Attachment_A-KC-135_ESS_PWS_23_Nov_2021.docx

PERFORMANCE WORK STATEMENT

C/KC-135 ENGINEERING SUSTAINMENT SUPPORT (ESS)

Ordering Period 1

AFLCMC/WLTMC-PWS-23-023

Date

23 November 2021

Prepared by

AFLCMC/WLTA & WLTMC

3001 Staff Dr. TINKER AFB OK 73145

ATTACHMENT A

Table of Contents

AFLCMC/WLTMC-PWS-23

23 November 2021

File Name: KC-135 ESS PWS Boeing Contract_CY23-24

SECTION I – DESCRIPTION OF SERVICES

1.0 Scope

This Performance Work Statement (PWS) describes all the requirements necessary to provide Sustaining Engineering Services for the United States Air Force (USAF) C/KC-135 Weapon System, and its Foreign Military Sales (FMS) customers. This PWS includes the necessary requirements for recurring and nonrecurring engineering support services to sustain and modernize the -135 aircraft series. The Legacy Tanker Division, AFLCMC/WLT, will provide technical and program direction.

1.1 Mission Essential Contractor Services

Mission essential contractor services IAW DFARS 237.76 are not applicable to this contract.

1.2 Contractor Personnel Identification

Contractor personnel shall identify themselves 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 personnel in telephone conversations and formal and/or informal written correspondence IAW DFARS 211.106.

2.0 Applicable Documents

The contractor shall comply with the current versions of applicable regulatory and compliance documents at the time the contract or modification is issued. The contractor shall have access to or possession of all C/KC-135 aircraft design, engineering, qualification, test and reliability and configuration data (including all proprietary and limited rights drawings and technical data) for the C/KC-135 aircraft and its variants. The contractor shall also have access to or possession of a complete set of Technical Orders for the C/KC-135 aircraft including maintenance manuals (-2s), Structural Repair manual (-3s), Illustrated Parts Breakdown manuals (-4s), and Inspection Requirements Manuals (-6s).

3.0 Engineering Sustainment Support Requirements

3.1 General Requirements

The contractor shall accomplish both “recurring” and “non-recurring” services in support of the task requirements. The “recurring” service shall include continuous contractor action and shall not require additional contractual authorization or tasks for accomplishment. The “non-recurring” services shall be accomplished as Task Assignments (TAs) and will be issued as individual task orders by the Procurement Contracting Officer (PCO). The contractor shall provide personnel who are capable of effectively communicating with the government.

3.2 Performance Requirements

The contractor shall accomplish tasks using accepted engineering practices and principles. The contractor shall apply the accepted principles/rules of Reliability & Maintainability; Reliability Centered Maintenance, System Safety (per MIL-STD- 882E and/or the C/KC-135 Weapon Systems Sustainment Mechanical Subsystems Integrity Program (MECSIP) Master Plan, Hazardous Materials and Ozone Depleting Chemicals; Human Engineering, and System Engineering) as defined and directed by the Program Office.

3.2.1 Personnel Requirements

3.2.1.1 Contractors requiring access to government facilities or databases to complete the requirements of this PWS shall work with the appropriate government sponsor to obtain a Common Access Card, or visitor badges.

3.2.1.2 The contractor shall provide qualified engineering/technical personnel in performing a full range of engineering skills in airframe design, aircraft systems, aerodynamics, software, structures, test, liaison engineering, and safety engineering are required to accomplish the requirements of this PWS.

3.2.2 Performance on a Government Installation

At government facilities, the contractor shall follow the direction of government in regards to emergency procedures, i.e., fire, tornado, active shooter and bomb threats, to include participating in any emergency drills at no additional cost to the government. It is the contractor’s responsibility to provide accountability of their employees, guidance and/or procedures for responding to an emergency for their employees.

3.2.3 Access to Government Data Systems

Access to government data systems (Reliability and Maintainability Information System (REMIS), GO-81, Joint Reliability Availability Management System (JRAMS), DO-43, Joint Engineering Data Management Information and Control System (JEDMICS), Air Force Safety Automated System (AFSAS), Functional Systems Integrated Database (FSID), etc. may be required to execute the requirements of this PWS. Clearance for individual access shall be initiated by the contractor as required.

3.2.4 Materials, Supplies, and Services

The contractor shall be required to obtain/procure unique services and/or hardware, material, supplies, services etc. from approved system, subsystem, equipment manufacturers.

3.2.5 Program Documentation Delivery

All records generated by the contractor shall be marked with appropriate distribution statement in accordance with the DD1423 (CDRL) and delivered to the government. Additionally, the contractor shall upload records to the appropriate location in Multiple Application for Technical Resources and Information Xchange (MATRIX), and to the appropriate module, as required on the KC-135 FSID site. The contractor shall notify the government (i.e., the PCO, sustaining Program Manager, and TA focal point(s)) via e-mail and the Contract Data Requirements List (CDRL) Delivery tool designed by the government.

