DRAFT CKI 2 PWS 20240701.pdf

PERFORMANCE WORK STATEMENT (PWS)

FOR

C-130J BLOCK UPGRADE (BU) 7.0/8.1 CONTRACTOR KIT

INSTALLATION (CKI) II

DRAFT BASIC PWS

DATE: 1 July 2024

PREPARING ORGANIZATION:

AFLCMC/MOBILITY DIRECTORATE

C-130 HERCULES DIVISION

C-130J PROGRAM BRANCH

WRIGHT-PATTERSON AFB OH 45433-7233

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SCOPE

3.0 PRE-EXECUTION REQUIREMENTS

3.1 Kick-Off

3.2 Scheduling

3.3 Program Planning and General Requirements

3.4 Communications/Status Reports/Travel

4.0 AIRCRAFT PRE-ARRIVAL REQUIREMENTS

4.1 Deliveries, Inventory, and Inspection

4.2 Contractor Furnished Equipment (CFE)

5.0 EXECUTION: AIRCRAFT ARRIVAL AND INSTALLATION

5.1 Preparation for Aircraft Arrival

5.2 Kit Installation

6.0 MAINTENANCE ACTIONS

6.1 Maintenance Records, Forms and Publications

6.2 Repair and Replenish

6.3 Reporting Maintenance Actions

6.4 Non-BU 7.0/8.1 Aircraft Maintenance Actions and Discrepancies

6.5 Loss, Damage, and Destruction (LDD)

7.0 ACCEPTANCE TEST PROCEDURES (ATP) THROUGH COMPLETION

7.1 Test Plan/Checklist and Acceptance Test Report

7.2 Record Review

7.3 Test, Inspections, and Completion

7.4 Aircraft Transfer and Post-Install Ferry Support

8.0 ADDITIONAL WORK

9.0 SECURITY

9.1 General

9.2 Communication Security (COMSEC)

9.3 Physical Security

9.4 Controlled/Restricted Areas

9.5 Operations Security (OPSEC)

10.0 OTHER GENERAL REQUIREMENTS

10.1 Government Furnished Property (GFP) Management

10.2 Support from Outside Entities

10.3 Associate Contractor Agreement (ACA)

10.4 Transfer/Transportation Requirements for Foreign Contractors

11.0 QUALITY REQUIREMENTS

11.1 Contractor Point of Contact (POC)

11.2 Services Summary

11.3 Quality Management System

12.0 DATA

12.1 Contract Data Requirement List (CDRL) Deliveries

12.2 Data Accession List (DAL)

ATTACHMENT 1: PLANNED AIRCRAFT INDUCTIONS PER YEAR

ATTACHMENT 2: KICK-OFF CRITERIA

ATTACHMENT 3: Installation Readiness Review (IRR) CRITERIA

ATTACHMENT 4: ACRONYM LIST

ATTACHMENT 5: DATA DICTIONARY

ATTACHMENT 6: C-130J WEIGHT AND BALANCE REQUIREMENTS

ATTACHMENT 7: O&A PROCEDURES

ATTACHMENT 8: GFE LIST

ATTACHMENT 9: CKI AIRCRAFT CARE AND FEEDING

ATTACHMENT 10: PRICING MATRIX

1.0 INTRODUCTION

This Performance Work Statement (PWS) defines the requirements for Contractor services to complete Block Upgrade (BU) 7.0/8.1 kit, and delta kit, installations onto various United States

Air Force (USAF) C-130J/-30, HC-130J, and WC-130J aircraft. On applicable C-130J-30 (Stretch) aircraft, the Contractor shall accomplish the Time Compliance Technical Orders (TCTO) for

Dynamic Re-tasking Capability (DRC) De-confliction, on up to 25 aircraft. The Contractor shall also successfully install Group A and Group B BU 7.0/8.1 on up to 123 aircraft in accordance with

(IAW) TCTOs and associated Technical Orders (TO); successfully accomplish the Acceptance

Test Procedures (ATP) with Defense Contracts Management Agency’s (DCMA) sign-off of the

DD250 within the contract schedule; and DD1149 transfer back to the owning USAF Major

Command (MAJCOM). For all actions completed under this contract, “Work Scope” shall refer to provisions of the Basic contract. The owning MAJCOMs are as follows:

Air Mobility Command (AMC)

Air Education and Training Command (AETC)

Air Force Reserve Command (AFRC)

Air National Guard (ANG)

Pacific Air Forces (PACAF)

United States Air Forces in Europe (USAFE)

Air Combat Command (ACC)

2.0 SCOPE

The work scope shall consist of the installation of Government-furnished BU 7.0/8.1 modification kits across two (2) C-130J variants, C-130J (Short) and C-130J-30 (Stretch,) as well as the HC-

130J, and WC-130J aircraft IAW TCTOs and associated TOs. The Contractor shall complete the installation, employing Government-furnished installation kits and identified support equipment, and shall return the aircraft to flyable status IAW established practices, procedures, and instructions documented in approved USAF C-130J TOs and this Basic PWS.

For approximately 23-25 aircraft that have DRC included on the aircraft, the work scope shall also consist of removing DRC conflicting hardware and components, installing Government-furnished

DRC de-confliction kits, and manufacturing cargo compartment insulation blankets concurrent with the BU 7.0/8.1 modification. The Contractor shall manufacture the cargo compartment insulation blankets on site, to include all necessary snaps, buttons, fasteners, and details required to return the aircraft to it’s original configuration.

