Attachment 2 - Statement of Work - 70Z03822RJ0000002.pdf

ATTACHMENT 2: STATEMENT OF WORK (SOW)

GEARBOX OVERHAUL

70Z03822RJ0000002

1.0 Scope

1.1 This SOW requirement is for the anticipated following gearboxes:

Nomenclature National Stock Number (NSN)

Part Number (P/N) Input

Modified and

Overhauled NSN/ P/N

Est.

Total Contract

Qty Main Gearbox

(Minor) 1615-01-552-3522 70351-38100-049 1615-01-552-3522, 70351-38100-049

Main Gearbox (Major) 1615-01-552-3522 70351-38100-049

1615-01-552-3522, 70351-38100-049

Alternate NSNs and P/Ns for the Main Gearbox

1615-01-289-4810 1615-01-483-2438 1615-01-534-8106

70351-38100-047 70351-38100-048 70351-38100-050

Input Module Gearbox

1615-01-230-6218 1615-01-353-3825 1615-01-527-8175

70351-08001-046 70351-08001-049 70351-08001-050

1615-01-527-8175, Intermediate Gearbox

1615-01-074-5152 1615-01-201-5623

70357-06300-042 70357-06300-043

1615-01-201-5623, Tail Rotor Gearbox

1615-01-291-7572 1615-01-372-5467 1615-01-376-5089

70358-26600-044 70358-26600-045 70358-06600-046

1615-01-372-5467, 70358-26600-045

Accessory Gearbox

1615-01-078-5718 1615-01-383-8992

70351-08080-043 70351-08080-045

1615-01-383-8992, 70351-08080-045

The gearboxes are utilized on the MH-60T aircraft. Upon receipt of the gearboxes, the Contractor shall perform a test and evaluation to determine the condition of the component. Any gearbox where no faults are found (NFF) or the component is determined to be Beyond Economical Repair (BER) shall be returned to the United States Coast Guard (USCG) in accordance with (IAW) Sections 3.2. All other gearboxes shall be overhauled IAW Section 2 of this SOW.

1.2 The objective for the Contractor will be to provide the Aviation Logistics Center (ALC) with overhauled gearboxes that are Ready for Issue (RFI) in support of our efforts to sustain approximately forty- six (46) aircraft. The Contractor should be capable of delivering the overhauled gearboxes within the delivery requirements established in this SOW. The USCG anticipates the material will be shipped to the vendor within five (5) business days after issuance of a delivery order. The Contractor will not be penalized if the USCG is not timely in the shipment of the material.

70Z03822RJ0000002

2.0 Overhaul

2.1 Requirements

Work under this contract shall be performed at the Contractor’s facility or an USCG approved facility. The Contractor shall provide all necessary parts, materials, labor, tooling, test equipment and facilities to evaluate and overhaul the gearboxes listed in this contract at the firm-fixed prices listed in the schedule. The Contractor shall inspect, test, and determine if a gearbox is RFI or requires overhaul.

The gearboxes listed in section 1.1 shall be overhauled to like new condition. Note, the input NSN may differ from the required output NSN.

2.1.1 Certification

In accordance with the National Defense Authorization Act for Fiscal Year 2004, Public Law 108–136, § 802, 117 Stat. 1392 (2004), the Naval Supply (NAVSUP) Systems Command, Weapons Systems Support (WSS), Philadelphia, PA, is the design control activity and as such, has the sole authority for approving sources for the procurement, repair, and overhaul of components managed by the Navy. However, ALC MRR Engineering has the responsibility for approving sources for components unique to or maintained solely by the Coast Guard.

Responsible Contractors are limited to only Original Equipment Manufacturer (OEM) and NAVSUP WSS approved sources for the gearboxes listed herein. The Contractor shall provide immediate notification to the Contracting Officer upon loss of any required certifications.

2.2 Specific Tasks

2.2.1 Overhaul Services

The Contractor shall perform all overhaul services IAW the SOW and Federal Aviation Regulations Parts 43 and 145. The Contractor shall perform a thorough visual and technical inspection of each gearbox requiring overhaul and correct all deficiencies found. This shall include replacement of broken parts and the removal of any foreign matter or corrosion. Parts found to be defective shall be replaced with new parts. A DD Form 1577-2, Unserviceable Tag-Material, or a CG-1577-A (11-90), Unsatisfactory Report Tag, will be attached to each Not Ready for Issue (NRFI) component describing faults. Once the gearboxes have been overhauled to like new condition, the Contractor shall remove the unserviceable tag from the component.

2.3 Place of Performance

The place of performance will be at the Contractor’s facility or an USCG approved facility.

2.4 Government Furnished Resources

The Government will provide the gearboxes specified in paragraph 2.0 to the Contractor for overhaul work required under this contract. The Government will not furnish any drawings, parts, hardware, specifications, tooling, or any other overhaul documents required to overhaul any of the gearboxes herein.

2.5 Contractor Furnished Property

The Contractor shall provide all necessary parts, material, tooling, labor, repair/overhaul manuals, test equipment and facilities to fulfill the requirements of this contract, except for the Government Furnished Resources specified in SOW paragraph 2.4, Government Furnished Resources.

2.6 Procedures

Sikorsky Aircraft Corporation is the OEM of the gearboxes listed in section 1.1 and the only NAVSUP WSS approved vendor(s). The Contractor shall perform all overhauls IAW the Component Maintenance Manuals (CMM) listed in section 3.1. All services shall be accomplished on an as required basis, as directed by the Government. Request for clarification shall be directed to the Contracting Officer.