3.2.5.1 Digital Enterprise / Acquisition and Sustainment Data Package (ASDP) The Contractor shall use Digital Engineering (DE) tools and processes to design, develop, test, verify, validate, and certify, the system as described in the Department of Defense Digital Engineering Strategy, June 2018. The Contractor shall invoke these same requirements with its subcontractors or vendors at any tier requiring the delivery of ASDP artifacts, except contractual items determined as commercial in accordance with FAR 2.101. The Contractor shall provide remote direct access to the contractor’s system with Government user role-based access. This Contractor-provided system access shall include all licenses required to use the Contractor’s DE tools. The Contractor shall provide formal delivery of the model(s)/data sets at the Systems Engineering Technical Reviews (SETR) and Milestones (MS) as laid out in the Integrated Master Plan (IMP), Acquisition and Sustainment Data Package (ASDP), and other Contract Data Requirements Lists (CDRLs). All DE models shall conform to the Contractor’s Configuration control plan. The contractor shall ensure the DE models produce the data required for ASDP and other CDRLs / Data Item Descriptions (DIDs) with ability to extract the data.

3.2.6 Insourcing Requirements

The contractor may be requested to assist in determining the recommended type and quantity of workload that can transition back to the government based on; labor, skill levels, expertise, access to proprietary data, availability of automated computer tools, etc. required to effectively and efficiently execute it.

3.2.7 Markings and Legends

3.2.7.1 All deliverables (i.e., drawings, briefing charts, analyzes, reports, Technical Order (T.O.) source data, T.O. changes, etc.) accomplished under this contract and/or task order shall be marked with appropriate legends to allow for AF use in accordance with the applicable FARs/DFARS.

3.2.7.2 All documentation developed under this contract and/or task order, whether produced in hard copy or in digital format, shall be marked IAW AFI 61-201. The contractor shall ensure all engineering and technical information is marked with Distribution Statement specified on the DD1423.

3.3 Recurring Engineering Services Requirements

3.3.1 Recurring Mission Support (Firm Fixed Price Tasks)

3.3.1.1 Single Point of Contact

3.3.1.1.1 USAF

The contractor shall provide a single point of contact (POC) and any alternate(s), not to Exceed (NTE) two alternates, who shall represent the contractor for management of projects. The name(s) shall be provided to the PCO in writing within three calendar days after contract award. The contractor POC shall ensure proper planning, scheduling, visibility, control, and performance of the C/KC-135 Sustaining Engineering Services contract. The contractor POC shall channel requests to proper organizations and plan/program all tasks to ensure timely actions and responses to Air Force requirements. (CDRL A001)

3.3.1.1.2 Foreign Military Sales (FMS) FMS

Establish Point-of-Contact – The contractor shall establish a single point of contact to coordinate with internal functional groups to support this statement of work (SOW) and report status of all ongoing recurring and nonrecurring activities.

3.3.1.2 Telephone Logs and Status Reports

3.3.1.2.1 The contractor shall maintain and provide on a quarterly basis, a log of all responses, and actions taken to telephone inquiries from depot/field activities, contractor engineers, etc. (CDRL A002)

3.3.1.3 Systems Engineering Management Plan (SEMP)

The contractor shall prepare and deliver an updated version of the current Systems Engineering Management Plan (SEMP) for use in the performance requirements of all tasks under this PWS, as required. The contractor shall ensure OSS&E is addressed in accordance with (IAW) AFI 63-101_20-101. (CDRL A003)

3.3.1.4 Program Management

3.3.1.4.1 The contractor shall conduct monthly Project Status Review meetings to review the status of all TAs with scope, cost, or schedule problems and/or any other special subjects deemed appropriate by the government or contractor. The time/place of the meeting and format for briefing charts provided during the reviews shall be approved by the Government focal. Most meeting attendees will participate in this meeting in a face-to-face conference room setting; however, it is permissible for attendees to participate in the meetings virtually to eliminate/reduce TDY/travel costs. (CDRLs A004, A005, A006)

3.3.1.4.2 The contractor shall host and conduct two Program Management Reviews (PMR) for USAF and one annually for the FMS customers to discuss engineering support status. The government shall approve the agenda items; however, all open TAs shall be included. The contractor shall prepare and provide proposed agenda and presentation materials prior to the meeting. The reviews must include detailed information (such as individual TA spend plan, current cost and schedule status, potential problem areas, etc.) to allow a thorough understanding of the “health” of each TA. The contractor shall furnish a necessary facility within the Oklahoma City Metro area. (CDRLs A007, A008, A005)

3.3.1.4.3 The contractor shall provide a monthly financial status report for all Cost Plus Fixed Fee (CPFF), Cost Plus Incentive Fee (CPIF), and Time and Materials (T&M) EAs in accordance with the CDRL. (CDRL A009)

3.3.1.4.4 The contractor shall provide a Technical Manual Status and Schedule (TMSS) report in accordance with the CDRL. (CDRL A010)

3.3.1.4.5 The contractor shall provide a monthly summary report of all RTIs initiated during period of performance, to include status of additional initiatives outlined in paragraph 3.3.1.4.8, 3.3.2.1, and 3.3.2.2.2.8. (CDRL A011)