As a complement to the installation, per the TCTOs, the work scope shall include kit integrity, change management, and aircraft knowledge and maintenance to include but not limited to:

- kit receipt, inspection, inventory and warehousing

- aircraft receipt and aircraft induction (DD1149)

- aircraft arrival inspection and preservation tasks

- technical data management

- installation scheduling

- execution of preservation kits

- identification and resolution of aircraft maintenance actions and issues (can include non-

BU 7.0/8.1 actions and issues)

- quality assurance checks

- successful completion of prescribed Acceptance Test Procedures (ATP) (culminating in

Government acceptance and DD250 signature)

- aircraft return to USAF via DD1149

3.0 PRE-EXECUTION REQUIREMENTS

3.1 Kick-Off

3.1.1 Kick-Off Meeting. The Contractor shall plan, schedule, and execute a kick-off meeting

No Later Than (NLT) sixty (60) calendar days in advance of first aircraft arrival (see Attachment

1, Aircraft Schedule). The kick-off meeting shall include, at a minimum all items documented in Attachment 2, Kick-Off Criteria. The Contractor shall provide the C-130J Program

Management Office (PMO) a target date for the kick-off meeting at the initial install site NLT thirty (30) business days after award notification. The Contractor shall develop and deliver a meeting agenda, briefing slides, and minutes for the Kick-Off Meeting. (A001, DI-ADMN-

81249C, CONFERENCE AGENDA; A002, DI-ADMN-81373, PRESENTATION

MATERIALS; A003, DI-ADMN-81250C, CONFERENCE MINUTES)

3.1.2 DCMA Site Survey. DCMA will conduct a site survey of the modification location prior to aircraft arrival. The Contractor shall make ready for DCMA all procedures in accordance with DCMA INST 8210.1. DCMA will review the site and procedures to ensure the Contractor can meet the PWS and DCMA INST 8210.1 (series) requirements before aircraft arrival at any/all locations the Contractor will perform modifications.

3.1.3 Installation Readiness Review. The Contractor shall plan, schedule, and execute an

Installation Readiness Review (IRR) at least forty-five (45) calendar days in advance of first aircraft arrival (Attachment 3, IRR Criteria). The United States Government (USG) will travel to the Installation Site ten (10) days prior to the IRR for an on-site review. The site review and

IRR meeting shall enable USG verification of the status of the Contractor’s infrastructure, execution processes (e.g., scheduling, inventory management, acceptance test procedures), Contractor-furnished equipment, manpower (including training, recruiting, retention, relevant experience (large aircraft infrastructure) and certifications (i.e. airframe and power plant)) and use of qualified maintenance technicians and facility/personnel security in advance of kit and aircraft arrival. The USG security team will conduct a full review of security on the premises. For scheduling purposes, the Contractor shall provide the C-130J PMO with a target date for the install-site IRR meeting NLT thirty (30) business days after award notification.

The IRR completion criteria, verification approaches, and corrective action procedures are documented in Attachment 3, IRR Criteria. In support of the IRR meeting, the Contractor shall develop and deliver a meeting agenda, briefing slides, and minutes. (A001, DI-ADMN-81249C, CONFERENCE AGENDA; A002, DI-ADMN-81373, PRESENTATION MATERIALS;

A003, DI-ADMN-81250C, CONFERENCE MINUTES)

3.2 Scheduling

3.2.1 Integrated Master Schedule (IMS). Using Attachment 1, Aircraft Schedule, as a reference, the Contractor shall develop, coordinate, and execute an IMS for all assigned installations. The standard installation IMS shall be delivered to the C-130 PMO NLT thirty (30) calendar days after contract award. At a minimum, this schedule shall define the sequencing of planned aircraft inductions, the details of the installation cycle (from aircraft DD149 through

DD250) by tail number, and pre-defined touch points (defined by Contractor and approved by the

USG) to support quality assurance inspections, and planned contract deliverables. A milestone shall be included for kit arrival in the IMS showing a minimum of 30 days in advance of a/c arrival.

Arrival date and induction date should be two separate activities (although they may share the same date.) Similarly, the DD250 date and departure date should also be two separate activities.

(A004, DI-MGMT-81861C/T, INTEGRATED MASTER SCHEDULE)

3.2.2 Integrated Master Schedule (IMS) Maintenance. The Contractor shall update and maintain the USG-approved IMS to manage, report, and forecast program activities for each aircraft. The Contractor shall update the IMS regularly with changes, out-of-cycle actions, additions of Over and Above (O&A) activities, actual start/finish dates, and rationale and impacts to the installation cycle. The updated IMS will be delivered monthly for an accurate accounting of program installation activities and their schedules to give an accounting of each aircraft’s activities while at the installation location. (A004, DI-MGMT-81861C/T, INTEGRATED MASTER

SCHEDULE)

3.3 Program Planning and General Requirements

3.3.1 TCTO Instructions. The Contractor shall complete installation IAW applicable

TCTOs, TOs, and related publications, instructions, and procedures. As a complement, all applicable technical manuals, forms, publications, bulletins, specifications, standards, and field procedures guides shall be utilized. When/if a document provided by the USG is revised, supplemented, replaced or rescinded, the Contractor, upon notification or receipt of it, shall comply with the change(s). The Contractor shall review and provide potential impacts and rationale for non-compliance to the USG NLT three (3) business days.

3.3.2 Contractor Risk Management Plan. The Contractor shall develop and submit a Risk

Management Plan IAW Air Force Instruction (AFI) 63-101/20-101 or Contractor equivalent instruction that will be used to monitor risks associated with management, cost, schedule, and performance of the contract. The Contractor shall provide a current summary of risks and watch items that identify: the risk item number, title, description, risk levels, and mitigation/reduction steps for each risk. (A007, DI-MGMT-81808/T, CONTRACTOR’S RISK MANAGEMENT

PLAN; A008, DI-MGMT-81809, RISK MANAGEMENT STATUS REPORT (RMSR))

3.3.3 Configuration Management (CM). The Contractor shall implement, utilize, maintain, and fully comply with fundamental configuration management practices and procedures as part of this modification for the C-130J Program. At a minimum, the Contractor shall have documented processes that addresses the following:

3.3.3.1 Configuration Planning. The Contractor shall apply the appropriate level of

CM functions throughout the modification. Tailored CM activities/processes for the modification shall be documented in the Configuration Change Management Plan deliverable in Section 3.3.3.4 for kit installation.

