F-16 SLEP Stand Design Build SOW_Final.docx

STATEMENT OF Work (SOW)

F-16 SLEP FALL PROTECTION WORK STAND DESIGN-BUILD

U.S AIR FORCE

309 AMXG

11/21/2022 F-16 SLEP Fall Protection Work Stand Design-Build>> Subject << i

TABLE OF CONTENTS

SCOPE

This Statement of Work (SOW) defines the effort required for the design, fabrication, delivery and installation of an F-16 Fall Protection Work Stand Prototype at Hill Air Force Base, UT. The work stand prototype must be specifically configured to support the Service Life Extension Program (SLEP) of the F-16. This effort also includes an iterative design process working collaboratively with AMXG Engineering, site visits, maintainer training, and deliverable of a comprehensive Technical Data Package (TDP), the data of which USAF will have unrestricted rights to.

BACKGROUND

The current F-16 Fall Protection Work Stands are difficult to maintain, difficult to move and are nearing the end of their useful life. The current stands also fail to provide full "wrap around" coverage resulting in the use of clip-in harness fall protection when personnel are aft of the cockpit, on the wings, and occasionally on the tail section. This clip-in harness system, or vertical life line (VLL), is commonly referred to as “active” fall protection. USAF must move to a comprehensive, full wrap fall protection work stand design, commonly known as a “passive” safety solution. A passive solution is required in order to ensure agile maintenance operations can be conducted for successful execution of the F-16 SLEP workload. The SLEP process takes over a year to complete, requiring the airframe to be “on dock” for the duration of the maintenance process, and is executed with the airframe in multiple configurations, e.g. wings-on/wings-off, etc. The new fall protection work stands must enable efficient, effective and safe maintenance operations in order to maintain the SLEP production schedule, i.e. the stands must be agile while also providing passive fall protection. At the same time, the SLEP stands must also be compatible with all SLEP airframe configurations and must also allow personnel access to all required areas of the airframe with no or minimal movement of the stands.

REQUIREMENTS

GENERAL

The work required for this effort shall be performed in accordance with Section B – Supplies and Prices, and Section C – Description/Specifications/Work Statement, of the purchase order award and this SOW. The contractor shall provide all equipment, tools, software and programming, labor, management, etc. necessary for the entirety of the design, fabrication, delivery and install of this requirement; any exceptions will be specifically identified within this SOW.

APPLICABLE DOCUMENTS

The following documents are applicable to this SOW along with the attached appendices cited below.

SAFETY REQUIREMENTS, STANDARDS, AND CODES

· OSHA 29 CFR 1910 Subpart D, Walking - Working Surfaces

· DAFMAN 91-203, Air Force Occupational Safety, Fire, and Health Standards

· OO-ALC Safety Requirements (Appendix C of SOW)

ADDITIONAL STANDARDS AND CODES

· NFPA 70, National Electrical Code (NEC)

· ANSI B4.1, Limits and Fits for Cylindrical Parts

· AWS D1.1, Structural Welding Code - Steel

· AWS D1.2, Structural Welding Code – Aluminum

· AWS QC7, Standard for AWS Certified Welders

· ASME Y14.100, Engineering Drawing Practices

STAND DEFINITION:

Forward stands are defined as the stands forward of the wing with the wing installed.

Aft stands are defined as the stands aft of the wing with the wing installed.

REFERENCE AND CALLOUTS

References and callouts for full wrap means full wrap around fall protection.

QUALIFICATIONS

Full Wrap Design Contractor shall have complete ownership of an existing F-16 full wrap design that will be used as the basis to leverage a comprehensive F-16 full wrap design that supports the particular production attributes of the SLEP Program. The contractor’s existing F-16 full wrap design shall have been procured, fabricated and installed, as well as both successfully accepted and deployed for use at a minimum of one DoD facility.

Personnel Contractor shall have a licensed Professional Engineer (PE) on staff, i.e. licensed PE shall not be a subcontractor or employed via similar type arrangement but shall be a direct employee of the contractor’s firm. All design services furnished by the contractor shall be performed under the direct supervision of the licensed PE. The contractor, via its licensed PE, is responsible for the accuracy, adequacy, timeliness and professionalism of the design solutions and design documents. Contractor shall ensure design solutions meet requirements of the purchase order award and F-16 SLEP attributes.