2.6.1 The Contractor must have access to required overhaul specifications and test/acceptance criteria and data to ensure all gearboxes are tested and overhauled IAW the current specifications and procedures. The USCG may review overhaul manuals and performance/test/acceptance criteria as required. The Contractor is solely responsible for obtaining any and all specifications required for this effort. Original design or functional capabilities of the end item and parts thereof shall not be changed unless authorized or directed by the requirements of this SOW.

2.7 Test, Evaluation, and Inspection

If, after visual and functional inspections, a gearbox is found to be RFI (No Fault Found) or is considered to be BER IAW Section 3.2, the Contractor will be allowed the firm fixed price for NFF/BER/Scrap only. The Contractor shall prepare a failure data report IAW Section 3.4 in these instances. This report shall be included with the returned component. The parts shall be marked "RFI” or “BER” and returned IAW Section 3.2. A copy of the failure data report shall be attached to the invoice.

2.7.1 The gearboxes shall be inspected at the Contractor’s place of performance for serial number(s) received per paragraph 8.2. The Contractor shall perform a visual and technical inspection of each gearbox and correct all additional deficiencies found. This shall include replacement of broken parts and the removal of any foreign matter or corrosion. Parts found to be defective shall be replaced with new parts.

The following definitions shall apply to the main gearbox:

Minor: The process of disassembly sufficient to inspect all the operating components and the basic end article.

It includes replacement or servicing as necessary followed by reassembly and testing. Upon completion of the overhaul process, the gearbox or end article will be capable of performing its intended service life or tour.

Major: In addition to those actions required for a minor overhaul, a complete disassembly, to include 100% visual and 100% Nondestructive Inspection of all components, 100% replacement of housing with Rockhard coated zero time unit shall include new main bridge dowel pin. Replace the carrier assembly with a zero time Improved Durability Gearbox Improved Planetary Carrier. Replace any time/life gearbox with less than 3,500 hours remaining to retirement with a zero time gearbox.

2.8 Discrepancy Evaluation

NRFI gearboxes shall be overhauled and returned to RFI condition IAW the functional performance specifications. Gearboxes shall be overhauled for the specific fault noted on the DD Form 1577-2, Unserviceable (Repairable) Tag-Material, or CG-1577-A (11-90), Unsatisfactory Report Tag, which will be attached to each NRFI component. The Contractor shall perform an inspection and correct deficiencies found.

This shall include, but is not limited to, replacement of missing or broken parts and the removal of any foreign matter or corrosion.

Discrepancies (over and above repair components) may be identified during initial evaluation. Over and above repair gearboxes consist of any findings of unusual damage IAW Section 3.8. The Contractor shall be responsible for documenting and reporting all over and above repair gearboxes to the Contracting Officer after receipt of gearboxes at the contactor’s facility. The Contractor’s quote shall be valid for thirty (30) calendar days and the documentation must include:

• Description of each discrepancy found

• Number of man-hours per discipline required to complete each discrepancy

• Parts costs (if the part is not listed on the separately priced parts list, this must be notated in the quotation and price for each part will be negotiated IAW Section 3.6)

• Total dollar amount for each discrepancy

• Total dollar amount for complete list of discrepancies

• Delivery Order Number and applicable Line Item

2.8.1 The Contracting Officer will be responsible for reviewing the list of discrepancies and either accept, negotiate, or decline the Contractor’s proposal. The Contracting Officer shall provide a response to the quotation within thirty (30) calendar days after receipt. Additional work shall not be performed until the quotation is accepted and a modification to the delivery order is provided by the Contracting Officer. The Contractor will have ninety (90) calendar days (plus the number of calendar days it takes the Contracting Officer to provide a response to the over and above quotation) to complete the repairs and return the gearboxes to the Government. In the event that a quotation is declined by the Contracting Officer, the Contractor shall return the gearbox “As-Is.” The Contractor will be authorized the firm-fixed Test and Evaluation fees established in the contract.

3.0 Scrap Procedures

3.1 Condemned Parts and Material

All non-repairable parts, including parts replaced during the overhaul process, shall be scrapped, rendered unusable to the point they cannot be returned to service, in accordance with the USCG Aviation Logistics Center Instruction 4100.1, Aviation Logistics Center Material Disposal Procedures – or the Contractor’s Government approved scrap procedures.

3.2 Beyond Economic Repair

In the event a gearbox cannot be overhauled to like new condition and is found to be BER, the Contractor shall immediately stop working on the gearbox and notify the Contracting Officer in writing. The Contractor’s written notification shall include the following information at a minimum: contract number, delivery order number, line item number, nomenclature, national stock number, part number, serial number, and a brief description supporting the determination. The Contracting Officer will provide disposition instructions via modification within thirty (30) calendar days after receipt of notification. The Contractor shall only be entitled to BER/Scrap Fee on the schedule for that specific line item.

After receipt of a quotation for the over and above overhaul of a gearbox, the Contracting Officer may determine that a gearbox is BER and will provide a written modification to the Contractor. The USCG will provide disposition instructions for all gearboxes that are considered BER. The Contractor shall not dispose of a gearbox until they have been notified by a written modification to the order. When returning the gearbox to ALC, the component(s) shall be clearly marked as “BER” with the supporting evidence. The Contractor will only be authorized the firm-fixed BER/Scrap fees listed in the schedule.