3.3.3.2 Configuration Identification. The Contractor shall maintain the current configuration identification of the bill of material, modification drawings and TCTOs as listed in the installation kit for each aircraft. The Contractor shall also validate the current configuration documentation is being used to modify the aircraft.

3.3.3.3 Baseline Management. The Product Baseline is established by the Kit

Contents and TCTOs. A Bill of Material and Modification drawings for each installation are delivered in the installation kit. Changes to the baseline can only be changed through a formal configuration change management process.

3.3.3.4 Configuration Change Management. The Contractor shall establish and document a configuration change management process that addresses baseline issues, questions, and recommended changes. (A015, DI-SESS-80858D, SUPPLIER CONFIGURATION

MANAGEMENT PLAN) A change request form shall be raised for all requested baseline changes. Each change request form shall have a unique identifier to track the request for change.

The change request form must include the following information:

• Title

• Scope of the Issue o Aircraft Type o Aircraft Serial Number o Tail Number o Author o Approver

• Reference List

• Description of Issue

• Suggested Disposition

3.3.3.5 Configuration Status Accounting. The Contractor shall maintain a

Configuration Status Accounting (CSA) system that provides tracking and reporting of configuration documentation changes, tracks configuration items according to the TCTO at aircraft induction and makes this information available to the USG.

3.3.4 Engineering Support. The Contractor shall provide engineering support. The

Contractor shall assess drawings and TOs/TCTOs to prepare for the modification. The Contractor shall evaluate any discrepancies in work, the aircraft, documentation, and issues with the aircraft

(to include both mod and non-mod related). The Contractor shall suggest proper resolution of the issues according to the descriptions in this document. The Contractor shall assess work changes as updated guidance is received from the USG (i.e. TOs/TCTOs) when software or engineering changes result in a directional change. If necessary, the Contractor shall propose technical changes as an Engineering Change Proposal (ECP). (A014, DI-SESS-80639E/T, ENGINEERING

CHANGE PROPOSALS)

3.3.5 Contract Change Proposals (CCPs). Non-technical contract changes shall be prepared as CCPs. (A009, DI-ADMN-81401C/T, CONTRACT CHANGE PROPOSALS)

3.3.6 Request for Shortfall/Variance. The Contractor shall propose and document all non-conformances from the specified modification requirements via a Shortfall/Variance (a.k.a.

Request for Deviation/Waiver) for approval by the USG. The USG may require monetary withholds against the Contractor for any Shortfall/Variance until the issue is corrected. Shortfalls and Variances shall be tracked and made available to USG. (A010, DI-SESS-80640E/T, REQUEST FOR VARIANCE)

3.4 Communications/Status Reports/Travel

3.4.1 Communications Plan and Program Management Reviews (PMRs). The

Contractor shall develop their Communications Plan for kit installation requirements. The

Contractor shall plan for delivery of CDRLs, at least one (1) PMR per year, and at least two (2) weekly meetings for aircraft status (1 with the C-130J PMO and 1 with mod sites, MAJCOMs and

C-130J PMO). The Contractor may supplement this information with other content that affords

USG insight into the installation progress (by tail number), and proactive coordination and mitigation of issues impacting the installation schedule. Events that occur impacting the program

(schedule, performance) must be brought to the C-130J PMO attention NLT one (1) business day by either email or telecom. In such events, the Contractor shall document the event and provide a get-well plan to include a schedule for corrective action NLT three (3) business days after notification. The Contractor shall respond to all USG requests for information NLT three (3) business days of USG inquiry. The Contractor shall develop and deliver a meeting agenda, briefing slides, and minutes for the PMR (held at the Contractor’s Facilities). (A001, DI-ADMN-81249C, CONFERENCE AGENDA; A002, DI-ADMN-81373, PRESENTATION MATERIALS;

A003, DI-ADMN-81250C, CONFERENCE MINUTES)

3.4.2 Monthly Status Report (MSR). The Contractor shall generate and provide a MSR which includes the overall project status. The MSR shall include the technical activities that have been accomplished, objectives of efforts, results of efforts, identification of major problems/deficiencies with impact, and recommended solutions. (A005, DI-MGMT-80368A/T, MONTHLY STATUS REPORT)

3.4.3 Access to Contractor-Owned Automated Information Systems (AIS). The

Contractor shall provide On-Site USG personnel with access to a Contractor-Owned AIS to enable independent assessments of the status of aircraft within the installation cycle. Access shall commence NLT seven (7) calendar days after first aircraft induction at the Contractor’s facility and shall be maintained across this contract’s period of performance.

At a minimum, the AIS shall be up to date and present the installation completion status for each inducted aircraft (per the Contractor’s integrated master schedule), any identified issues (e.g., kit repair requirements, aircraft issues, DCMA coordination, etc.) per tail number that could impact the installation cycle, the status of aircraft maintenance actions (if approved by the USG), and pending installation scheduling dates (e.g., quality assurance inspections, acceptance test start) requiring USG participation.

3.4.4 Travel. The C-130J Program Office occasionally has site inspections, conferences, and crosstalk meetings where the Contractor’s presence is required. The Contractor shall attend when requested by the USG and be prepared to discuss the modification status, trouble shooting, supply chain issues, and anything else covered under this contract. Known travel includes the 2x/year

Crosstalk Meetings with the shareholders.

4.0 AIRCRAFT PRE-ARRIVAL REQUIREMENTS

4.1 Deliveries, Inventory, and Inspection

4.1.1 Installation Kit Deliveries. Installation kit deliveries will occur NLT thirty (30) calendar days in advance of aircraft arrival. Aircraft specific kits will include all components and technical documentation required to complete TCTO installations. Kits will be provided as

Government Furnished Property (GFP) to include the DRC Kits and necessary delta kits specific to the C-130J aircraft and its variants.