All welding required for the fabrication of the prototype shall be executed by American Welding Society (AWS) certified welders. Contractor shall have AWS certified welders on staff, i.e. welders shall not be subcontractors or employed via similar type arrangements but shall be direct employees of the contractor’s firm.

Welders shall be certified in accordance with AWS QC7 and all welding performed by the contractor shall be performed only by the AWS QC7 staff.

Facilities Fabrication of the prototype shall be wholly executed at the contractor’s facility by contractor’s staff, i.e. fabrication shall not be executed at an alternate location owned by any other entity than the contractor and labor associated with the fabrication shall not be executed by a subcontractor or individual employed via similar type arrangement but shall be a direct employee of the contractor’s firm.

Quality Standard The system used by the contractor to manage quality shall be compliant with all the requirements of, and at a minimum be functionally equal to, a current active version of the ANSI/ISO/ASQ Q9001, Quality Systems-Model for Quality Assurance in Design, Development, Production, Installation and Servicing. The Government shall have the right to audit the contractor’s quality system for ANSI/ISO/ASQ Q9001 compliance.

DESIGN

PRIMARY DESIGN ATTRIBUTES

The overall design of the F-16 SLEP Fall Protection Work Stands shall be structurally sound, maximize the safety of maintainers and provide for ease of use.

Design and construction shall comply with OSHA 29 CFR 1910 Subpart D and DAFMAN 91-203 requirements. The stand shall provide fall protection in compliance with these regulations and standards for personnel around the aircraft, for personnel on top of the aircraft and for personnel on top of the stands.

To maximum extent possible, the contractor shall design the stands incorporating the use of components and subcomponents in the design that are Commercial Off the Shelf (COTS) or commercially available. COTS or commercially available components and subcomponents selected for the design shall be readily available and easily replaced.

Selection of commercial components and subcomponents shall be based on a proven track record of high quality in similar industrial and/or government settings as F-16 maintenance operations that have a robust longevity associated with them. Major factors determining appropriate selection of component and subcomponent quality includes items that minimize preventative maintenance, maximize lifecycle and maximize ability to take abuse (i.e. all-metal construction, industrial duty, high-grade coatings, etc.).

The F-16 SLEP Fall Protection Work Stand design shall become the property of USAF such that Government shall have the unrestricted right to use, modify, reproduce, release, perform, display, or disclose the technical data associated with all designs, drawings, specifications, notes and other works developed and executed in the performance of this contract within and outside the Government as USAF deems necessary to support mission requirements. The final design, or TDP, shall be comprehensive and ensure that the Government can provide the design to third-party manufacturers for fabrication without having to engage in reach back to the contractor for clarifications, changes, updates, or explanations.

Design of the F-16 SLEP Fall Protection Work Stands shall be executed in a collaborative and iterative design process with the cognizant AMXG Engineer.

During the iterative design process, the contractor, cognizant AMXG Engineer and other government stakeholders shall work to address and incorporate the design attributes that support F-16 SLEP in a professional, respectful, and timely manner. The experience and expertise of the contractor shall be relied upon for guidance during the design process. In addition, the experience and expertise of the contractor shall be fully relied upon for ensuring that the final stand design is structurally sound, compliant with applicable safety regulations and maximizes agile execution of F-16 SLEP maintenance operations. However, the cognizant AMXG Engineer has the ultimate decision-making authority and approval of the drawings, design and design attributes including component and subcomponent selections throughout the iterative design process. Design attributes beyond those defined below may be identified during the iterative design process.

FULL WRAP CONFIGURATION

When the stands are used in a full wrap configuration, they shall allow for independent dissimilar configurations on right and left sides of the airframe and shall meet fall protection requirements in each of the three aircraft configurations listed below. Some handrails will need to be removeable to work in all configurations. See below and Figures 1 & 2 for concept design and aircraft configurations.

Aircraft configuration 1: Wing-on/horizontal stabilizer on. See Figure 2.

Aircraft configuration 2: Wing-on/horizontal stabilizer off. Not shown.

Aircraft configuration 3: Wing-off/horizontal stabilizer off. See Figure 2.

The full wrap design shall provide fall protection regardless of the airframe configuration.

The full wrap design may provide fall protection approximately from the aft of the radome at Fuselage Station 65 (FS65) to approximately FS500, on both sides of the aircraft to the outboard edge of the wings at Buttock Line 180 (BL180) as illustrated in Figure 1. The exact fall protection coverage area will be determined during the iterative design process and by coordinating with the cognizant AMXG Engineer.