3.3 Scrapping at Vendor

Gearboxes can be scrapped on site at the overhaul facility when a Government representative properly witnesses the scrapping of a flight safety critical aircraft part. The Contractor shall submit a letter to ALC on corporate stationary stating the part or parts have been “mutilated”. The letter shall include the serial number (S/N) if applicable, NSN, P/N, quantity, and be dated and signed by the Defense Contract Management Area Office or Government representative. The letter serves as a cradle to grave record and shall be filed with the contract. Receipt of the contract line item number cannot take place at ALC until the proper scrap documentation has been received. Failure to provide adequate documentation could cause rejection of submitted invoices resulting in postponement of payment.

3.4 Failure Data Report

The Contractor shall submit a failure data report for each overhauled gearbox. This report shall include NSN, P/N, S/N, nomenclature, date of overhaul, contract delivery order number, line item number, description of overhauled/repair failure, the USCG’s reported failure, a listing of parts repaired, and a listing of parts replaced.

The Contractor’s in-house work order may be used to satisfy this requirement if it includes the information requested above. This report shall be attached to the packing slip and shipped with the overhauled component.

3.5 Replacement Parts

Parts of a gearbox found to be in a serviceable condition as a result of functional testing shall be reused.

Missing parts and parts found to be defective or that require replacement by manufacturer’s instructions shall be replaced with parts meeting the manufacturer’s specifications and drawings. Replacement parts shall be new.

The cost for parts that are replaced systematically during overhaul shall be included in the price listed in the schedule for these operations. The Contractor shall submit a listing of all systematically replaced parts and other replacement parts to be utilized in support of the maintenance procedure of each component. The replacement parts listing must show the following information: Component Description, OEM P/N, and Price.

3.5.1 The USCG requires Parts Integrity on all items awarded under this contract. The USCG utilizes serial number tracking systems for safety of flight items and places a high priority on parts integrity within those components. As a result, any part that is determined to be in serviceable condition shall be reused in the assembly from which it was removed. The Contractor is advised that in order to expedite deliveries, parts may be transferred to/from USCG components, but serial number integrity documentation is required under this contract. The contractor shall ensure serviceable parts’ serial numbers are documented as installed on the overhauled gearboxes.

3.6 Separately Priced Replacement Parts

Pricing for other overhaul gearboxes and supply material, yet unspecified by part number at time of contract award, will be incorporated as firm fixed prices after negotiation of the first-time replacement. The Government reserves the right to provide separately priced replacement parts as Government furnished property on an as-needed basis as determined by the Contracting Officer. The Contracting Officer will either issue a modification to the delivery order authorizing use of the separately priced replacement part(s) or provide disposition instructions. The delivery schedule will be adjusted accordingly for any delay associated with requesting and obtaining the approval to utilize the specified separately priced replacement part(s).

3.7 Corrosion Treatment

During inspection and functional test, the presence of corrosion in a gearbox shall constitute reason for a more thorough disassembly and inspection. Should corrosion be found, disassembly shall be made to the extent necessary to remove corrosion or replace the part, or parts, affected. Corroded parts shall be replaced, except in those cases where removal of corrosion from a part will not impair efficiency or safe operation of the part.

Corrosion removal and treatment of affected areas will be accomplished IAW OEM specifications and FAA Advisory Circular AC 43-4B dated September 11, 2018, Corrosion Control for Aircraft.

The main gearbox assembly is subject to excessive corrosion in the vicinity of the mounting feet. As part of the overhaul process, the Contractor shall provide the effort necessary for the restoration of the corroded areas, to include any necessary disassembly, part replacement, and reassembly required in connection with the corrosion removal.

The USCG approved application of Rockhard coating will be performed on all gearboxes. The coating shall be applied in accordance with OEM specifications within the fixed prices established at contract award.

3.8 Exclusions – Unusual Damage

Prices do not include gearboxes that have been cannibalized or severely damaged due to mishandling, water immersion, or crash damage. Additionally, the MH-60T helicopter is used primarily around salt water at low altitude for search and rescue missions. Therefore, corrosion is to be anticipated and is considered "normal" for the aircraft. Corrosion does not constitute unusual damage.

Unusual Damage Evaluation: The Contractor shall provide written notice to the Contracting Officer within thirty (30) calendar days of receipt of gearboxes requiring unusual damage evaluation. Such gearboxes must, upon inspection, show obvious signs of misuse, cannibalization, or severe damage due to mishandling or crash damage. Gearboxes received by the Contractor in any of these conditions will be the only exclusions to the fixed prices established at contract award.

NOTE: Firm fixed-prices in the Schedule do not apply to assemblies and gearboxes which have been cannibalized of parts or severely damage due to mishandling or crash damage. The Contractor shall evaluate the component and forward a firm fixed-price proposal with delivery schedule to the Contracting Officer within sixty (60) days after induction.

3.8.1 Condemned Parts and Materials: All end item, non-overhauled/scrap parts shall be mutilated (rendered unusable for their intended purpose) in accordance with Coast Guard Aviation Logistics Center Instruction

4100.1 or an approved vendor scrap procedure and submit Standard Form 1428 to ALC. The form shall include the serial number if applicable, NSN, part number and quantity.

3.8.2 The Government shall not be liable for any amount expended by the Contractor in excess of the applicable firm fixed-price reflected in the Schedule unless prior written authorization has been given by the Contracting Officer.