4.1.2 Peculiar Support Equipment and Tooling Deliveries. Installation support equipment will be delivered NLT thirty (30) calendar days in advance of the first aircraft arrival. Installation support equipment consists of the peculiar assets (test articles and tooling) required to support BU

7.0/8.1 kit installations per the TCTOs and TOs. This equipment shall be handled and accounted for as GFP. If required, the Contractor shall ensure timely calibration of the equipment in accordance with the National Institute of Standards and Technology (NIST) or host nation equivalent standards.

4.1.3 Installation Kit Inventory and Inspection. Upon each installation kit delivery, the

Contractor shall complete a full inventory and inspection of all contents, to include any peculiar support equipment, tooling, and drawings IAW with the attached Bill of Materials and Harness

Assembly Drawings. Kit content shortfalls, if any, shall be immediately brought to the attention of the C-130J PMO and DCMA. Once the inventory is complete, the Contractor shall be responsible for warehousing, accounting, securing, and making inventory available (per the

Contractor-defined installation schedule) across the installation cycle. The Contractor shall provide storage, warehouse, and inventory control for stored kits in support of active installation lines. Installation kits will arrive NLT thirty (30) calendar days prior to aircraft induction.

For each installation kit and support equipment, the Contractor’s acceptance shall be documented on a DD Form 1149 (signed by an authorized Contractor representative). Copies shall be forwarded to the cognizant DCMA office and PMO. (A011, DI-MGMT-80441D, GOVERNMENT

PROPERTY INVENTORY REPORT)

4.2 Contractor Furnished Equipment (CFE)

The Contractor shall be responsible for obtaining Contractor Furnished Equipment, as defined in the Data Dictionary, Attachment 5, which includes all Common Support Equipment (CSE), consumables, tooling, bench stock and test equipment required to perform required work under the contract. CSE shall be in place NLT thirty (30) calendar days in advance of the first aircraft arrival.

5.0 EXECUTION: AIRCRAFT ARRIVAL AND INSTALLATION

5.1 Preparation for Aircraft Arrival

5.1.1 Pre-Induction Phase. The pre-induction phase shall be a maximum of ninety (90) calendar days—from the first Task Order award until first aircraft arrival. This is a one-time event across the contract period of performance. During this period, the Contractor shall complete installation planning prior to first aircraft arrival. The Contractor shall define and ready facility infrastructures (i.e. permanent structure, canopies, or other) to include but not limited to internal/external power, safety controls, aircraft access stands, office space, utilities (i.e. water, electricity, temperature control, bathrooms, etc.) The Contractor shall meet facility and other (e.g.

DCMA INST 8210.1) contract requirements prior to first aircraft arrival via USG/DCMA inspections. The Contractor shall establish required personnel and security verifications needed to execute Contract requirements.

5.1.2 Pre-Arrival Procedures. The Contractor shall develop and coordinate an incoming package/checklist for aircraft arrival crews. The Contractor shall articulate everything they require from the crew upon arrival to include but not limited to: arrival time, names/position of the crew, contact numbers of the crew as well as the Contractor, and any additional documentation needed prior to or upon arrival.

5.1.3 Pre-Induction Meeting. Approximately two (2) weeks prior to each aircraft arrival, the Contractor shall attend a pre-induction meeting via telecom with the USG unit providing the aircraft to be modified and the program office to ensure everything is prepared for the arrival of the aircraft and any pre-existing issues with the aircraft are understood. Also at this time, the

Contractor shall disseminate pre-arrival procedures and the PMO will articulate any required

Communications Security (COMSEC) documentation required prior to aircraft arrival.

5.1.4 Aircraft Arrival Procedures. The Contractor shall develop, coordinate, and execute aircraft arrival procedures specific to their installation location. At a minimum, the locations and procedures shall provide for safe arrival, landing, ground transit of the aircraft to a defined parking location, and relocation of the USG ferry crew to a central location for their return to base. The procedures shall not be modified without prior coordination with the C-130J PMO.

5.1.4.1 Contractor Acceptance. For each aircraft, the Contractor’s acceptance shall be documented on a DD Form 1149 (signed by an authorized Contractor representative).

Copies shall be forwarded to the cognizant DCMA office and the C-130J PMO. (A011, DI-

MGMT-80441D, GOVERNMENT PROPERTY INVENTORY REPORT)

5.1.4.2 Updating and Maintaining Aircraft Forms. The Contractor shall update and maintain the aircraft forms documented in Table 1 (Section 6.1 Maintenance Forms and

Publications of this PWS) for all aircraft at all Contractor install facilities.

5.1.5 Aircraft Arrival/Induction. The USG ferry pilots will be responsible for delivering the aircraft to the Contractor’s facility. At the point of aircraft arrival, the Contractor shall perform post flight aircraft inventory check with the USG (Flight-Crew/DCMA/PMO). The Contractor shall document missing, damaged items using the AFTO Form 781. The Contractor shall conduct inspection baseline checks (Acceptance Inspection). The Contractor shall develop, coordinate, and execute procedures for aircraft arrival inspections of the aircraft. The inspection shall encompass

Contractor-defined procedures, accomplished IAW approved USAF C-130J TO’s, to validate the aircraft’s physical and maintenance condition as well as readiness for induction into the installation line. At a minimum, the Contractor shall include an inspection of all lights, interior and exterior, for operation and aircraft bleed air checks for minimum bleed down upon arrival. The procedures shall not be modified without prior coordination with the PMO. Should aircraft issues be identified during inspections, the Contractor shall implement the procedures outlined in Section 6.4.1 Over and Above of this PWS.

5.1.6 Preservation Requirements. The Contractor shall execute procedures and preservation requirements (per TO 1C-130J-17, Long Term Storage USAF C-130J Series Aircraft) within seven (7) days of aircraft arrival.

