspectors, shall be qualified and certified for operation IAW applicable military specifications when listed in the PWS.

1.12.11 Fit and tolerance limits shall be IAW applicable overhaul TO/contractor’s processes and procedures unless otherwise specified.

1.12.12 Fluids, oil, greases and compounds shall conform to and be used as directed in the overhaul TO and instructions contained in this PWS.

1.13 SPECIFIC WORK REQUIREMENTS

1.13.1 Removal

1.13.1.1 Not Applicable

1.13.2 Disassembly

1.13.2.1 Disassemble the F100-PW-220 3rd Stage Vanes to the extent necessary to accomplish thorough cleaning and complete inspection of all parts and to accomplish the work IAW TO 2J-F100-13-9, work package WP 200 00.

1.13.3 Cleaning

1.13.3.1 F100-PW-220 3rd Stage Vanes shall be cleaned IAW TO 2J-F100-13-9, WP 201 00.

1.13.3.2 The contractor shall ensure that cleaning and preserving materials meet the requirements specified in TO 2J-F100-13-1, TO 2J-F100-13-2 WP 005 00, or TO 2-1-111 and that such materials are properly used during application

1.13.4 Inspection

1.13.4.1 Inspection of F100-PW-220 3rd Stage Vanes shall be accomplished IAW 2J-F100-

13-9, WP 300 00.

1.13.5 Corrosion Control

1.13.5.1 The corrosion control of F100-PW-220 3rd Stage Vanes during overhaul and storage shall be accomplished IAW TO 2-1-111.

1.13.6 Modification and Overhaul

1.13.6.1 Overhaul of F100-PW-220 3rd and 4th Stage Vanes shall be accomplished IAW 2J-

F100-13-9 WP 400 00

1.13.6.2 The contractor shall identify all overhauled F100-PW-220 3rd Stage Vanes with the contractor’s CAGE IAW MIL-STD-130N.

1.13.7 Installation

1.13.7.1 Not Applicable

1.13.8 Test And Government Acceptance

1.13.8.1 The Government shall accomplish acceptance.

1.13.9 Product Verification Audit(PVA)

1.13.9.1 Overhauled items shall be subject to PVA if requested by the government.

1.13.9.2 To perform PVA, the government shall be permitted to select at random such quantities of items as may be necessary to determine quality of workmanship and materials.

1.13.9.3 After notification by the ACO that a PVA is required, the contractor shall follow the procedures of Appendix 3 - Product Verification Audit Procedures.

1.13.10 Technical Publication Compliance

1.13.10.1 Compliance with all TO’s, Directives, Government Specifications, Drawings, etc., listed herein is mandatory, unless otherwise specified in this PWS, when:

1.13.10.1.1 They have not been previously accomplished

1.13.10.1.2 They are pertinent to the end item.

1.13.10.1.3 They prescribe Air Force Policies, use of materials and procedures for overhaul.

1.13.10.2 For solicitation purposes, the contractor may contact USAF F100 Engineering

Source Authority for instructions for viewing or purchasing technical data required for maintenance of this contract. Upon contract award, the contractor shall establish and maintain a TO distribution account IAW TO 00-5-1; and be placed on initial distribution for one copy each of the TOs and TCTOs listed in this PWS. The contractor shall contact the TOMA office at AFLCMC.

LPSAA.TOMA@us.af.mil within five (5) working days after contract award for guidance in obtaining a TODO account. Once the contractor’s TODO account is in operation, the contractor shall maintain all TOs and TCTOs and other technical directives listed in the PWS in an updated and current status IAW TO 00-5-1. The contractor is required to comply with the latest dated TO; TCTO and other technical directives issued and will be contractually covered during the time the work is accomplished. For example, an item already in work will continue to be worked under the existing contractual scope of work until such time that the latest TO revisions can be negotiated as to price and scheduled incorporation. The contractor shall submit a monthly review of changes to TOs, TCTOs, and other applicable directives received during that period. However, if a change is received that has a cost impact greater than 10% and/or is critical to safety of flight, the contractor shall notify the ACO within ten (10) calendar days of receipt of that change and also shall provide the cost impact with his backup data within 30 calendar days of receipt of the change. If evaluation of the cost impact will require more than 30 calendar days, the contractor shall request an exception from the ACO/PCO. These exceptions will be handled on a case by case basis. The contractor shall not begin working with new publication until authorization has been granted by the ACO/PCO.