3.3.1.4.6 The contractor shall provide FMS summary status reports in accordance with the workload and requirements of FMS section of paragraph 3.3.2.1.2, and 3.3.2.1.3. (CDRL A012)

3.3.1.4.7 The contractor shall provide a 24-hour per day 7 days a week focal point to support in-flight emergency assistance via telephone to crews and technical personnel assuring quick responsive actions to using activities experiencing in-flight emergencies. The contractor shall provide technical assistance to AF operating unit’s safety offices and AFLCMC/WLT for routine engineering questions for in-flight emergencies and flight safety issues. The contractor shall provide the POC, name and telephone number to the PCO within five (5) calendar days of contract award. The contractor shall ensure the instructions for in-flight emergencies are current at all times and disseminated to the appropriate government organization. (CDRL A013)

3.3.1.4.8 The contractor shall review and evaluate Government Industry Data Exchange Program (GIDEP) alerts. (CDRL A011)

3.3.1.5 Conference Attendance/Support

3.3.1.5.1 The contractor shall attend up to two (2) Flight Manual Review Conferences (FMRCs) and host no more than one (1) during the task order period of performance. No more than two (2) FMRCs will be conducted at a CONUS location outside the local Oklahoma City area and will last up to five days including travel time and conference attendance. Attendance at FMRC(s) outside the local Oklahoma City area will be limited to three persons. Attendance at FMRC(s) hosted by the contractor will be limited to five persons and will last up to three days. The contractor shall prepare minutes for each conference, and an agenda and presentation material for any meeting hosted. The government will review and approve the minutes prior to distribution. (CDRLs A004, A005, A006, A014)

3.3.1.5.2 The contactor shall attend the Aircraft Airworthiness and Sustainment Conference, and annual Aircraft Structural Integrity Program (ASIP) Conference (maximum 2 participants per conference). The contractor may recommend attendance to other technical conferences or symposiums for approval by the government. Any presentation materials received at attended conferences shall be delivered to the government focal point. (CDRL A006, A014)

3.3.1.5.3 The contractor shall conduct combined task kick-off meeting and TO Guidance Conference (TOGC) within 40 calendar days after Receipt of Order (ARO). Technical Manual Contract Requirements (TMCR) / TM 86-01(Q) will be tailored between Contractor and the T.O. Manager Authority (TOMA), and updated for next OY Tech Data requirement. (CDRLs A004, A005. A006)

3.3.1.6 On-Site Liaison Engineering Support for OC-ALC A/C Maintenance Line

The contractor shall provide structures and/or systems liaison engineering/technical support on-site at OC-ALC, Tinker AFB OK to analyze and disposition structural/systems-related AFMC Form 202s, Nonconforming Technical Assistance Requests and Replies, generated during completion of Programmed Depot Maintenance (PDM) or Un-programmed Depot Level Maintenance (UDLM) and Engineering Technical Assistance Requests, generated by Field Units on C/KC-135 aircraft.

The Contractor Liaison Engineer must have an engineering degree from an ABET accredited university, have broad and in-depth knowledge, and skills in C/KC-135 structural and system related technical inquiries as well as the government AFMC form 202 process, and must have successfully completed the Boeing KC-135 Liaison Engineering Course.

(1) Liaison Engineer shall evaluate, select and apply standard techniques, procedures, and criteria to perform a task or sequence of tasks for conventional projects with complex features.

(2) Liaison Engineer shall collaboratively use judgement to determine adaptations in methods for non-routine aspects of assignments.

(3) Liaison Engineer shall work individually on small projects or portions of larger ones.

(4) Liaison Engineer shall perform moderate C/KC-135 design tasks.

(5) Liaison Engineer shall prepare portions of project documents.

(6) Liaison Engineer shall edit specifications and perform research and investigations.

The objective is to provide first and second engineering signatures on 75% of the 202s within 1 working day of submission and 85% of the 202s within 2 working days of submission with the number of 202s being worked (Work in Progress (WIP)) not exceeding 20. AFMC Forms 202 shall be evaluated, dispositioned, and coded in accordance with AFLCMC/WLT Operating Instruction (OI) 21-109 and AFMCMAN 63-1202. Engineers shall attend status and production meetings, etc. to discuss the status or disposition of AFMC Form 202 as required. Engineers shall provide repair information for all repeat 202s (dispositions with the same repair used to repair two or more identical or similar defects in a 1 year period) in contractor format to AFLCMC/WLT. The contractor shall notify the government at least five business days prior to reassignment of a liaison engineer. The government requests, a 1 to 5 ratio of liaison engineer to support the maintenance line, which averages approximately 40 aircraft at a time. (CDRL A015)