5.2 Kit Installation

5.2.1 The USG will provide TOs required for the Contractor to perform duties in support of the contract NLT sixty (60) calendar days after contract award. Contractor personnel will not remove TOs from the work area at any time.

The Contractor shall execute the C-130J BU 7.0/8.1 kit installations and DRC effort consistent with the applicable TCTOs and referenced TOs—to include referenced engineering drawings, wiring diagrams, and functional and operational checkout procedures:

1) 1C-130J-1062, Installation of Block Upgrade 7.0/8.1 Modification Kits, Forward

Fuselage Stations 0.0 to 245.0, C-130J Aircraft

2) 1C-130J-1063, Installation of Block Upgrade 7.0/8.1 Modification Kits, Mid Fuselage

Stations 245.0 to 537.0, C-130J Aircraft

3) 1C-130J-1064, Installation of Block Upgrade 7.0/8.1 Modification Kits, Aft Fuselage

Stations 537.0 to 1202.1, C-130J Aircraft

4) 1C-130J-1065, Installation of Block Upgrade 7.0/8.1 Wiring Modification Kits, C-130J

Aircraft

5) 1C-130J-1066, Update of 698278-3 Data Transfer and Diagnostic System (DTADS) Host

Computer (DHC) Block 6.0 DTADS Software Assembly to 3363085-198 DTADS Software

Assembly, Block Upgrade 7.0/8.1, C-130J Aircraft

6) 1C-130J-1067, Update of Mission Computer (MC) from Part Number (PN) 3363077-( )

Air Vehicle Software Assembly to PN 3366233-5 Air Vehicle Software Assembly, Block

Upgrade 7.0/8.1, C-130J Aircraft

7) 1C-130J-1096, Block Upgrade (BU) 7.0/8.1 and Dynamic Re-tasking Capability (DRC)

De-confliction, C130J Aircraft if applicable

The Contractor shall execute the HC-130J BU 7.0/8.1 kit installations consistent with the applicable TCTOs and referenced TOs—to include referenced engineering drawings, wiring diagrams, and functional and operational checkout procedures:

1) 1C-130(AHM)J-668, Installation of Combat Systems Operator (CSO) Console Inc 2.5, HC-130J Aircraft

2) 1C-130(AHM)J-670F, Installation of Block 7.0/8.1 Modification Kits, HC-130J

Aircraft, Supplement to Basic Technical Order

The Contractor shall execute the WC-130J BU 7.0/8.1 kit installations consistent with the applicable TCTOs and referenced TOs—to include referenced engineering drawings, wiring diagrams, and functional and operational checkout procedures. Once the WC-130J TCTOs are available, they will be provided to the Contractor through a contract modification.

5.2.2 Weight and Balance.

Following completion of the BU 7.0/8.1 modification on the first variants of the C-130J (C-130J, C-130J-30, and WC-130J,) the Contractor shall weigh the aircraft IAW approved procedures.

The Contractor shall document the Actual and Corrected Weight and Balance results in a weight and balance report and update the required Aircraft Forms to include Air Force Technical Order

(AFTO) Form 781 (see Weight and Balance 8.1 Memorandum For Record, 15 Jul 19, Attachment 6). The Contractor shall report to the USG any analysis that exceeds the limits of a major modification IAW Air Force TO 1-1B-50. Any initial C-130J variant that has not been previously weighed at the Contractor’s facility with the combined BU 7.0/8.1 modification shall require weighing. (A016, DI-MGMT-81501A/T, Weight, Balance and Inertia)

Following completion of the BU 7.0/8.1 modification on the HC-130J, the Contractor shall weigh the aircraft IAW approved procedures. For the HC-130J, every aircraft shall result in a weight and balance report. The waiver for addition aircraft past the first aircraft in Attachment 6 does not apply to the HC-130J variant. The Contractor shall document the Actual and Corrected Weight and Balance results in a weight and balance report and update the required Aircraft Forms to include Air Force Technical Order (AFTO) Form 781. The Contractor shall report to the USG any analysis that exceeds the limits of a major modification IAW Air Force TO 1-1B-50. (A016, DI-

MGMT-81501A/T, Weight, Balance and Inertia)

5.2.3 Installation Cycle for First and Second Aircraft. The first aircraft delivered will arrive after the Pre-Induction Phase (see Section 5.1.1). For the first C-130J, HC-130J and WC-

130J aircraft delivered, the Contractor shall complete the installation cycle Not To Exceed (NTE) two-hundred ten (210) calendar days. For the second C-130J, HC-130J, and WC-130J aircraft delivered, the Contractor shall complete the installation cycle NTE one-hundred eighty (180) calendar days. Installation Cycle is from DD1149 (Aircraft Arrival) to DD250 (DCMA

Acceptance).

5.2.4 Installation Cycle for Third and Subsequent Aircraft. For all aircraft following the second C-130J or WC-130J aircraft, the Contractor shall complete the installation cycle (DD1149 to DD250) NTE one-hundred twenty (120) calendar days. Seven (7) additional days shall be allocated for the removal of DRC on the C-130J-30 (Stretch) DRC configured aircraft and installation of the de-confliction kits. If Weight & Balance must be done on the aircraft, an addition ten (10) days shall be allocated to the schedule. For all HC-130J aircraft following the second HC-

130J aircraft, the Contractor shall complete the installation cycle (DD1149 to DD250) NTE one-hundred thirty (130) calendar days as each aircraft must have Weight & Balance done on the aircraft. The USG will provide no more than twenty-two (22) aircraft for induction in any one contract year through annual or biannual Task Orders.

5.2.5 Aircraft Non-Conformances. Any non-conformances discovered that could negatively affect the modification installs and potential aircraft acceptance, to include factors that may cause damage to equipment or injury to personnel and cannot be resolved immediately by the on-site engineering staff, the Contractor shall notify the C-130J PMO/DCMA NLT twenty-four

(24) hours after discovery for resolution. All Major Non-conformances shall be reported and dispositioned by the Program Office.