FS measurements are in inches aft of FS0, e.g. FS65 is 65 inches aft of FS0. BL measurements are in inches outboard from aircraft centerline, e.g. BL180 is 180 inches outboard of the aircraft centerline.

When stands are used in the full wrap configuration, they shall connect and secure together and disconnect without the use of tools.

Stand design shall ensure there are no gaps between the stand and airframe which could lead to a fall hazard and/or unsafe conditions.

Stand design shall ensure trip and fall hazards from corners and edges are eliminated or mitigated to the greatest extent possible.

The full wrap design shall not have a platform at the wing tips see Figures 1 & 2. However, fall protection flush with, and covering the wing tip area is required.

Figure 1.

Stand configuration concept with wing and horizontal stabilizer installed Stand configuration concept with wing and horizontal stabilizer removed

Figure 2.

GENERAL FABRICATION/CONSTRUCTION

Work stands construction shall be aluminum unless otherwise approved by the cognizant AMXG Engineer. All structural members and corresponding sizing shall be determined during the iterative design process by coordinating with the cognizant AMXG Engineer. Structural rigidity is required to limit deflection.

The work stands shall have drain holes on all deck areas and structural members to prevent water from building up on, or inside, the work stands.

Stands shall be sized and optimized for efficient and effective use of the smallest existing dock space in Building (B) 225.

Stand design shall consider the available space on the hangar floor in B225.

Stands shall not extend past the yellow line indicating the maintenance area and the size of the dock.

Coatings.

All safety areas to include gates, guardrails, and handrails shall be painted safety yellow. Paint shall be powder coat. Materials shall be pre-treated or microetched before powder coat.

Other components of the stand areas do not need coating if the materials used are inherently corrosion resistant.

Any other coatings shall be approved by the cognizant AMXG Engineer.

Aircraft Protection Stand design shall ensure where instances of contact, or potential contact, between the airframe and the stands will and/or may occur, damage to the airframe shall not be possible; this shall be accomplished by using rubber bumpers and other non-marring materials on slide-outs and all other surfaces and edges that can contact the aircraft. These materials shall be COTS items and secured using fasteners, welding and adhesives are prohibited.

Casters Each stand shall have four (4) swivel casters, Swivel Eaz XL series casters or equivalent if approved by cognizant engineer. Casters shall have elastomeric high tensile (EHT) rubber on aluminum wheels. All materials except for the tread shall be metal construction. All bearings shall be non-serviceable sealed ball bearings. All casters shall have swivel locks and wheel brakes. Casters shall be fastened to the stand using fasteners, not welded.

All stands shall be designed such that no more than two (2) people are required to move any stand, assuming each person is able to exert a static lateral force up to 40 lbs.

Stabilizers Each stand shall have four (4) threaded downrigger stabilizers, one (1) fastened to each corner of the stand, with metal pads or feet. They shall be used to take load from the casters when the stands are in use.

Threaded shaft shall be steel and 1.25” minimum with the metal pad a minimum of 4” in diameter.

Stabilizers shall include handles to manually raise and lower the stabilizers.

Platform: Walking – Working Surface.

The platform for each stand shall comply with DAFMAN 91-203 Chapter 7 “Walking Working Surfaces” and OSHA 29 CFR 1910 Subpart D.

Material shall be extruded aluminum deck planking with anti-slip characteristics designed into the planking material.

Platforms on each stand shall be flat, i.e. platform shall not have steps or elevation changes other than stairways and ladders.

Each stand platform will be used simultaneously by four (4) users at a time. The maximum deflection of any part of the platform shall be 1/16” with a 250 lb (pound) load.

Stairways and Ladders.

Each stand shall be designed with a stairway or ladder. The type and location shall be determined during the iterative design process by coordinating with the cognizant AMXG Engineer. Stairways and ladders shall comply with DAFMAN 91-203 Chapter 7 and OSHA 29 CFR 1910 Subpart D.

Materials for all steps shall be extruded aluminum deck planking with anti-slip characteristics designed into the planking material.

Stairways and ladders shall self-adjust as the stand platform is raised and lowered.

Removal of stairways and ladders shall not be required to transport or tow the stands.

Stairways and ladders shall be secured to the stands using fasteners, welding and adhesives are prohibited. Stairways and ladders shall be easily removed when needed.