4.0 Applicable Documents

4.1 Directives

The USCG does not own nor can it provide the required directives for this requirement (except where stated below).

Overhaul services must be performed IAW the procedures established in this section. The following documents are listed in order of precedence. Latest revisions of all manuals shall apply. The information contained in this section is not intended to be all inclusive nor to detract from or modify procedures outlined in the manuals. If the applicable technical manual does not cover a procedure, the Contractor shall utilize the OEM overhaul manual. If the OEM manual does not cover a procedure, the Contractor shall utilize the best commercial business practice. Where an application of “best commercial practice” is in conflict with these manuals, the Contracting Officer may approve deviation from requirements. When applicable, each manual will specify if the Export Control Act applies.

• Naval Air Systems Command Technical Manual Main Module Assembly, A1-862QA-MDB-200, latest revision

• Naval Air Systems Command Technical Manual Main Transmission Assembly, A1-866QA-MDB-300, latest revision

• Naval Air Systems Command Technical Manual Intermediate Gear Box Assembly, A1-862QA-MDB- 000, latest revision

• Naval Air Systems Command Technical Manual Tail Gear Box Assembly, A1-862QA-MDB-100, latest revision

• All OEM shop, inspection, overhaul, repair, or other OEM CMM and revisions as applicable

• All OEM service bulletins, amendments, modifications, and specifications as applicable

• FAA Advisory Circular AC 43-4B, dated September 11, 2018, Corrosion Control for Aircraft

• Coast Guard Aviation Logistics Center Instruction 4100.1A, Aviation Logistics Center Material

Disposal Procedures (included as a separate attachment to this Federal Business Opportunities (FBO) notice under CG ALCINST 4100.1A)

• Coast Guard Aviation Logistics Center Instruction 4855.4A, Policy and Quality Assurance Procedures for the Receipt Inspection of New, Repaired, and Overhauled items from Vendors (included as a separate attachment to this FBO notice under CG ALCINST 4855.4A)

• Coast Guard Aviation Logistics Center Instruction 4200.3C, ALC Spare Parts Breakout/New Product Development (included as a separate attachment to this FBO notice under CG ALCINST 4200.3C)

The USCG has the sole responsibility for the development of internal procedures for the ALC’s Spare Parts Breakout Program. Any commercial Contractor that manufactures, repairs, overhauls, reverse engineers, or the like any USCG component is subject to Coast Guard Aviation Logistics Center Instruction 4200.3C, ALC Spare Parts Breakout/New Product Development.

• Occupational Safety and Health Standards (OSHA) 1910.1025 (Lead)

• OSHA 1910.1026 (Chromium VI)

• OSHA 1910.1027 (Cadmium)

• Military Standard (MIL-STD) MIL-STD-129R, Military Marking For Shipment and Storage

• MIL-STD-2073-1E, Standard Practice For Military Packaging

4.2 Availability of Documents

The documents listed in section 3.1 may be available from the USCG. Before obtaining copies of these documents, Contractors shall be registered in the Defense Logistics Agency’s Joint Certification Program.

More information on this certification can be found at http://www.dlis.dla.mil/jcp/Default.aspx. After ensuring registration, the Contractor shall complete Department of Homeland Security Form 11000-6, Sensitive but Unclassified Information Non-Disclosure Agreement (Attached to the Solicitation) and return with a written request to Hayley.W.Osmon2@uscg.mil. Copies will not be posted to https://www.SAM.gov.

http://www.dlis.dla.mil/jcp/Default.aspx https://www.sam.gov/

4.2.1 The USCG will only release these documents to United States (US) businesses that have followed the above procedures. The documents will not be released to any foreign entity. If the U.S. business plans to release these documents to any foreign entity, they must first provide the USCG with a copy of a valid Technical Assistance Agreement and DSP-5 authorizing release to that entity.

5.0 Government Property

5.1 Government Furnished Property

Government furnished property will be shipped to the Contractor’s facility from ALC and documented using DD Form 1577-2, Unserviceable (Repairable) Tag-Material, CG-1577-A (11-90), Unsatisfactory Report Tag, or Form 1348. These documents will accompany and remain with the equipment. Property shall be returned to ALC upon completion of the delivery order, unless otherwise directed by the Contracting Officer.

5.2 Government Property Records

Upon receipt, the Contractor shall update Government Property Records based on the DD Form 1577-2, Unserviceable (Repairable) Tag-Material, CG-1577-A (11-90), Unsatisfactory Report Tag or Form 1348 information provided and any discrepancies. The Contractor shall account for all end-components received from, and shipped to the Government. The Contractor shall provide a copy of its Government Property Records to the Contracting Officer no later than the 15th of each month. Government Property Records will include the following minimum information:

• Kit/Equipment/Component Description, P/N, S/N

• USCG consignee

• Date received

• Status of contract service

• Expected contract service completion date

6.0 Improvements

6.1 Changes to Government Depot Maintenance Manuals

The Contractor shall notify the Contracting Officer when changes are made to the technical manual’s specifications or drawings which are applicable to the gearboxes specified herein. Such notification shall include the nature of the change and details sufficient for the USCG to evaluate the scope and impact of the change. Prior approval to perform in accordance with revised specifications or drawings shall be obtained in writing from the Contracting Officer before proceeding with the overhaul. The USCG reserves the right to waive any specification.