5.2.6 Technical Issues, Engineering Disposition Requests. Technical issues, engineering disposition requests or questions shall be presented to the C-130J PMO as soon as possible for disposition. Engineering disposition requests shall (1) describe the request in detail and (2) provide a recommended disposition for consideration. Contractor-generated delays in submitting requests shall not be reason to extend the installation period.

5.2.7 Aircraft Non-Essential Equipment. The Contractor shall remove and disposition non-essential equipment (e.g., cables, connectors, circuit breakers, racks, panels, structural components, and associated equipment) in accordance with the TCTOs.

5.2.8 Support DCMA Quality Assurance. Per each installation schedule, the Contractor shall support installation line quality assurance inspections by DCMA personnel. Any DCMA-identified discrepancies or findings shall be corrected within the installation cycle.

6.0 MAINTENANCE ACTIONS

6.1 Maintenance Records, Forms and Publications

6.1.1 General. The Contractor shall update and maintain the forms and publications listed in

Table 1, as required. The Contractor shall seek clarification from the C-130J PMO if the records are illegible at point of aircraft delivery. All forms, publications, and records listed shall be updated and maintained from the date of the DD1149 until the aircraft is accepted by the signed DD250 and departs the Contractor’s facility. The Contractor shall ensure forms and records that arrived with the aircraft or generated during the modification (i.e. General Information Grid (GIG) sheets, DD-250 modification records, Weight & Balance (W&B) data) shall be returned with the aircraft.

Documentation that is proprietary or belongs to the Contractor, will be retained by the Contractor.

Table 1: Summary of Aircraft Forms

Form Number Form Title Applicable Directive

AF 2692 Aircraft/Missile Equipment Transfer/Shipping Listing AFI 21-103 AFTO 95 Significant Historical Data TO 00-20-1

AFTO 781 Aircrew Mission Flight Data Document TO 00-20-1 AFTO 781A Maintenance Discrepancy and Work Document TO 00-20-1 AFTO 781H Aerospace Vehicle-Flight Status and Maintenance TO 00-20-1 AFTO 781J Aerospace Vehicle-Engine Flight Document TO 00-20-1 AFTO 781K Aerospace Vehicle Inspection, Engine Data, Calendar

Inspection and Delayed Discrepancy Document

TO 00-20-1

Electronic Automated Weight and Balance System (AWBS) TO 1-1B-50

6.1.2 AF Form 2692. The Contractor shall review aircraft equipment transfers and shipping information on the AF 2692. If the aircraft does not have an AF 2692 available, the Contractor shall use an equivalent form to annotate loose equipment inventory upon aircraft arrival and departure.

6.1.3 AFTO Form 95. The Contractor shall annotate TCTO compliance and completion on the AFTO Form 95 IAW TO 00-20-1.

6.1.4 AFTO Form 781. The Contractor shall annotate flight hours conducted during the

TCTO installation and verification checks on the AFTO Form 781 IAW TO 00-20-1.

6.1.5 AFTO Form 781A. The Contractor shall annotate maintenance discrepancies during the TCTO installation on the AFTO Form 781A IAW TO 00-20-1. In addition, the Contractor shall periodically review the Form 781A for any upcoming maintenance inspections.

6.1.6 AFTO Form 781H. The Contractor shall annotate the aircraft flight and maintenance status, fuel servicing, engine oil servicing, liquid oxygen (LOX) servicing, and flight hours on the

AFTO Form 781H IAW TO 00-20-1.

6.1.7 AFTO Form 781J. The Contractor shall annotate the aircraft accumulated engine run hours, flight hours, and landing gear retractions conducted during TCTO installation and verification checks on the AFTO 781J IAW TO 00-20-1.

6.1.8 AFTO Form 781K. The Contractor shall annotate the aircraft engine data, calendar inspections, and delayed discrepancies during the TCTO installation and verification checks on the AFTO 781K IAW TO 00-20-1. In addition, the Contractor shall periodically review the Form

781K for any upcoming maintenance inspections.

6.1.9 General Information Grid (GIG) Sheets. The Contractor shall document all discrepant aircraft conditions throughout execution of the modification. For issues that are not handled through the Over & Above (O&A) process or through Engineering Disposition Requests, the Contractor shall use an AFTO Form 367, Aircraft Discrepancy GIG sheet. The GIG sheet will go home with the aircraft and other aircraft forms upon completion of the modification. The Mod

Manager from the PMO will review all discrepancies for disposition of work.

6.1.10 Aircraft Weight & Balance System (AWBS). The Contractor shall annotate changes to the aircraft weight and balance during installation and completion of the TCTO on the AWBS

IAW TO 1-1B-50.

6.2 Repair and Replenish

6.2.1 Kit Content Repairs and Replenishing Requisitioning Process. If kit contents require repairs and/or replenishing at any point prior to or during installation, then the Contractor shall notify the C-130J PMO NLT two (2) business days and assign a Supply Liaison to order, track, ship, receive, inspect, and provide status on all requisitions, repairs and assets ordered under contract through the USG. The Contractor shall NLT two (2) business days of receipt of the requisitions, act as a liaison for the USG, process, and fill requisitions, generate material release orders, provide requisition status using standard Military Standard Requisitioning and Issue

Procedures (MILSTRIP) supply status codes via electronic means, reconcile/validate backorders, and perform cataloging actions as applicable. The Contractor shall be responsible for managing and ordering/replenishing stock (i.e., consumables) using the Inventory Control Point for source of supply spares at Keesler AFB, MS.

6.2.2 Packaging, Handling, Storage and Transportation (PHS&T). The Contractor shall be responsible for the Packaging, Handling, Storage and Transportation of installation items in accordance with MIL-STD 2073-1E (1), Standard Practice for Military Packaging, when military packaging is specified. The Contractor shall comply with the American Society for Testing and

Materials (ASTM) D3951-10 when commercial packaging is specified. The Contractor shall be responsible for shipping and tracking items to the designated installation receiving point(s) or to other locations as directed by the Procuring Contracting Officer (PCO). For shipments outside the

Continental United States (OCONUS), the Contractor shall use USG provided World Wide

Express (WWX) carrier services. When OCONUS shipments are directed by the USG, the

Contractor shall request use of WWX services through DCMA.