3.3.1.7 On-Site Liaison Engineering Support for OC-ALC Backshops

The contractor shall provide liaison engineering/technical support on-site at OC-ALC, Tinker AFB OK to analyze and disposition AFMC Form 202s, Nonconforming Technical Assistance Requests and Replies, generated during repair or overhaul of structural components and Management of Items Subject to Repair (MISTR) items in the AFMC “backshops”. Backshops include any maintenance shop where KC-135 parts/assemblies are overhauled and/or repaired. The objective is to provide first and second engineering signatures on 75% of the 202s within 1 working day of submission and 85% of the 202s within 2 working days of submission. The AFMC Forms 202 shall be evaluated, dispositioned, and coded in accordance with AFLCMC/WLT OI 21-109 and AFMCMAN 63-1202. The engineer shall support AFLCMC/WLT process improvement initiatives. The engineer shall interface with backshop personnel in determining adequacy of existing overhaul Statements of Work (SOWs) and recommend/generate changes to improve the quality/durability of overhauled items. The engineer shall generate repair/overhaul SOWs to support un-programmed overhaul actions. (CDRL A016)

3.3.1.8 Conversion of Repeat AFMC Form 202 Dispositions into Permanent Technical Order Repair Procedures

The contractor shall convert the repair dispositions from repeat 202s into Level III T.O. source data for inclusion in the appropriate C/KC-135 Technical Orders. The government will provide 202s to the contractor at approximately a rate of 5 per month from a list of potential candidate repeat 202s maintained by AFLCMC/WLT. The contractor shall generate and release appropriate Advanced Drawing Change Notices (ADCNs) if the repair procedures require a formal drawing change or update. The contractor shall accomplish appropriate stress/structural analyses on each repair to ensure its damage tolerance and durability.

The contractor shall provide the new procedures to the government for tabletop validation/verification and/or prototyping on an aircraft undergoing PDM. The contractor shall incorporate any changes or lessons learned during the validation/verification or prototyping efforts in the T.O source data prior to delivery to the government. The contractor shall submit each repair procedure in accordance with the CDRL. (CDRL A017)

3.3.1.9 Evaluation of Commercial 7X7 Airworthiness/Service Publications for C/KC-135 Applicability

3.3.1.9.1 The contractor shall review, evaluate, and provide recommended actions to the -135 fleet for new/revised 707, 727, 737- 100/200/300/400/500 and 747-100/200 Service Bulletins (SBs), Airworthiness Directives (ADs), Service Letters (SLs), Structural Item Interim Advisories (SIIAs) and Special Airworthiness Information Bulletins (SAIBs) that are non-operator specific for applicability to the –135 aircraft. The review/evaluation shall be accomplished in two phases:

(a) Phase 1: For every commercial service publication, the contractor shall determine whether the publication is Applicable - Recommended, Applicable – Not Recommend or Not Applicable – Not Recommended for implementation on the C/KC-135, definitions included in CDRL. The contractor shall notify the government by e-mail within 24 hours of receiving an AD and provide the initial evaluation within three calendar days; the contractor shall notify the government via e-mail within three calendar days of receiving any other service publication listed above and shall provide the initial evaluation within 10 calendar days. All associated documents shall be delivered to the government. In addition, all documents shall be uploaded to the appropriate location in MATRIX. This requirement shall be completed in accordance with the CDRL. (CDRL A018)

(b) Phase 2: For up to six commercial service publications identified by the government for further evaluation, the contractor shall provide information in accordance with the CDRL. The contractor shall provide this additional information within 10 calendar days of being requested to develop it. The contractor’s MATRIX system may be used to notify the government when Phase 2 evaluations are completed. (CDRL A019)

3.3.1.9.2 The contractor shall provide a focal point to support AFLCMC/WLTAC in coordinating the identification of commercial 7X7 airworthiness/maintenance requirements documents for C/KC-135 applicability and tracking the development and implementation of any engineering and maintenance actions required to mitigate them. The focal shall maintain and update a master schedule of all documents reviewed by the contractor and the current status at least quarterly. (CDRL A020)

3.3.1.10 Maintenance of C/KC-135 Inspection Requirements Documents

3.3.1.10.1 The contractor shall provide inputs concerning T.O. 1C-135-6 corrections, additions and clarification submitted from C/KC-135 field units on Recommended Change (RC) Evaluation Requests (previously known as AFTO Form 22s) and coordinate recommended approvals/disapprovals answers for them with the approval/disapproval authority within AFLCMC/WLTAE.

3.3.1.10.2 The contractor shall review RC Evaluation Request for proposed changes, updates and revisions to the C/KC- 135 inspection technical orders (T.O. 1C-135-6 and all associated work cards), Work Unit Code manual (1C-135-06), and Equipment Inventory List technical order (1C-135-21), conduct preliminary evaluations of them and route proposed changes, updates and revisions to the appropriate approving authority. The RC Evaluation Request will be provided to the contractor by the AFLCMC/WLTAE T.O. 1C-135-6 point of contact. The contractor shall complete the change evaluations according the following schedule from the date of request. (CDRL A021)

3.3.1.10.3 The contractor shall prepare Recommended Change (RC) Instructions (previously known as an AFMC Form 252, T.O. Publication Change Request), for each specific technical order change and T.O. source data or supporting documentation required to be submitted with them. The contractor shall forward copies of the RC Instructions and supporting documentation to the Technical Content Manager (TCM) for incorporation into the T.O within 60 calendar days of identifying that a publication change is required. (CDRL A022)