1.13.10.3 Copies of other Air Force publications required in the performance of work outlined in this PWS will be requisitioned through the ACO. Submit requests to appropriate ACO representative for review. TO 00-5-1 provides an explanation of the Technical Order System and for pertinent distribution, requisition and storage information.

1.13.10.4 In the event of a follow-on contract is awarded to this contract, the “Package

File” at the contract facility as of the end of the previous contract will be applicable to the follow-on contract and will be updated through amendments to the new PWS of the new contract. This procedure will ensure continuity of the publication data from one contract to another.

1.13.10.5 Initial Production Evaluation (IPE)

1.13.10.5.1 Overhauled items shall be subject to an IPE if the contractor has not overhauled these items successfully within the last three years.

1.13.10.5.2 The IPE will be composed of two parts, a Site Visit and then an Overhaul Demonstration. The contractor will have a 45 calendar day period from contract award to complete the Site Visit. After the site visit the DCMA QAR will have 10 calendar days to complete the site visit Survey and perform an exit briefing with the contractor and the IPE Team. If necessary the contractor will have 30 calendar days from the Site Visit exit briefing to correct any critical or major deficiencies. Upon approval of the Site Visit Survey by the ESA the contractor will be notified in writing by the ACO.

mailto:AFLCMC.%20LPSAA.TOMA@us.af.mil mailto:AFLCMC.%20LPSAA.TOMA@us.af.mil mailto:AFLCMC.%20LPSAA.TOMA@us.af.mil

After notification of a successful Site Visit Survey by the ACO the contractor will have a 75 calendar day period to perform the Overhaul Demonstration part of the IPE. Upon completion of the Overhaul Demonstration and submission of the Overhaul Demonstration Report the ESA will have 30 calendar days to review the report. If necessary the contractor will have 30 calender days to correct any critical or major deficiencies after the ESA review of the Repair Demonstration Report.

Upon a successful Repair Demonstration and approval of the Repair Demonstration Report by the ESA the PCO will notify the contractor of the results. At this time the ESA will provide a letter to show that the contractor has been unconditionally approved to repair the contract items.

1.13.10.5.3 Overhaul of production items will not commence until the contractor has successfully passed the IPE and received the unconditional approval letter from the ESA. If the contractor cannot pass the Site Visit of the Repair Demonstration in the time periods allotted this constitutes contract cancellation.

1.13.10.5.4 To perform IPE, the government shall be permitted to select at random such quantities of items as may be necessary to determine quality of workmanship and materials. The ESA may waive parts of the IPE as it deems appropriate.

1.13.10.5.5 To perform the IPE, the contractor shall follow the procedures of Appendix

4- Initial Production Evaluation (IPE) Procedures.

1.14 APPICABLE TECHNICAL ORDERS

This is a preliminary list of Technical Orders. The contractor is responsible for ensuring they are using the latest edition.