6.2 Service Bulletins

The Contractor shall provide the Contracting Officer with two (2) copies of all service bulletins within ten (10) calendar days of receipt. The Contracting Officer will notify the Contractor in writing when incorporation of mandatory or optional service bulletins is required. The Contractor shall submit, within thirty (30) calendar days after receipt of this notification, a detailed proposal which shall include a listing of replacement parts and/or materials required, the time needed to affect the modifications, estimated price breakdown of each part, and the number of labor hours required.

6.3 Service Bulletins, Modifications, Engineering Change Proposals (ECP), Local Engineering Change Proposals (LECP) and Time Compliance Technical Orders (TCTO) The Contracting Officer shall notify the Contractor in writing of gearboxes requiring incorporation of a service bulletin, modification, ECP, LECP, or TCTO. Upon receiving such notice, the Contractor shall submit, within thirty (30) calendar days, a firm fixed price (FFP) proposal for an incremental charge to be assessed each time the service bulletin or change is incorporated. The proposal shall contain a breakdown of material and labor costs based upon the FFP labor rates and material factors. The incremental charge agreed upon for incorporation of a service bulletin shall apply only to those components for which the Contractor has incorporated a required service bulletin, not those for which the service bulletin has been previously incorporated. Upon agreement of an incremental charge and issuance of an order modification to reflect this change, the service bulletin shall be incorporated into each subsequent gearbox received at the overhaul facility if the service bulletin has not already been incorporated. When incorporation of a service bulletin changes the P/N of the gearbox contained in the schedule, the new P/N and NSN (if applicable) will be added to the order via modification.

6.4 Obsolete Part or Process

In the event certain parts or processes become obsolete, the Contractor shall, within thirty (30) calendar days after receipt of the gearbox, notify the Contracting Officer and submit:

a) Rationale and verification of any obsolete part or process; and

b) A written estimate of the effort required to make the overhaul.

Such estimates shall include nomenclature, part number, cost and quantity of replacement parts and total labor hours. The Contractor shall verify cost of parts with invoices or catalogs. The Contractor’s delivery obligation for the gearboxes identified shall be suspended as of the date of notice to the Contracting Officer. The Contracting Officer will, within thirty (30) calendar days after receipt of the Contractor’s written estimate, make a written determination as to the disposition of the gearbox. After receipt of the Contracting Officer’s disposition instructions, the Contractor shall have thirty (30) calendar days for delivery.

7.0 Quality

7.1 Quality Control

The Contractor is required to be certified and maintain a quality system that complies with the requirements of International Organization of Standardization 9001-2000 Quality Management Systems – Requirements or equivalent. The Contractor is responsible for performing or assuring all inspections, tests and calibration necessary to substantiate that the goods or services furnished conform to Government’s requirements. The Contractor shall take prompt action to correct conditions that have or could result in goods or services that do not conform to contractual requirements. Records of conformance shall be maintained on file at the Contractor’s facility and made available or provided for review by the Government upon request. The Government reserves the right to conduct surveillance at Contractor’s facility to verify the existence, adequacy and effectiveness of the quality system. Upon request of the Government, the Contractor(s) shall forward a copy of their current certification and Quality Assurance Manual for review.

7.2 Warranty

The Contractor’s standard commercial warranty, including extended warranties, provided to the Government at no additional cost, shall apply.

8.0 Records and Reports

8.1 Aviation Computerized Maintenance System (ACMS)

8.1.2 Flight Critical

The gearboxes listed below are considered FLIGHT CRITICAL and ACMS tracked.

Modified and Overhauled NSN/

Main Gearbox (Minor) 1615-01-552-3522 70351-38100-049 1615-01-552-3522, 70351-38100-049

Main Gearbox (Major) 1615-01-552-3522 70351-38100-049 1615-01-552-3522, 70351-38100-049

1615-01-289-4810 1615-01-483-2438 1615-01-534-8106

70351-38100-047 70351-38100-048

Input Module Gearbox

1615-01-230-6218 1615-01-353-3825 1615-01-527-8175

70351-08001-046 70351-08001-049

Intermediate Gearbox

1615-01-074-5152 1615-01-201-5623

70357-06300-042

Tail Rotor Gearbox

1615-01-291-7572 1615-01-372-5467 1615-01-376-5089

70358-26600-044 70358-26600-045 70358-06600-046

1615-01-372-5467, 70358-26600-045

Accessory Gearbox

1615-01-078-5718

70351-08080-043 70351-08080-045

1615-01-383-8992, A flight critical safety item is a part, assembly, installation, or production system with one or more critical characteristics that, if not conforming to the design data, or quality requirements, would result in an unsafe condition. Unsafe conditions related to mishap severity I (Catastrophic) and II (Critical), and include conditions which could cause loss or serious damage to the end item or major component, loss of control, serious injury to personnel, or death of personnel.

8.1.3 Documentation Requirements

Serial number tracking shall be used for validating the correct gearbox was received at the Contractor’s overhaul facility and returned to the USCG. Upon the receipt of any gearbox from the USCG, the Contractor shall verify the delivery order number and serial number of each gearbox. The Contractor shall notify the Contracting Officer in writing only if a discrepancy is identified.

The USCG places high priority on parts integrity within aircraft components. As a result, any part which is determined to be in a serviceable condition as a result of inspection and functional testing shall be reused in the gearbox from which it was removed, if practical, with the exception of parts specifically replaced during the overhaul as required by the directives as specified within the contract.