3.3.1.10.4 Update/maintain the currency of the C/KC-135 Inspection Requirements Document (IRD) with new/revised maintenance inspection requirements. Data sources used for updating the IRD will include, at a minimum, Airworthiness/Service Publication reviews, ASIP details, MECSIP findings, Analytical Condition Inspection (ACI) details, PDM SOW and T.O. 1C-135-6. Only routine changes to these documents will be incorporated into the IRD. Substantial/extensive changes to these documents shall be accomplished as stand-alone efforts on follow-on TAs. (CDRL A023)

3.3.1.11 Maintenance/Sustainment of Historical Files and Electronic Databases

3.3.1.11.1 The contractor shall maintain a historical file of fleet support records such as interim letters, closing actions, status reports, funds reports, etc. The contractor shall maintain paper and electronic records on safety issues to retrieve information on past incidents. The contractor shall establish backup and recovery process that assure the electronic records will not experience catastrophic loss and can be transferred completely to the Program Engineers at the end of the contract.

3.3.1.11.2 The contactor shall sustain/maintain the MATRIX electronic database, including its hardware components and software, to allow storage and retrieval of TA documentation (statements of work, interim letters, closing letters, deliverables, etc.) and accomplish programmatic functions needed to execute the requirements of this PWS. The contractor shall accomplish improvements and/or upgrades MATRIX as required to maintain its currency, and functionality.

3.3.1.11.3 The contractor shall maintain C/KC-135 engineering/technical data files at the contractor’s facility as specified in a specific TA. This file shall consist of both contractor developed data and data provided by the Air Force. Ownership and rights to the data remains unchanged. The contractor shall have no additional rights in the data based on its custodial role. The government shall retain all existing rights and responsibilities with respect to government provided data. Data provided by the government will be treated as Government Furnished Information (GFI) subject to DFARS 252.227-7025.

3.3.1.11.4 If the follow-on contractor is not the incumbent contractor, or the government terminates the contract at any time, the incumbent contractor shall participate in and complete a phase-out joint inventory no later than (10) calendar days prior to the end of the last performance period. (CDRL A024)

3.3.1.11.5 When requested by the government, the contractor shall incorporate AFLCMC/WLT generated AFMC Form 3925s (Engineering Order), AFMC Form 3926s (Engineering Order - Continuation Sheet) and/or AFMC Form 3927s (Engineering Order – Parts List Changes) into the C/KC-135 master drawings maintained by the contractor in accordance with the CDRL. The contractor shall provide the name and e-mail address of the POC to receive these documents within 10 calendar days of contract award. (CDRLs A025, A026)

3.3.1.11.6 When requested by the government, the contractor shall provide reference services, to maintain and provide copies of all Boeing specification documents and drawings, inclusive of Boeing documents referenced on USAF documents drawing and documents to AFLCMC/WLT, as requested. Data furnished to the Air Force under this requirement shall be delivered in accordance with the CDRL. (CDRL A027)

3.3.1.11.7 The contractor shall submit digital copies of updated/revised C/KC-135 drawings not already being delivered under other tasking’s or TAs to the JEDMICS office at Tinker AFB OK. (Note: For the purposes of this PWS, JEDMICS is considered the only drawing database that reflects the current configurations of C/KC- 135 systems/components). (CDRL A028)

3.3.1.12 Liaison Engineering Support for Advanced PDM Evaluation and Planning

The contractor shall provide experienced structural liaison engineering support to evaluate/determine the condition of up to 30, but a minimum of 20 KC-135R/T aircraft (based on the equivalency of two man-years) at CONUS and OCONUS locations one year prior to their input to Programmed Depot Maintenance (PDM). The contractor engineer(s) shall provide a tail by tail summary report detailing expected Major Structural Repairs (MSR) and non-MSRs for planning to use in preparation for PDM in accordance with CDRL. (CDRL A029)

3.3.1.12.1 The contractor shall inspect aircraft undergoing periodic inspection or other maintenance actions for indications of problems/deficiencies that could impact the flow of the aircraft through PDM in conjunction with base personnel. Aircraft teardowns in excess of normal field scheduled maintenance activities will not be accomplished to complete this assessment. In the event, additional inspections are warranted as indicated by data search, additional aircraft teardowns can be accomplished and with pre-coordinated unit concurrence.

3.3.1.12.2 The contractor shall analyze/trend the discrepancy data collected during the periodic inspections and provide a quarterly report in accordance with CDRL.

Contractor on-site personnel shall assist the maintenance group as necessary during inspections when applicable, in the creation of the of non-conformance -107 reports (TO 00-25-107). If a discrepancy is identified during the inspection, a simple step-by-step repair procedure to address the defect shall be submitted to the unit to use as guide for the -107 development. Repair sketches and available material/fasteners for performing the repair shall be considered during the repair development process. The authority to disposition the discrepancy shall reside with the KC-135 Program Office. (CDRL A030)

3.3.1.12.3 Travel (CR-No Fee) is authorized to support up to twenty (20) trips to CONUS field locations and up to ten (10) trips to OCONUS field locations during USAF performed Periodic Inspections (IAW 1C-135-6WC-2) or other maintenance events for a total of up to thirty (30) trips.