TECH ORDER BASIC CH CHANGE

NUMBER DATE NO DATE SHORT TITLE

00-5-1

14 JUN 16

AIR FORCE TECHNICAL

ORDER SYSTEM

00-5-2 01 APR 01 TECHNICAL ORDER

DISTRIBUTION SYSTEM

00-5-15 22 SEP 14 TIME COMPLIANCE TECH

ORDER (TCTO) SYSTEM

00-20-1 11 JUL 16 PREVENTIVE

MAINTENANCE PROGRAM

00-20-2 15 MAR 16 MAINTENANCE DATA

COLLECTION SYSTEM

00-20-3 15 AUG 15 MAINTENANCE PROCESSING

OF REPARABLE

PROPERTY AND THE REPAIR

CYCLE ASSET CONTROL

SYSTEM

00-25-113 1 APR 95 CRITICAL ALLOY AND

PRECIOUS METAL

00-25-113-F100-

ENG

1 AUG 88 50 15 DEC 14 CRITICAL ALLOYS AND

PRECIOUS METALS

PARTS LIST F100 ENGINE

00-25-254-1 15 AUG 01 11 1 JUL 08 COMPREHENSIVE ENGINE

MANAGEMENT SYSTEM

(CEMS) PROCEDURES

00-35D-54 1 OCT 09 0 USAF DEFICIENCY

REPORTING,

INVESTIGATION, AND

RESOLUTION

2-1-111 15 FEB 90 60 15MAY16 STANDARD MAINTENANCE

PROCEDURES

2J-F100-9 1 NOV 95 58 15 OCT 15 NONDESTRUCTIVE

INSPECTION

2J-F100-94 1 MAY 92 58 15 OCT 15 ILLUSTRATED PARTS

BREAKDOWN (IPB) FOR

SUPPORT EQUIPMENT

2J-F100-53-1 15 FEB 07 1 1 JUL 08 INTRODUCTION AND

GENERAL INFORMATION-

DEPOT

2J-F100-53-2 15 FEB 07 2 15 JUL 09 ON CONDITION

MANTENANCE (OCM) –

DEPOT

2J-F100-54 15 JAN 93 51 15 MAR 08 ILLUSTRATED PARTS

BREAKDOWN (IPB)

2J-F100-53-5 15 FEB 07 2 15 JUL 09 ENGINE-DEPOT

6J8-41-3 15 MAR 07 0 OVERHAUL INSTRUCTIONS

WITH IPB FOR UNSTAGED

PW-229 FUEL NOZZLE

33B-1-1 1 OCT 16 NONDESTRUCTIVE

INSPECTION METHODS

1.15 APPLICABLE DIRECTIVES

AIR FORCE

INSTRUCTIONS

CHANGE DATE TITLE

AFI 21-101 21 MAY 15 AIRCRAFT AND EQUIPMENT

MAINTENANCE MANAGEMENT

AFI 21-118 21 NOV 14 IMPROVING AEROSPACE

EQUIPMENT RELIABILITY &

MAINTAINABILITY

MILITARY STANDARDS CHANGE DATE TITLE

MIL-STD-129P 18 FEB 14 U.S. MILITARY MARKING FOR

SHIPMENT AND STORAGE, CHG 4

MIL-STD-130N 16 NOV 12 ID MARKING OF U.S. MILITARY

PROPERTY

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) ISO 9001 15 SEP 15 QUALITY MANAGEMENT

SYSTEMS – REQUIREMENTS -

FOURTH EDITION

DEPARTMENT OF DEFENSE (DoD)