ACMS is a computerized system used to record maintenance of aircraft components and assemblies. All gearboxes listed in this paragraph are ACMS and serial number tracked. Tracked gearboxes will be shipped to the Contractor’s facility with a Significant Component History Record (SCHR) and a Component Repair Record (CRR). The SCHR records the maintenance history of the serial number tracked gearboxes. It remains with its corresponding part until reinstalled on an aircraft or is annotated “BER” and scrapped. (NOTE: written approval from the Contracting Officer is required prior to scrapping a serial number tracked component). The SCHR for scrapped components shall be returned with the component. The Contractor shall retain a copy of the SCHR for ninety (90) calendar days.

The Contractor’s responsibilities with ACMS consist of submission of required forms as outlined herein.

The Contractor shall provide a CRR with the repaired component(s). The CRR records the maintenance performed on a serial number tracked component and enrolls or disenrolls components from ACMS when those components are scrapped, added to, or removed from the USCG inventory. At a minimum, the CRR shall identify the equipment and contain a description of the maintenance action performed, parts replaced, service bulletins and modifications. The Contractor shall mail one (1) copy of the CRR to USCG ALC, ATTN:

AVENG/ACMS, 1664 Weeksville Road, Elizabeth City, NC 27909-5001 no later than five (5) business days following completion of the rework effort. The original CRR shall be packed with the component. The Contractor shall retain a copy of each CRR for ninety (90) calendar days. The Contractor may request that their in-house work order be accepted to fulfill the CRR requirement. The Contracting Officer will provide a written determination in response to the request.

The Contractor shall verify the SCHR and CRR and ensure they correspond with the gearbox’s part number and serial number. All discrepancies shall be reported in writing to the Contracting Officer prior to induction. The Contractor shall complete the CRR.

The original copy of the CRR shall be mailed to:

Engineering Services Division 1664 Weeksville Road ACMS Tracking, Bldg 78 Aviation Logistics Center Elizabeth City, NC 27909-5001

A copy of the CRR shall be shipped with the overhauled gearbox and affixed to the outside of the shipping container. The Contractor shall maintain a copy of each complete CRR for a period of ninety (90) calendar days.

8.2 Contractor Verification of Receipt of Components

Serial Number tracking shall be used for validating the correct gearboxes were received at the Contractor’s overhaul facility and returned to the USCG. Upon receipt of the gearboxes from the USCG, the Contractor shall verify each gearbox received to ensure that the S/Ns match the ones specified in the order within five (5) calendar days. Should a discrepancy be identified, the Contractor shall notify the Contracting Officer in writing of the discrepancy. Email notification is acceptable. The USCG utilizes an S/N tracking system and places high priority on parts integrity within aircraft components. As a result, any part which is determined to be in a serviceable condition as a result of inspection and functional testing shall be reused in the gearbox from which it was removed, if practical, with the exception of parts specifically replaced during the overhaul as required by the directives as specified within the order.

Occasionally, a gearbox may be received without a data plate. When a data plate is missing, the Contractor shall notify the Contracting Officer in writing requesting approval of serial number assignment. Upon the Contracting Officer’s acceptance of the serial number proposed, a modification may be issued stating the serial number to be assigned. Upon receipt of a fully executed modification authorizing assignment of the stated serial number, the Contractor shall affix a new data plate to the gearbox. The data plate shall include all the required information about sited component including the newly assigned serial number.

8.3 Certificates

The Contractor shall maintain NAVSUP WSS and/or USCG certifications for overhaul of gearboxes identified in the schedule for the entire duration of this contract. The Contractor shall provide immediate notification to the Contracting Officer upon loss of any required certifications. The Contractor shall also:

• Comply with the certification/documentation requirements specified herein.

• Attach certifications/documentation to the outside of the shipping container.

All components overhauled under the provisions of this contract must be airworthy and suitable for installation on USCG aircraft. Each returned component shall be tagged with a DD Form 1574 Serviceable Condition Code Tag or a FAA Form 8130-3, Airworthiness Approval Tag, completed in its entirety. The Contractor shall furnish a Certificate of Airworthiness in accordance with FAA procedures (or USCG approved alternate procedure) and a Certificate of Conformance (COC) IAW FAR 52.246-15 for all components. If the Contractor cannot provide an Airworthiness Certificate, the alternate ALC MRR Engineering approved document is a COC. The COC shall be signed by an authorized official of the approved source and must specify the nomenclature, manufacturer’s P/N, and date of manufacture. The Contractor’s FAA certification must reflect authorization to repair the exact category of components specified in this SOW. These forms shall be packaged with each component and copies shall be included with the invoice. FAILURE TO SUBMIT THE

APPROPRIATE CERTIFICATES SHALL CONSTITUTE AN IMPROPER INVOICE AND WILL

RESULT IN NONPAYMENT.

The COC shall be signed by an authorized official of the approved source and must specify the nomenclature, manufacturer's P/N, and date of manufacture. For Production Approval Holder, a COC and a copy of the FAA Parts Manufacturer Approval or other manufacturing authority shall be provided. Contractors shall also provide documentation reflecting the complete unbroken history of ownership of the parts from purchase from the approved manufacturing source until delivery to the USCG.

8.4 Monthly Production Report

The Contractor shall submit a monthly production report to the Contracting Officer no later than the tenth (10th) business day of each month. The production report shall provide the status of each contract line item number (CLIN) received, being overhauled, and shipped during the monthly reporting period. Any format is acceptable as long as the report provides the following information: nomenclature, P/N, NSN, S/N, CLIN, delivery order, and receipt date at Contractor’s facility, date scheduled to be inducted, date inducted, date scheduled for delivery, total days in work, if the part is late, and any comments.