3.3.2 Recurring Technical Support (Cost Plus Fixed Fee Tasks)

3.3.2.1 Request for Technical Information

The contractor shall provide engineering/technical assistance to support C/KC-135 maintainers on a daily basis for repetitive/rapid response tasks to support Requests for Technical Inquiries, Modification Support, and Technical Data Reviews/Updates. (CDRL A031)

3.3.2.1.1 The contractor shall provide timely Response to Technical Inquiries (RTIs) as requested by government personnel concerning structural, electrical, or mechanical system issues from AFLCMC/WLT. These inquiries will include assessments and information on questions relating to design data, flight test data, qualification tests, performance, reliability, or other areas of interest or concern.

The USAF has developed an RTI module within the Government’s FSID site. Boeing shall respond to USAF RTI requests received within FSID and answer follow up questions/clarifications when an RTI is demoted back to Boeing for more explanation. RTIs that are answered in FSID are not required to be part of the RTI CDRL requirement. Any RTIs demoted back to Boeing in FSID are not considered a CDRL rework or rejection.

(a) Level I RTIs can be accomplished in less than 40 labor hours per occurrence and may be authorized by government PCO, Contracting Officer’s Representative (COR), government program manager, or government engineer personnel within the KC-135 Program Office. Big Safari Level I RTIs require email coordination with 645th AESS, Big Safari Program Manager Liaison at Tinker in L3 Harris, and approved by the Government.

(b) Level II RTIs that require more than 40 labor hours but less than 250 man-hours per occurrence to complete will not be accomplished without prior authorization from the PCO or a COR. Big Safari Level II RTIs require Big Safari Program Manager Liaison at Tinker approval/submission.

(c) Level III RTIs that require more than 251 labor hours but less than 1,000 labor hours to complete will be not be accomplished without prior authorization from the PCO. RTIs that require more than 1,000 labor hours to complete will be accomplished as non-recurring TAs under the applicable paragraph of this PWS. Engineering requests shall not be segregated or phased as multiple RTIs for same or similar engineering investigations to avoid appropriate level approvals. Big Safari Level III RTIs require PCO approval.

3.3.2.1.2 FMS RTI:

No request will incur more than 100 labor hours, without prior PCO approval. If an RTI is identified to exceed 100 labor hours, the contractor will notify the FMS Office – TCP engineer, or other TCP technical personnel with recommendation of actions or labor hours required to complete the RTI. When authorized by the PCO, requests that require more than 100 labor hours may be accomplished until a Task Assignment (TA) is established.

a) Priority 1 (P1) – Grounding, Safety, or Work stoppage (flight line) requires 24 hour status update

b) Priority 2 (P2) – Potential Grounding, Safety, Imminent work stoppage requires no greater than 72 hours status

c) Priority 3 (P3) – Possible work stoppage (PDM impact) requires no greater than 5 days status update

d) Priority 4 (P4) – No immediate impact/General inquires - requires no greater than 20 day status update

If no priority level is identified in the request, it will be worked as a priority level 4.

Status updates will be provided to the KC-135 FMS Office in accordance with their priority. However, for any identified unsafe conditions, Boeing shall inform the FMS Office and the respective Foreign Liaison Officer, within three (3) days after identifying an unsafe condition.

France-French.FLOTinker@coxinet.net Chile-gewert@fach.mil.cl Turkey-TURAF.FLO.TINKER@hvkk.tsk.tr

All requests will be worked to provide the quickest and most accurate response, and all responses will include at a minimum; analysis determining root cause(s), proposed corrective action, and/or fatigue problems, or additional required inspections associated with repair actions.

3.3.2.1.3 FMS Emergency RTI; Aircraft on Ground (AOG), and Safety related inquires

Each emergency inquiry will be limited to 50 labor hours. If an emergency inquiry is identified to exceed more than 50 labor hours, the contractor will notify the FMS Office TCP engineer or TCP supervision with recommendation and draft TA required to complete the inquiry. When authorized by PCO, Emergency inquiries identified to exceed 50 hours may be accomplished, subject to limitation of cost, until a formal tasking is established for a non-recurring effort. The contractor shall be reimbursed, subject to limitation of cost, up to 50 labor hours on each emergency inquiry on the established TA. When the TA is formalized, cost for the effort will be reallocated to the non-recurring TA.

3.3.2.1.4 Modification Support

The contractor shall perform structural and aerodynamic analysis in support of KC-135 modification programs, which may require multiple iterations of a government or a third party contractor design. Analysis will determine if the design is structurally and aerodynamically acceptable, meeting all aerodynamic and design load requirements. If the design does not meet acceptable limits, contractor shall provide recommendations for bringing the design within acceptable limits.

3.3.2.1.5 Tech Data Review/Update

The contractor may be required, as a result of work conducted in support of recurring tasks, to review and update existing technical data. The contractor may be required to provide a list of impacted technical data. Requests for such data will be limited to that required for support of the aircraft identified in this contract. The contractor may be required to develop and deliver technical source data in response to new operational, maintenance or logistic procedures/requirements. Delivery method will be IAW with CDRL for required effort. Delivery of pre-publication technical order (TO) source data shall be not less than 98% accurate and error free. Delivery of final publication shall be 100% accurate and error free. (CDRL A032)

3.3.2.1.6 RTI Material

The contractor may be required to perform RTI efforts such as site surveys, engineering design, technical data development, TCTO preparation, fabrication, kit procurement, installation, testing, military certification efforts, and delivery of reports that require the procurement of material.