6.3 Reporting Maintenance Actions

The Contractor is responsible for care, upkeep, and general maintenance actions associated with the aircraft while it is in residence at the Contractor’s facilities (Attachment 9, CKI 2 Care and

Feeding). The Contractor shall report maintenance data IAW TO 00-20-2 upon completion of each aircraft installation. The Contractor shall distinguish between the installation of the modification and day-to-day maintenance activities/items. The Contractor shall document all maintenance activities/items, not associated with the TCTO modification installation, to include servicing and inspections, and over and above findings and associated approved maintenance actions in the aircraft AFTO 781 forms. The Contractor shall submit copies of the AFTO 781 forms twice per

Aircraft: 1) 15 days prior to the Scheduled Acceptance Check Flight (ACF) date and 2) approximately 1 week prior to the aircraft returning to the MAJCOM. (A017, DI-MISC-80508B, TECHNICAL REPORT-STUDY/SERVICES (AFTO 781 SUBMISSIONS))

The Contractor shall document all maintenance activities related to installation of the modification separately in the Contractor’s work package. Upon return/release of the aircraft to the MAJCOM, the Contractor shall submit copies of the work package to the MAJCOM by placing a copy of each work package in the aircraft jacket file with a copy of the Form 95. The Contractor shall document each TCTO completion separately such as: “Block Upgrade (BU) 7.0/8.1 Time Compliance

Technical Order (TCTO) 1C-130J-10XX required” and with a basic sign off “TCTO 1C-130J-

10XX Complied With, see Contractor work package for maintenance break down”. All items authorized by the USG to include time change and inspection requirements and/or safety of flight inspections due during the bailment period to the Contractor shall be completed and signed off prior to aircraft delivery to the USG (DD250).

6.4 Non-BU 7.0/8.1 Aircraft Maintenance Actions and Discrepancies

6.4.1 Over and Above (O&A). “Over and above work” means work discovered during the course of performing overhaul, maintenance, and repair efforts that is—

(i) Within the general scope of the contract;

(ii) Not covered by the line item(s) for the basic work under the contract; and

(iii) Necessary in order to satisfactorily complete the contract.

O&A issues are NOT related to the actual physical installation of the BU 7.0/8.1 TCTOs nor any maintenance actions included with general movement or upkeep of the aircraft during the time it is in residence at the Contractor’s facility (i.e. towing, records maintenance, movement of other aircraft, ACF preparation, ground servicing, etc.) O&A are issues identified during the pre-induction inspection, the installation effort, final inspections, ACF preparation, during ACF, or identified and directed by the USG.

Aircraft actions and discrepancies shall be resolved under the O&A provisions included in

Attachment 7 and must be completed by qualified maintenance technicians. The Contractor may supplement aircraft certified maintenance technicians with qualified maintenance technicians for modification installation, to include avionics and general maintenance activities. Certified and qualified maintenance technicians shall have the qualifications described in the Data Dictionary, Attachment 5. Certified maintenance technicians shall be responsible for, and provide oversite and quality checks of, qualified maintenance technicians during authorized installation and avionics and maintenance work.

6.4.2 Repairs and Corrective Actions. The Contractor shall identify needed repairs and recommended corrective action for non-modification-related, aircraft discrepancies identified during the installation. The Contractor shall also advise if the corrective action must be accomplished to continue the install (i.e., a prerequisite to maintenance or safety of flight and execution of the ATP cycle) and anticipated duration of the corrective action, or if the work can be deferred until after DD250. The Contractor shall notify the C-130 PMO/DCMA via telephone and in writing NLT 0800 local time the next business day. The Contractor shall follow up in writing

NLT four (4) hours as to the scope of the maintenance concern, required TOs and support equipment (if any), and shall request disposition guidance. If a maintenance action is approved and not covered by an existing TO, then the Contractor shall notify the C-130J PMO to obtain the required engineering or maintenance assistance for proper disposition and procedures or approaches to correct the identified discrepancy. The Contractor shall document all discrepancies requiring aircraft maintenance in the aircraft forms.

6.4.3 Discrepancy Authorizations. The USG will decide on a case-by-case basis if each discrepancy shall be worked by the Contractor, USG team at the Contractor's facility, or left unresolved. The Contractor shall not perform any work until authorization for that work is received from the Administrative Contracting Officer (ACO). Support equipment (if any) and applicable

TOs for that work will be authorized by the PCO. "CANN" (Cannibalization): A cannibalization request is for the movement of parts from one aircraft to another, in the event that the supply system cannot provide the part. Cannibalization will only be used as a last resort and must be approved and executed according to the attached O&A procedures. The C-130J Retrofit Logistics

Manager will coordinate with the USAF Command and provide guidance to DCMA Quality

Assurance Specialist (QAS) regarding cannibalization requests.

6.4.4 Maintenance Notifications. For O&A requirements, Contractor shall follow O&A direction included in Attachment 7 and notify DCMA of the scope of the maintenance issue, required TOs and support equipment (if any). The Contractor’s O&A request shall include the estimated maintenance labor categories, to include engineering, and labor-hours required; and total project cost (labor and material). The Contractor shall continue the installation on a noninterference basis for the O&A while waiting for direction. The USG will notify the Contractor the USG’s preferred disposition (i.e., Contractor repair, delay repair, Field team repair, etc.) of the maintenance issue. If the maintenance issue is approved for Contractor repair, then the Contractor repair shall require USG acceptance given by the PCO through the ACO. Any O&A issue that results in a delay to the installation being completed shall not prevent the Contractor from receiving the next aircraft IAW the agreed upon schedule.