Stairways shall be parallel to the overall stand structure, rather than perpendicular to it, to minimize the overall footprint in the maintenance area.

Toe and kick protection shall be present on all stairways.

The maximum deflection of any stairway and ladder steps shall be 1/16” with a 250 lb (pound) load.

Slide-Outs.

Slide out planks, “slide-outs”, shall be utilized for all stands where the work platform meets the airframe. Slide-outs may need to have capability for at least 3’ extension to mesh with the contours of the airframe in different configurations. The ends of the slide-outs shall be rubber insulated to eliminate metal to metal contact. These materials shall be COTS items and secured using metal fasteners, welding and adhesives are prohibited.

Slide-out material shall be extruded aluminum deck planking with anti-slip characteristics designed into the planking material.

Slide-outs shall slide easily when moved in and out by one (1) person while working on top of the work stand deck structure.

Slide-outs shall be designed for heavy use and long-term outdoor storage.

Slide-outs shall have a locking mechanism that securely fastens each pullout section in place without the use of tools. The locking mechanism and/or methodology utilized shall provide clear indications to the operator when the pullout is properly or improperly locked in place.

When a person is standing on a slide-out, it shall not be able to extend or retract.

The maximum deflection of any slide-out shall be no more than 1/8” when extended 24” with 250 lb (pound) load at the end.

Guardrails.

Guardrails shall comply with DAFMAN 91-203 Chapter 7 and OSHA 29 CFR 1910 Subpart D.

Guardrails shall be provided with toe and kick protection to keep tools from sliding off the platform surface.

Some guardrails may be designed to be permanent if approved by the cognizant AMXG Engineer. However, all removeable guardrails and other components required for different configurations shall be easily removed and easily installed for different configurations and have storage locations on the stands when not in use.

Removeable guardrails shall be easily pinned into place when in use and shall be easily removed and stored by two (2) people.

All storage locations for these parts shall be rubber insulated to eliminate metal to metal contact. These materials shall be COTS items and secured using metal fasteners, welding and adhesives are prohibited.

Towing.

All stands shall have a tow bar with pintle ring used for transport on the aircraft ramp and apron. Stands shall be rated for 5 MPH towing on the aircraft ramp between B225 and the flightline structures known as TAMS.

The tow bar shall fold up and secure to the stand when the tow bar is not in use. When folded, the tow bar shall not protrude from the stand and create a risk of personnel walking into it.

The tow bars shall be located such that when the stands are towed, they are stable and do not tip over.

All stands shall be capable of being towed over the railroad tracks used by aircraft hangar doors without damage at B225.

Foreign Object Damage (FOD) Control Program.

Provisions must be made for all fasteners, pins, or other removable items on the work stands to be attached with tethers or other features to prevent the introduction of FOD into the work environment. These materials shall be COTS items and secured using metal fasteners, welding and adhesives are prohibited.

All pinning features shall meet a Class 9 running and sliding fit (RC 9) in accordance with ANSI B4.1.

ADDITIONAL ATTRIBUTES

Working space between the stands and the airframe:

Airframe underside accommodates the support cradle under the cockpit and up to seven (7) tripod jack stands to support the airframe. Current AMXG jacking fixtures and support stands will be required throughout the SLEP process; The stands must be compatible with this GSE.

Underside of the full wrap stand configuration must provide space between the airframe and GSE, and the frame of the stands to the maximum extent possible so personnel can walk and work below the stands without movement of stands away from airframe, Design should provide sufficient space for working below the airframe strake cap and between the airframe and the stands while minimizing or eliminating the need to move the stands away from the airframe. The requirement is to permit undisrupted maintenance operations so that personnel can simultaneously work on the dock floor around the airframe while other personnel work above them on the stand platforms.

To the greatest extent possible, all support columns and/or sections of the work stands shall be located such that it allows unobstructed access and openings to all aircraft internal component access panels below the strake cap. The number of stringers and girders should be limited.

Storage All removable parts used on or for the stands shall have storage placement on the stands when not in use. All storage locations for these parts shall be rubber insulated to eliminate metal to metal contact. These materials shall be COTS items and secured using metal fasteners, welding and adhesives are prohibited.

The fall protection set shall include part storage for six (6) gun barrels, two (2) flaperons, and two (2) leading-edge flaps (LEFs).

Each stand shall include at least six (6) hooks fastened to the frame for storage. Hook placement shall be approved by cognizant AMXG Engineer. The forward-most stand on each side shall include fastened storage hooks for broom and dustpan. Hooks shall be COTS items.