The Contractor shall provide a monthly, bi-weekly if needed, progress summary via email, telephone, video conference or electronic submission. Progress summaries shall include those gearboxes listed in paragraph 1.1.

9.0 Delivery Requirements

9.1 Standard delivery and monthly output rate after induction for each gearbox is listed below. Induction shall be no later than fifteen (15) calendar days to meet the contract scheduled delivery date.

Output NSN and

Lead Time (days)

Monthly Rate

Main Gearbox* (Minor)

1615-01-552-3522

1615-01-552-3522;

1/10 months 2/2 months

Main Gearbox* (Major)

1615-01-552-3522

1615-01-552-3522;

1615-01-289-4810;

1615-01-483-2438;

1615-01-534-8106

70351-38100-047;

70351-38100-048;

Input Module

1615-01-230-6218;

1615-01-353-3825;

1615-01-527-8175

70351-08001-046;

70351-08001-049;

Intermediate

1615-01-074-5152 1615-01-201-5623

70357-06300-042;

Tail Rotor

1615-01-291-7572;

1615-01-372-5467;

1615-01-376-5089

70358-26600-044;

70358-26600-045;

70358-06600-046

70358-26600-045

Accessory

1615-01-078-5718;

70351-08080-043;

*The first ten (10) months of the contract the output is one (1) per month. The last two (2) months of the contract the output is two (2) per month. The total yearly output is fourteen (14) gearboxes, regardless if minor or major overhaul.

If the number of gearboxes in the Contractor’s possession falls below what is needed to maintain the contract delivery rate, the contract will be allowed a one for one exception to the delivery requirement.

9.2 The USCG desires early deliveries therefore early shipments are encouraged at no additional cost to the Government. In the event the Contractor anticipates or encounters difficulty in complying with the delivery schedule or date, they shall immediately notify the Contracting Officer in writing. All requests for time extensions shall be in writing and shall include substantiation of the need for such time extension(s) IAW FAR 52.212-4(f), excusable delays. If nonperformance is not covered by an excusable delay, the Contractor and the Contracting Officer shall negotiate consideration for the approval of the extended delivery date. A modification will be issued to the order to reflect the consideration and the extension.

9.3 F.O.B. Point

The F.O.B. point for shipments under this contract is F.O.B. Origin. F.O.B. Origin orders require prepayment of all shipping costs to the address specified in Block 15 on the SF 1449, page 1. Shipping costs must appear as a separate item on the invoice. A carrier’s invoice must accompany the invoice when shipping costs exceed $100. The Government shall reimburse actual shipping costs only.

10.0 Contract Information

10.1 Contract Administration Data

Only the Contracting Officer is authorized to issue and modify any order, approve changes in any of the requirements, or obligate funds. Notwithstanding any term or condition contained elsewhere in the order, the authority to modify the order remains solely with the Contracting Officer. If the Contractor makes any order changes at the direction of any person other than the Contracting Officer, the change will be considered to have been made without authority and no adjustment will be made in the order to cover any increase in costs that may result. The Contracting Officer has the authority to perform any and all post-award functions in administering and enforcing an order IAW its terms and conditions.

10.2 Laws and Regulations

The Contractor shall be knowledgeable of and comply with all applicable federal and state laws and regulations and any local laws and ordinances regarding environmental protection. In the event environmental laws and/or regulations change during the term of this order, the Contractor is required to comply as such laws come into effect.

10.3 Quarterly Audits

The ALC conducts quarterly audits validating Government Furnished Property at commercial Contractor facilities. The Contractor shall follow the instructions provided each quarter by ALC and comply with its instructions. The Contractor’s role shall be to validate each gearbox identified by S/N by ALC. Validation shall take place on the same date as the audit.

10.4 Environmental Requirements

All parts must be thoroughly cleaned IAW applicable CMMs or FAA Advisory Circular 43-205, Guidance for Selecting Chemical Agents and Processes for Depainting and General Cleaning of Aircraft and Aviation

Products, to ensure they are as free as practicable of all hazardous dust to include hexavalent chromium, cadmium, lead, etc., prior to being returned to ALC. ALC may take random samples of parts to ensure they are free as practicable of all hazards. Information on these hazards can be found in Occupational Safety and Health Standards 1910.1025 (lead), 1910.1026 (Hexavalent Chromium) and 1910.1027 (Cadmium).

10.5 Shipping Instructions

Unless otherwise specified on individual delivery orders issued hereunder, deliverable items shall be shipped to the following address:

USCG ALC

1664 Weeksville Road Receiving Section, Bldg. 63 Elizabeth City, NC 27909-5001

Contract No. ______________________________ (To be assigned at time of issuance)

Delivery Order No. ______________________________ (To be assigned at time of issuance)

10.6 Urgent Requirements

10.6.1 Aircraft on Ground (AOG) Situations

In the event an Aircraft on Ground (AOG) status occurs as a result of a lack of component specified herein, the Contractor will be notified and requested to provide a response within twenty-four (24) hours of the notification. The Contractor’s response shall provide status of the gearbox needed to satisfy the AOG situation and the requirements to expedite shipment.