6.4.5 Maintenance Contractual Direction. Once contractual direction is received, the

Contractor shall execute the maintenance action IAW the referenced TO(s). If the maintenance action falls within the CKI Mandatory Government Inspection (MGI) list, it shall conclude with the completion of a physical inspection—specific to the requirement and IAW the referenced TO, to include documentation of the corrective action and clearing of the discrepancy in the applicable aircraft forms after USG inspection and acceptance. The physical inspection will be conducted by the cognizant DCMA office for USG acceptance.

6.5 Loss, Damage, and Destruction (LDD)

The Contractor shall document LDD items and notify the USG upon discovery of LDD items. The

Contractor shall submit LDD item documentation to the C-130J PMO/DCMA for review and disposition NLT twenty-four (24) hours from when the LDD is identified. The Contractor shall, when authorized by the USG, complete repair or replacement.

7.0 ACCEPTANCE TEST PROCEDURES (ATP) THROUGH COMPLETION

7.1 Test Plan/Checklist and Acceptance Test Report

The Contractor shall generate a Test Plan/Checklist. The Test Plan/Checklist shall consolidate testing required by the TCTOs and demonstrate compliance by the Contractor. In addition, the

Contractor shall generate and submit Acceptance Test Reports documenting the results of each acceptance test for each aircraft. The Contractor shall document and notify the USG of non-conformances noted during these TCTO checks and review for safety of flight issues. Any non-conformances requiring changes to the technical drawings or TCTOs shall employ the procedures in the Engineering Technical Assistance Request (ETAR) Policy, AFMCMAN 63-1202. The

Contractor shall reconcile reported discrepancies, following the ACF, attributable to the installation of the kit. (A012, DI-NDTI-80603A, ACCEPTANCE TEST PLAN; A013, DI-

QCIC-81891, ACCEPTANCE TEST REPORT)

7.2 Record Review

The Contractor shall conduct a record review prior to any flight or delivery. The Contractor shall update aircraft records (e.g., AFTO Form 95, AFTO Form 781, USAF Form 2692, etc.) The

Contractor shall include post-Line Replacement Unit (LRU) installation information onto the

AFTO Form 781 aircraft record and provide upon aircraft delivery. The LRU information shall include part number, position, serial number, and any pertinent software information including the identification number. The Contractor shall provide updated records with delivery of modified aircraft.

7.3 Test, Inspections, and Completion

7.3.1 Acceptance Test. The Contractor shall operationally and functionally test the final installation IAW the TCTOs to verify readiness for flight.

7.3.2 Pre-Flight/Safety-of-Flight Inspections. Pre-flights are due every 72 hours prior to flight, regardless of possible delays, and are included as part of this contract. The Contractor shall develop, coordinate, and execute the sequence of pre-flight inspections IAW approved USAF C-

130J TO’s and additional activities on the C-130J for ACF (including but not limited to: DCMA

Inspections, LOX servicing, emergency response support, towing of vehicles). The pre-flight inspections shall be accomplished in advance of every flight readiness determination: in preparation for USG ACFs as well as before ferry flights home. Once approved these procedures shall not be modified without USG approval. All pre-flight inspections will be overseen by the cognizant DCMA office and/or USG program office personnel.

7.3.3 Acceptance Check Flight (ACF) Completion. After completion of the Contractor’s

ATP, the Contractor shall prepare the necessary aircraft forms and records for the USG’s acceptance of the aircraft. The Contractor shall submit a DD250 after the successful completion of the USG ACF IAW applicable contract provisions; and shall support, as required, the cognizant

DCMA office’s sign-off of the DD250. The ACF process shall not be completed until DD250 sign-off. NOTE: Sign-off will not be delayed by any aircraft issue that was identified by the Contractor, if deferred for execution by the USG.

7.4 Aircraft Transfer and Post-Install Ferry Support

The Contractor shall develop, coordinate, and execute aircraft transfer and post-ACF ferry procedures specific to their installation location. At a minimum, the Contractor shall ensure ferry crew receipt and transit to the aircraft, support for pre-flight inspections, turn-over of applicable aircraft documentation to the USG flight crews, and aircraft departure. These procedures shall not be updated without USG concurrence.

8.0 ADDITIONAL WORK

On occasion, a modification is added to the C-130J Platform which necessitates a subsequent modification to the BU 7.0/8.1 effort under this PWS. Such projects include replacement, removing, or adding new parts/systems onto the aircraft. Projects could be caused or generated from O&A work, safety provisions, or upon request from the USG. The Contractor shall submit a proposal for review to the USG to complete the tasks involving minor modifications.

Subsequently, the USG will decide on whether to issue a new Task Order of a modification to a

Task Order to complete the requirement. If this need should arise, a new CLIN with appropriate pricing will be added to the contract at that time.

9.0 SECURITY

9.1 General

The Contractor shall comply with and execute security requirements as identified in the security annex. The Contractor shall ensure that only properly cleared personnel, with appropriate clearances, will handle classified material under the contract. The USG will provide subsets for security classification guides for all COMSEC equipment. The Contractor shall obtain requisite clearance eligibility on all employees prior to contract award. To reduce program vulnerabilities and to protect controlled unclassified information technologies from inadvertent disclosure, the

Contractor shall designate either the Site Lead/Manager or Deputy Site Lead/Manager to be the focal point for program security issues and Operations Security (OPSEC). The Contractor shall ensure compliance with DoDD 5205.02E, DoDM 5205.02-M, and/or other applicable USG security regulations including procedures to protect classified and/or controlled unclassified information, USG projects and/or programs (contract clauses).

9.2 Communication Security (COMSEC)

The Contractor shall be responsible for removing, storing, installing, maintaining, operating, inventorying, and shipping and receiving of cryptographic equipment/information management.

The Contractor shall have a designated COMSEC Manager and COMSEC Account, either Tier 2…