JOINT AERONAUTICAL 4 AUG 05 EXHIBIT H: UNIVERSAL

LOGISTICS COMMANDERS/ VENDOR SITE SURVEY

AVIATION CRITICAL SAFETY CHECKLIST

1.16 APPLICABLE DOCUMENTS

1.16.1 FEDERAL ACQUISITION REGULATION - ISSUED MARCH 2005

1.16.2 LPF-QAR-001: GENERAL QUALITY ASSURANCE DOCUMENTS FOR

F100 ENGINE FC/DC BREAKOUT COMPONENTS

1.16.3 LPF-QAR-002: CHANGE PROCEDURES FOR PROCESS ORDERS

1.16.4 LPF-QAR-004: LPFR QUALITY ASSURANCE REQUIREMENTS FOR

F100 ENGINE COMPONENTS

1.16.5 LPF-QAR-006: LPFR QUALITY ASSURANCE REQUIREMENTS FOR

PRODUCT VERIFICATION AUDIT (PVA) TEST PLANS AND

REPORTS

1.16.6 LPF-QPR-004: LPFR QUALITY PLAN REQUIREMENTS FOR

WELDED ASSEMBLIES

1.16.7 LPF-QPR-009: LPFR QUALITY PLAN REQUIREMENTS FOR

VACUUM BRAZED ASSEMBLIES

1.16.8 LPF-QPR-016: LPFR QUALITY PLAN REQUIREMENTS FOR

DURABILITY CRITICAL PARTS

1.16.9 LPF-QPR-018: LPFR QUALITY PLAN REQUIREMENTS

FOR NONDESTRUCTIVE INSPECTION

1.16.10 LPF-QR-001: BASIC TECHNICAL DATA REQUIREMENTS FOR

FRACTURE CRITICAL AND DURABILITY CRITICAL PARTS

1.16.11 LPF-QR-002: CONDITIONS OF WAIVER FOR FRACTURE CRITICAL

AND DURABILITY CRITICAL PARTS

1.16.12 EI FOR RQR-1: GENERIC ENGINEERING INSTRUCTIONS FOR REPAIR

OF F100 PARTS IN RQR-1

1.17 MISSION ESSENTIAL SERVICES

1.17.1 The contractor shall prepare for the continuation of essential DoD services during crisis IAW Depart of Defense Instruction (DoDI) 3020.37. In a state of emergency, if the Government deems necessary, the contractor shall provide all services necessary to ensure mission accomplishment. On occasion, services may be required to support an activation, or exercise of contingency plans outside normal duty hours. IAW DoDI 3020.37, the contractor shall develop a contingency plan and furnish a copy to the PCO for those tasks identified as essential to provide reasonable assurance of continuation during crisis conditions.

SECTION II

SERVICE

SUMMARY

The contractor service requirements are summarized into performance objectives that relate directly to the mission essential items. The performance threshold describes the minimum acceptable levels of service for each requirement. The contractor shall be aware that the absence contract requirement from the service summary does not detract from its enforceability nor limit the rights or remedies of the government under any other provision of the contract. The government will use the surveillance methods contained in the Performance Plan to evaluate the Contractor’s performance for the performance objectives listed below. In the event the performance objective is not met, the Contractor will be given a reasonable time after notification to correct the unacceptable performance, if such correction is possible. The Contractor shall immediately take corrective action in accordance with the performance threshold(s). In cases where the Contractor fails to implement corrective action, the PCO will take appropriate measures.

NOTE: For those requirements listed in Section II, Service Summary, the Performance Plan will follow the methods of surveillance specified in the Performance Plan. The Performance Plan is authorization for the Government’s PCO to participate in the administration of this contract.

2.1 SERVICE SUMMARY REQUIREMENTS

2.1.1 The contractor shall ensure the performance objectives and performance thresholds identified in table 2-1 of this PWS are achieved as follows:

Table 2-1

Performance Objective

Reference Paragraph

Performance Threshold

SS-1 Quality:

No defective parts shall be delivered to the Government.

PWS #s 1.3 100% of parts delivered shall be defect free.

SS-2 Delivery Performance:

The delivery schedules shall be IAW the contract delivery schedule

PWS # 1.4.1 No less than 98% of deliveries on time and IAW the contractual delivery schedule.

For all others, the contractor shall submit a corrective action plan to the PCO within 3 business days. The corrective action plan shall include these elements:

1. Cause of the delay

2. When delivery will be performed

3. Preventive measures to be implemented.

2.2 CONTRACTOR PERFORMANCE EVALUATION

2.2.1 The contractor shall be aware that the evaluation of performance will occur when the

Program Manager evaluates the services of the contractor to determine whether or not it meets the performance measures of the contract.

2.2.1.1 SS-1: The contractor’s failure to meet the requirements for this item shall result in the possibility of a poor rating under the Contractor Performance Assessment Review (CPAR) and remedies as allowed under Federal Acquisition Regulation (FAR) 52.246-4 Inspection of Services-Fixed Price.

2.2.1.2 SS-2: The contractor’s failure to meet this requirement shall result in a negative CPAR rating and remedies as allowed under FAR 52.246-4 Inspection of Services-Fixed Price.

SECTION III

GOVERNMENT PROPERTY

3.1 GOVERNMENT PROPERTY

3.1.1 Contractor shall furnish all material, support equipment, tools, test equipment and services. Government Furnish Material shall not be provided.