3.3.2.2 Weapon System Integrity Program Support

3.3.2.2.1 Aircraft Structural Integrity Program (ASIP) USAF:

The contractor shall conduct and maintain an ASIP IAW Air Force Instruction (AFI) 63-101 and MIL-STD-1530D_ch1

The contractor shall:

(1) Update and maintain the currency of the C/KC-135 Individual Aircraft Tracking Program (IATP) with AFTO Form 76 data available through Tinker Aircraft Structural Integrity Management Information System (ASIMIS) office, findings from applicable inspections and information concerning major structural repairs and/or replacements

3.3.2.2.1.1. The contractor shall provide software engineering support to the C/KC-135 electronic library, accomplish minor modifications to the Individual Aircraft Tracking Program/Force Structure Maintenance Plan (IATP/FSMP) analysis tools and establish contractual vehicles as required to secure access to vendor/supplier proprietary engineering specification, drawings, blueprints and/or other data required to complete the requirements of this PWS.

3.3.2.2.1.2. Aircraft Structural Integrity Program (ASIP) FMS

(a) The contractor shall receive and process flight data records.

· Data shall be received by the TCG (AFLCMC/WLTNI) in digitized, or hard copy batch files from each FMS version of Form AFTO76.

· The Contractor shall enter the data into the IATP database and test for data errors

· The Contractor shall correct data with warnings and errors when the level of warning/errors is below 20%. The corrected data is to be entered into the respective C/KC-135FMS IATP database

· If more than 20% of the data is required to be corrected, the batch wile will be returned to the respective FMS customer without being processed. The FMS respective customer will reduce the incorrect data to less than 20% error or warnings before returning.

· Corrections are to be made in accordance with the respective FMS Customers; Validation Rules Form 76

· Corrected data files shall be maintained and provided in the final report

(b) Maintain FMS Customer’s respective IATP database

(c) Provide the TCG with Force Structure Maintenance Plan (FSMP) inspection details for scheduled or unscheduled request. (CDRL A036)

· Inspection requirement details will be provided IAW FMS Customer Requirements(France- CSTO FRIC-135-36 Figure 8-1-7, Chile- CSTO CI1C-135-36 Figure 8-1-7 Form 38, Turkey-Form 38)

· Inspection requirement details numbers will be provided no less than two weeks prior to aircraft inspection schedule date or two weeks after unscheduled requires (email) for inspections.

· Unscheduled Inspections - Estimate no more than one unscheduled inspection would per 12 month period

· Scheduled Inspections – Estimate 14 scheduled inspections for Mid PDM and/or PDM, during POP. Tail number request will be provided yearly by the FMS Customer. Boeing is to provide FSMP inspection within three weeks of aircraft input date.

(d) Receive and process record of inspection IAW FMS Customer requirements (France – FR1C-135-36, Figure 8-1-8, and Figure 8-1-7, Form 38A, or FAF source data equivalent, Chile- Chile- CSTO CI1C-135-36 Figure 8-1-7 Form 38, and Figure 8-1-8, Form 38A Turkey Form 38 and Form 38A)

· The contractor shall enter record of inspection data in the respective ASIP IATP database

· The contractor shall retain digitized copy for report purposes.

(e) The Contractor shall conduct analysis on the mission profile data and inspection data reporting results at the midterm interval and final reports. Identify and provide any adverse conditions or trends in usage of the FMS Customer Fleet, KC-135R, and C-135FR, FACh KC-135, TurAF KC-135R, which may have an impact on structural integrity, service life, or possible increase of maintenance to the aircraft.

(f) Reports- Intermediate and Final

· Intermediate Reports will be provided to USAF within two weeks upon request

· Intermediate reports request will align with USAF Technical Coordination Program Dates, to be determined by the FMS Customer, estimated one meeting per year (CDRL A037)

· Intermediate reports will consist of List of Batch Data collected and Calendar Year Quarter (CYQ) data processed (data collection and processed between reports). Analysis of historical Form 38 defects report and any anticipation the effects on the FMS Customer Fleet. Identify any trends that could affect the FMS Customer Fleet Operations and/or Maintenance

· Final Reports- shall consist of a brief summary of the results from the data analysis conducted under Paragraph (e), any data processed since last intermediate report, and last CYQ data processed. (CDRL A038)

· Closing Letter- All documents shall be tallied for submission to the respective FMS Customer. (CDRL A039)

3.3.2.2.2 Mechanical Equipment and Subsystems Integrity Program (MECSIP):

The contractor shall provide engineering/technical support to assist the KC-135 System Program Manager in maintaining a proactive and effective MECSIP for all mechanical subsystems, equipment and components of the KC-135R/T aircraft. The contractor shall comply with the latest MECSIP processes and procedures per MIL-STD-1798C.