Upon notification from the USCG that an AOG situation exists, the Contractor shall expedite overhaul and initiate shipment within twenty-four (24) hours after notification. The shipping container shall be marked on the outside in highly visible lettering "A.O.G." in letters not less than 2” high. At the time the Contractor is notified of an AOG requirement, the Contractor shall advise the Contracting Officer, or their representative, if there are additional shipping charges. The Contracting Officer will provide special shipping instructions and authorization for reimbursement in these instances. The gearbox shall be shipped by the fastest traceable means (i.e., air freight, next day delivery). The Contracting Officer may issue an order modification authorizing additional funding as agreed upon by the Government and the Contractor to accomplish the expedited overhaul.

The Contractor shall ship the gearboxes directly to the destination the Contracting Officer designates as quickly as possible using the fastest traceable means (i.e., air freight, next day delivery).

10.7 Packaging and Preservation

10.7.1 Packaging and Marking

The Contractor shall comply with MIL-STD-129 (latest version), Military Marking for Shipment and Storage, with the following exceptions:

a. Each gearbox shall be individually packed in a separate approved shipping container.

b. Each individual container shall be labeled on the outside with Nomenclature, NSN, P/N, S/N, Quantity, Contract Number, delivery order number, and contract line item number on a permanent label.

c. The internal packaging material shall be sufficient to prevent damage during shipment, handling, and storage. Preservation and protection shall be provided to prevent corrosion, deterioration or decay during warehouse storage for a period of one (1) year.

d. Packing List and Certification/Documentation shall be placed on the outside of individual containers.

e. Packaging material shall not consist of the following materials: popcorn, shredded paper, Styrofoam of any type, or peanut style packaging.

f. Each container shall be marked with a notice of warranty. The notice must include a brief statement that a warranty exists, the substance of the warranty, the duration of the warranty, and who to notify if the supplies are found to be defective.

g. Direct shipments of RFI condition assets to USCG Air Stations when an AOG situation arises may be necessary. An AOG condition occurs when there is no stock of a gearbox on hand and the gearbox is shipped directly from the Contractor to the air station.

h. When there is an AOG, the Contractor shall expedite the overhaul and return the required gearbox(s) IAW the established AOG plan. The outside of the shipping container shall be marked “AOG” in highly visible lettering, at least 2” inches in height.

The Contracting Officer will notify the Contractor when noncompliance with any of the requirements set above is noted so that corrective action may be taken. The Contractor shall, within twenty-four (24) hours after such notification, give the Contracting Officer disposition instructions for such gearboxes. If the Contractor elects for the USCG to correct the deficiency, the USCG may assess the actual costs for correcting the deficiency. The Contractor agrees that the total cost may be deducted from the invoiced amount prior to payment. An estimate of the actual cost for the USCG to correct noted deficiency(s) will be provided at the time the Contractor is notified of any noncompliance.

10.7.2 Packaging, Handling, and Preservation

ALC is a supply depot therefore material will be stored and transshipped to various users. The container shall be packed and labeled suitable for shipment via land, air or sea.

The Contractor shall ensure that all gearboxes, when packed in shipping containers or packaging, will be capable of being transported on standard transportation systems, commercial or military carriers. The Contractor shall preserve, pack, and package in approved shipping containers to ensure complete delivery at destination without damage or deterioration of the supplies due to the hazards of shipping, handling, or storage.

The Contractor agrees that any gearbox damaged in shipment from the Contractor will be repaired inclusive of this order. The Contractor agrees to notify the Contracting Officer of the existence of any damaged and unusable shipping containers. Packaging, handling, shipping, and transportation procedures shall be IAW ASTM D3951-10 (2010) Standard Practice for Commercial Packaging; latest revision shall apply. If commercial practices cannot adequately protect and preserve the equipment, the Contractor shall package, handle, ship and transport gearboxes IAW MIL-STD-2073-1E Standard Practice for Military Packaging; latest revision shall apply.

10.8 Markings of Warranted Items

Pursuant to the requirements of FAR 46.706 (b) (5), the Contractor shall stamp or mark the supplies delivered, or otherwise furnish notice with the supplies, of the existence of the warranty. For commercial items, the Contractor’s trade practice in warranty marking is acceptable if sufficient information is presented for supply personnel and users to identify warranted supplies. Markings may be brief, but should include the information below:

• A brief statement that a warranty exists.

• The substance of the warranty.

• The duration of the warranty.

• Who to notify if the supplies are found to be defective.

10.9 Inspection and Acceptance

Final inspection and acceptance shall be performed at origin by the Defense Contract Management Agency (DCMA). Full and clear traceability must be provided with delivery of each part. If full and clear traceability is not provided, ALC will not accept delivery of the part and invoicing may not be approved for payment. An OEM COC is required for all gearboxes delivered under this contract. The OEM COC shall be signed by an authorized official of the approved source and shall specify the nomenclature, manufacturer’s part number, and date of manufacture. These forms shall be packaged with each gearbox and copies shall be included with the invoice. If DCMA is not available, final inspection shall be performed at ALC by local USCG personnel.

Inspection and acceptance shall be performed at destination by USCG quality assurance personnel for count, condition, and proper completed documentation. Inspection and acceptance deficiencies may delay or cause rejection of invoice payments.

The Government considers gearboxes RFI upon acceptance. Gearboxes determined to be NRFI upon installation may be returned to the Contractor with a Product Quality Deficiency Report (PQDR) for rework/evaluation/investigation as mutually agreed upon.