APPENDIX 1

A1.1 ACRONYMS

ACO Administrative Contracting Officer AFMC Air Force Material Command ALC Air Logistics Center CAGE Contractor and Government Entity CAO Contract Administration Office CEMS Comprehensive Engine Management System DOD Department of Defense EC Engineering Change ESA Engineering Source Authority FAR Federal Acquisition Regulation GFM Government Furnished Material GFP Government Furnished Property GPA Government Property Administrator IAW In Accordance With IPB Illustrated Parts Breakdown MRB Material Review Board NDI Nondestructive Inspection OC-ALC Oklahoma City Air Logistics Center OEM Original Equipment Manufacturer PCO Procurement Contracting Officer PIR Publication Improvement Report PQDR Product Quality Deficiency Report PVA Product Verification Audit PWS Performance Work Statement QAD Quality Assurance Document QAR Quality Assurance Representative QCD Quality Control Deficiency SL Salvage Layout SR Service Repair TO Technical Order USAF United States Air Force WP Work Package

APPENDIX 2

A2.1 NOTES

A2.1.1 Contractor is authorized to establish and convene a Material Review Board (MRB) to evaluate and determine disposition on non-conforming material or parts. Board members shall consist of representatives from the Contractor’s Quality Production Control, Engineering (Industrial, Product Support or Design) and the Government QAR. The MRB shall be convened when the contractor identifies non-conformance of material or parts during and after assembly. The MRB is not authorized to violate any TO limit. When MRB action is required on material or parts during and after assembly, the contractor shall provide information, to include part number, serial number and statement of non-conformance and corrective action taken, to 536 ACSS/GFEA via email within (5) working days after approval of the MRB.

APPENDIX 3

A3.1 PRODUCT VERIFICATION AUDIT PROCEDURES

A3.1.1 This attachment contains procedures and instructions for contractual accomplishment of Product Verification Audits (PVAs). This attachment does not supersede instructions contained in the contract overhaul work requirements or other contractual provisions.

In instances of conflict, the latter applies. The contractual issuance of this attachment and performance of PVAs does not relieve the contractor of the responsibility for maintaining a Quality Control System that will assure productions of items that conform to contractual requirements. PVAs are management tools used to independently evaluate and validate the conformance of a repaired/overhauled item and contractor compliance to contractual requirements as well as the adequacy of the Government's contractually stipulated requirements.

A3.2 TERMS EXPLAINED

A3.2.1 PVA. The physical examination, functional testing and complete disassembly of an item to determine conformance to contractual requirements as well as adequacy of the contractual requirements which may require in excess of the original contractor overhaul effort. The audit includes correction of defects, reassembly, retesting, repackaging, remarking, update of records and correction of contractual requirements as required.

A3.2.2 Cognizant Quality Assurance Element. The DOD contract administration service element having direct responsibility for implementing the Government Quality Assurance Program at the contractor's plant.

A3.2.3 Overhaul Work Requirement. Any contract instrument, TO, drawing, specification or directive which contains instructions and requirements for overhaul and rehabilitation of a reparable/unserviceable item.

A3.2.4 Procedural Deficiency. A deficiency which is noted during the audit and which results from either:

A3.2.4.1 Failure by contractor to establish processes/procedures in conformity with contractual requirements; or, A3.2.4.2 Failure by contractor to follow established processes or procedures.

A3.3 RESPONSIBILITIES

A3.3.1 The contractor shall:

A3.3.1.1 Perform audit functions under the surveillance of the cognizant DOD CAO and Air Logistics Center (ALC) representative(s).

A3.3.1.2 Provide technical personnel, tooling, measuring/test equipment, work areas, forms and clerical assistance, as required, to perform the PVA.

A3.3.2 The cognizant DOD QAR shall:

A3.3.2.1 Be designated as audit team chairman, unless otherwise directed by the Procuring Contracting Officer (PCO).

A3.3.2.2 Schedule the product verification audit and select the item(s) to be audited.