3.3.2.2.2.1. The contractor shall maintain the Critical Components Lists (CCLs) using established CCL methodology, and selected structural components as directed by the MECSIP manager. The contractor shall establish and maintain electronic server access to the CCLs. The contractor shall provide the updated CCLs to the government MECSIP focal point in accordance with CDRL. (CDRL A040)

3.3.2.2.2.2. The contractor shall monitor all mechanical systems and subsystems using established CCL methodology. For those components with Mean Time Between Failure Type I (MTBF-1) that fall below 80% of the established Mean Acceptable Performance (MAP) value, issue CCL performance degradation alerts for those components with a validated degradation correlation that include recommendations for continued monitoring or further assessment in accordance with paragraph 3.3.2.2.2.3 below. The contractor shall issue alerts in accordance with CDRL. (CDRL A041)

3.3.2.2.2.3. The contractor shall develop a plan and support completion of specific tasks as determined by the government MECSIP focal point included in MIL-STD-1798C Table 1 MECSIP Tasks. Examples include reviewing the -06 Work Unit Code (WUC) manual for accuracy, ensuring technical data is available and current, developing safety and mission critical component inspection and/or replacement intervals, monitoring component repairs, and overhauls. The contractor shall work and monitor the status of open actions tracked in the MATRIX tool (reference Paragraph 3.3.2.2.2.14). (CDRL A042)

3.3.2.2.2.4. The contractor shall provide a prioritized list of all candidate initiatives to improve safety or Reliability, Maintainability & Availability (RM&A) of current mechanical/electrical systems, subsystems, equipment or components. The list shall include a recommendation whether or not serially tracking system components is appropriate based on the particular situation. (CDRL A043)

3.3.2.2.2.5. The contractor shall update/ maintain / provide the MECSIP “Top Ten” components list using the established MECSIP prioritization methodology. The contractor shall generate a cost of unreliability for components on this list in terms of annual dollar costs, Maintenance Man-hours (MMH), Non Mission Capable (NMC) time and part replacement/repair/overhaul costs. (CDRL A044)

3.3.2.2.2.6. The contractor shall publish an annual MECSIP systems health assessment report that summarizes the top MECSIP drivers for the year including TNMCM (Total Non-Mission Capable Maintenance), inherent failures, cannibalizations, aborts, cost of unreliability, and change in performance/MTBF alerts. Additional topics included in this report shall be determined by the government MECSIP focal point. The contractor shall make it available for review on the electronic server. (CDRL A045)

3.3.2.2.2.7. The contractor shall identify changes/updates to Joint Reliability Availability Management System (JRAMS), Life Cycle Management Process (LCMP), FSID or other computer databases to support, improve or streamline the generation or storage of data required by subparagraphs 3.3.2.2.2.1 through 3.3.2.2.2.14 to the government MECSIP focal point. (CDRL A046)

3.3.2.2.2.8. The contractor shall accomplish MECSIP Aircraft System Task (AST) analysis on specific KC-135 mechanical systems anomalies and/or deficiencies identified through MECSIP monitoring and assessment, aircraft mishaps, Safety Investigation Board recommendations, Product Improvement Working Group (PIWG) action items, Engineering Investigation Deficiency Reports/Product Quality Deficiency Reports (EIDRs/PQDRs), etc. as requested by the government MECSIP focal point and approved by the COR. All ASTs will be worked to provide the quickest and most accurate response, all assessments will include at a minimum; analysis determining root cause(s) and proposed corrective action. Each AST will be limited to 500 labor hours. If an AST is identified to exceed more than 500 labor hours, the contractor will notify the MECSIP focal and COR with AST completion recommendations. Examples of assessments that may be included under this effort include Reliability Assessments, Risk Assessments, Service Life Agreements, and Life Cycle Assessments (CDRL A047)

3.3.2.2.2.9. The contractor shall run a scenario on each previously developed fuel/hydraulic model and sub-model. The run times shall be recorded and reported to the government focal. The contractor will study the user guides provided for the latest, most current model and make any updates or improvements needed, from the perspective of the user. The guides shall be released in the Boeing document system. The high and low fidelity models shall be revised to simulate specific operational scenarios and proposed modifications. Minor improvements and corrections shall be identified and implemented. The contractor shall study various means to improve the run time of the models, and assist AFLCMC/WLT in implementation. The executable software code for low fidelity modules (if changed) and related user’s guides shall be delivered to the government in accordance with CDRL. The contractor shall conduct a WGM to demonstrate the capabilities, operation and use of the low fidelity and high fidelity models to the government. The contractor shall continue to stay current of changes in Geoduck and other related software changes, implementing updated versions if required. (CDRLs A048, A004, A005)

3.3.2.2.2.10. The contractor shall determine potential solutions for safety issues or RM&A opportunities that are either identified as part of the MECSIP process or other activities as requested by the government MECSIP focal point. Solutions must be validated by quantitative data through detailed, comprehensive root cause analyses ensuring proper solutions to the problems are identified. There are no limitations or restrictions to the potential solutions that may be proposed to resolve the problems; i.e., they may include parts upgrades, procedural changes, system modifications, etc.