A3.3.2.3 Notify the PCO and the contractor when the PVA will begin. Notification shall be provided at least 15 working days prior to the audit date. Scheduled audits may be waived by the PCO on a case-by-case basis.

A3.4 AUDIT PROCEDURES

A3.4.1 Classifying Defects. Defects observed in the audited item(s) will be classified according to the following:

A3.4.1.1 Category I - Critical Defect. Defect that judgment and experience indicates likely to result in hazardous/unsafe conditions for individuals using, maintaining or depending upon the product; or a defect that judgment and experience indicates is likely to prevent performance of the tactical function of a major end item such as an aircraft, engine communication system, surveillance system or major part thereof. Critical defects are furthered identified as follows:

A3.4.1.1.1 Category IA - Defect attributable to the contractor's failure to comply with contractual requirements.

A3.4.1.1.2 Category IB - Defect not attributable to contractor's failure to comply with contractual requirements such as a design deficiency, inadequate or omitted requirement or defective Government Furnished Property (GFP).

A3.4.1.2 Category II - Major Defect. Defect other than critical that is likely to result in failure or reduce materially the usability of unit or product for its intended purpose. Major defects are further identified as follows:

A3.4.1.2.1 Category IIA - Defect attributable to the contractor's failure to comply with

A3.4.1.2.2 Category IIB - Defect not attributable to contractor's failure to comply with contractual requirements such as a design deficiency, inadequate or omitted requirements or defective GFP.

A3.4.1.3 Category III - Minor Defect. Defect that is not likely to reduce materially the usability of the unit or product for its intended purposes or is a departure from established standards having little bearing on the effective use or operation of the unit. Minor defects are further identified as follows:

A3.4.1.3.1 Category IIIA - Defect attributable to the contractor's failure to comply with

A3.4.1.3.2 Category IIIB - Defect not attributable to the contractor.

A3.4.1.4 Category IV - Defect caused during accomplishment of the audit disassembly or inspection process which would not have occurred had the contractor exercised proper care of the audit item, i.e., improper handling, improper disassembly technique.

A3.4.1.5 Procedural Defect - Reference paragraph 2d.

A3.4.2 Scheduling/Frequency

A3.4.2.1 During the initial production phase, one of the first five items may be audited. The frequency for performing subsequent audits will be as specified in the schedule of the contract or by the PCO.

A3.4.2.2 The contractor may be directed by the PCO to extend or increase the frequency of the audits or to increase or decrease the scope thereof pursuant to the "changes" clause of the contract.

A3.4.2.3 Like or similar items may be grouped for audit purposes when the concurrence of the

PCO or his designated representative has been obtained.

A3.4.3 Inspection and Test

A3.4.3.1 Audit candidates shall be randomly selected by the cognizant DOD QAR from all items currently available. It shall be the responsibility of the ACO to assure that an adequate number of items from which a random selection can be made are on hand at the time of the audit. Selection, except as specified in paragraph c (2) below, shall be made from items which have been accepted by the Government but have not been shipped.

A3.4.3.2 The first five items of the initial production phase shall be set aside after having been tendered by the contractor as in conformity with the contract and inspected by the Government and not rejected for failure to comply with contractual requirements.

Upon completing the testing and disassembly portion of the audit of the selected candidate and if no Category I or II defects are found during the audit, the other four items will be accepted by the Government. In any Category I or II defect is found in the audit candidate, the contractor shall satisfy the Government that such defect does not exist in the other four items prior to Government acceptance thereof.

The audit candidate shall be accepted by the Government upon compliance with paragraph 4d (6) below.

A3.4.3.3 The items selected for audit shall be inspected for adherence to preservation, packing, packaging and marking requirements prior to removal from the shipping container.

A visual inspection and functional test shall be performed prior to disassembly.

A3.4.3.4 Disassembly shall be performed in a secure area accessible only to audit participants.

Normally, audit participation will be limited to specified contractor production and quality control personnel, the cognizant DOD QAR and ALC personnel.

A3.4.3.5 Visual inspection, dimensional checks (such as backlash, end clearance and running clearance) and non-destructive testing will be accomplished during and after disassembly IAW applicable technical directives. Audit findings will be recorded for comparison with contractual requirements and the contractor's production/inspection records. Measuring and test equipment shall be reviewed for current calibration prior to use.

A3.4.3.6 Applicable accessories and components will be functionally tested and inspected to contractual specifications. This action may require disassembly in excess of the original contractor effort as determined necessary by the Government.

A3.4.4 Corrective Actions

A3.4.4.1 In the event a critical or major defect is observed, Government acceptance of further production will be withheld until the Government has either inspected other items for the observed defect(s) or has received suitable evidence from the contractor that the cause of such defect(s) has been corrected and the defect does not exist in other items. In the case where there is a probability of such defect existing in previously shipped items, the contractor shall promptly advise the Government of the identity and destination of such previously shipped items.

A3.4.4.2 When Category IA, IIA or IIIA defects are found, the contractor shall implement measures in the repair/overhaul process which will preclude recurrence.

A3.4.4.3 When Category IB, IIB or IIIB defects are found, actions will be taken as directed by the Government pursuant to the contract.

A3.4.4.4 When Category IV defects are noted, the contractor shall take those actions necessary to preclude recurrence.

A3.4.4.5 When Procedural Deficiencies are noted, the contractor shall take those actions necessary to correct the procedures or operations concerned.

A3.4.4.6 Upon completion of the audit, all defects attributable to failure to comply with contractual requirements or attributable to the performance of the PVA shall be corrected. All noted defects shall be corrected and the item assembled and functionally tested IAW applicable overhaul specifications including preservation, packing, packaging, marking and update of records.

A3.4.4.7 After the audit is completed, the DOD QAR shall conduct a critique attended by contractor personnel and ALC representative(s). Findings, classifications and corrective actions shall be discussed and determination of defect cause(s) established (e.g. workmanship, tooling, technical requirements, etc.). The contractor shall take immediate action to correct and preclude recurrence of all defects or deficiencies attributable to failure to comply with contractual requirements, subject to the provisions of paragraph 5j below.

A3.5 AUDIT RESULTS

A3.5.1 The quality office of the CAO activity shall prepare and forward to the responsible PCO the finalized audit findings within 10 working days after completion of the audit.

Finalized findings will contain the following information:

A3.5.1.1 Name and address of the contractor.

A3.5.1.2 Contract number.

A3.5.1.3 Descriptive noun, Federal Stock Number, part number and serial number of the item audited.

A3.5.1.4 Summary of total defects.

A3.5.1.4.1 Category IA

A3.5.1.4.2 Category IB

A3.5.1.4.3 Category IIA

A3.5.1.4.4 Category IIB

A3.5.1.4.5 Category IIIA

A3.5.1.4.6 Category IIIB

A3.5.1.4.7 Category IV

A3.5.1.5 A complete listing of audit findings.

A3.5.1.6 A description of defects listed by category (commencing with critical). The defective item will be identified by part number and standard nomenclature.

A3.5.1.7 Cause(s) for each noted defect.

A3.5.1.8 Corrective action(s) taken on each classified defect attributable to failure to comply with contractual requirements, or a projected target date for completion when not otherwise immediately corrected.

A3.5.1.9 Procedural deficiencies noted and the corrective actions applied.

A3.5.1.10 The signature of the DOD QA participants, contractor management personnel and

ALC representative(s). Non-concurrence with the findings shall be specifically annotated in the vicinity of the applicable signatures. Non-concurrence by the contractor as to the existence or classification of a defect or as to whether or not a defect is attributable to failure to comply with contractual requirements shall be subject to the procedures set forth in the clause entitled "Dispute."

APPENDIX 4

A4.1 CAV CFM REPORTING REQUIREMENTS

The purpose of this attachment is to provide Contract Depot Maintenance (CDM) guidance for contractor technical responsibilities and reporting requirements of the Commercial Asset Visibility Air Force (CAVAF) system. CAVAF shall be the primary system of record for providing daily status of all Government owned assets located at contractor repair facilities. Reporting within CAV AF shall not be limited to end items subject to repair but are to include assets stored at a contractor Inventory Control Point (ICP). Any CAVAF system down-time will be identified on the CAVAF home page banner. Contractors are responsible for ensuring current User Guides are utilized by their CAVAF reporters. NOTE: Contractor User’s Guide may be accessed from the CAVAF Homepage.

CAVAF FAMILIARIZATION TRAINING:

1. Familiarization training for CAVAF reporting will be requested by the contractor via the applicable ICP CAVAF system administrator (SA). For assistance, guidance or questions to specific contract transactional reporting requirements may be addressed to the CAV AF contract monitor (CM). ICP CAVAF (SA and/or CM) points of contact (See Contractor Responsibility Item #4).

CONTRACTOR RESPONSIBILITY:

1. Contractor CAVAF reporting requirements shall be accomplished daily and/or within one (1) business day of a maintenance action occurrence IAW the applicable CAVAF CDRL and CAVAF system, version

8.0.1 or higher. Accurate and timely reporting of maintenance transactions into CAVAF is critical to the management of repair requirements and the management of world-wide asset distribution.

Contractor shall ensure asset record in CAVAF is an accurate reflection of physical assets on hand at all times.

2. Each CAVAF reporter shall submit a completed System Authorization Access Request, DD Form 2875, per instructions within 10 days after contract award date. All DD Form 2875(s) shall be digitally signed.

There “must be two CAVAF reporters” for the contractual reporting requirements to ensure there is no possibility of a lapse in reporting coverage.

3. User(s) shall complete initial DoD Information Assurance (IA) Cyber awareness Challenge training and submit a course completion certificate with the DD Form 2875. IA Cyber awareness Challenge course completion certification shall be accomplished annually. Users shall access IA training on the Cyber Awareness Challenge website, under the Department of Defense Employees section, click hyperlink;

“Launch New Cyber Awareness Challenge Department of Defense Version” using the following website:

http://iase.disa.eta/cyberchallenge/launchPage.htm

a. First time CAV AF users will email initial IA Cyber awareness Challenge course completion certificates, AF Form 4394, AF User Agreement Statement, and completed DD Form 2875 to point of contact at applicable ICP (see item #4).

b. All following annual course completion certificates shall be completed before lapse in certification occurs and will be emailed to respective ICP identified in paragraph 4a, 4b, and 4c below.

c. Product Functionality Caution: To meet technical functionality requirements, this awareness product was developed to function with Windows operating systems http://iase.disa.eta/cyberchallenge/launchPage.htm

(Window 7, VISTA, and XP), when configured correctly) using either the Internet Explorer (IE) or Firefox browsers. Users employing either OS or browser may experience difficulties and may not be able to complete the training or print the certificate of completion. They Cyber awareness Challenge course completion is a contractual requirement and the contractor must comply.

4. Reporters requiring the default password or password resets should contact their applicable ICP CAV AF System Administrator POC listed below:

a. Robins AFB, GA, call (478) 327-6602 or 327-6603, or send email request to:

406scms.cav.af.ar@us.af.mil

b. Hill AFB, UT, call (801) 586-3736, or send email request to:

420scms.cdm@us.af.mil

c. Tinker AFB, OK, call (405) 622-7325 or (405) 736-7329, or send email request to:

420.scms.tinker.cdm.workflow@us.af.mil

5. To access the CAVAF system, contractor and subcontractor reporters shall follow “initial log-in procedures” as prescribed within the Contractors User’s Guide.

6. Contractor shall ensure accountability of all Government Furnished Property (GFP) within their Enterprise Resource Planning (ERP) or Commercial Off-the-Shelf (COTS) system, which must be reported accurately for same GFP records within CAVAF at all times.

7. Contractual Induction-at-Risk of end items is prohibited on all repair contracts.

8. Contract/Delivery Order Closure Disposition– Government will provide disposition instructions to contractor’s reporter. Contractor shall begin shipping assets within 10 days of receiving government disposition instructions and have completed all shipping actions 30…