Each stand shall have a solid flat base, or floor, on the bottom level to accommodate maintainer storage needs. Material shall be 3/16” (inch) thick aluminum diamond plate or other if approved by the cognizant AMXG Engineer.

Labels and Signs:

All labels and signs shall be on metal labels and affixed with metal fasteners. No glue or adhesive shall be used.

All stands shall have lift points suitable for lifting with a forklift. These points shall be identified with labels with "Lift Here" and show where the center of gravity is located so that the weight of the stand can be centered on the forks of the forklift. A label shall also be included with the approximate weight of the stand.

Each stand shall include a feature to block off the bottom of stairs or ladders with a metal chain and metal sign indicating “Keep Off”. The sign shall be constructed of metal. One end of the chain shall be fastened to the frame of the stand and the other end shall easily attached to dedicated hooks when the sign is in use and not in use.

Each stand shall include a metal label with engraved characters with the following information:

Title shall be: F-16 Maintenance Work Stands Set Number (e.g. Set 1) Stand Identifier as applicable (e.g. Forward Left, Forward Right, Middle Left, Middle Right, Aft Left or Aft Right) Date of Manufacture (XX/YY/ZZZZ format) Manufacturer Name Part Number (P/N) Contract Number Platform height adjustment:

Work stands shall have a vertical adjustment of at least 3’.

When all stands per side are combined to create the full wrap configuration, the platform level shall be at the height of the aircraft strake cap.

When the stands are not used in a full wrap configuration, each stand shall be designed to be used at different platform heights. Each stand shall be designed with different platform height ranges from ground level.

Adjusting the height of the platform for each stand shall be accomplished at a single location such that one (1) person can raise or lower the platform using either a power drill with a socket or hand tool with a socket. All linkage shall be supported by sealed precision bearings for durability and smooth operation. No components or materials shall rub or rattle during operation and transport.

All components shall be completely sealed from water intrusion.

A platform height indicator shall be installed and shall be clearly visible to the user at the location where the user raises and lowers the platform. This indicator shall display the current platform height in inches above ground level.

To the greatest extent possible, all components and materials shall be COTS items and secured using metal fasteners. Welding and adhesives are prohibited.

Electrical.

Each stand shall have electrical connections and infrastructure.

All electrical wiring components shall be NEMA 3R and comply with NFPA 70 (NEC).

All wiring infrastructure on the stands shall be with metal tube conduit. Flexible conduit may be used only where required to work with platform height adjustment. No conduit is required for extensions cords to connect breaker panel to the facility or cords used to interconnect the stands.

One breaker panel per airframe side (i.e. left and right) shall be included on the forward stand; two (2) total breaker panels per aircraft. Breaker panel shall be appropriately labeled for each breaker. Breaker panels shall utilize ground fault circuit interrupters (GFCI) breakers.

Power supply to breaker panels shall be from existing facility connections utilizing industrial duty cord. Government provided facility power shall be 120/208V. Design shall ensure connection is compatible. A metal hanger shall be provided for storage of the cord when not in use or during transport.

Electrical connection between stands shall be accomplished via a locking connection. Enough cord length shall be provided to connect the stands in all configurations. A dedicated hanger on each stand shall be provided to store the cord when not in use or during transport.

Minimum of four (4) electrical outlets on top level of stand and minimum of four (4) electrical outlets on bottom level of stand. Outlets shall be installed so that the ground of outlet is on the top side of outlet for safety purposes (ground on top). Outlets shall be compatible with the equipment used. Outlets shall be 120V, 60 Hz, 20-Amp.

Exact placement of the outlets shall be determined during the iterative design process.

All female outlets shall be fixed to the stand structure.

All electrical wiring infrastructure shall use 12-gauge wire or larger.

All electrical infrastructure and components shall be designed for outdoor storage. All components shall be completely sealed from water intrusion. Appropriate components shall be used with gaskets and seals. Sealant shall not be used.

Lighting:

Each stand shall have lights powered by the electrical infrastructure. Location of lights shall be approved by the cognizant AMXG Engineer.

Each stand shall have 4’ LED light fixtures with full metal frame and housing construction. Shorter lights may be used if approved by cognizant engineer. Each stand shall have up to four (4) evenly spaced light fixtures on the lower level pointed towards the aircraft. Fixture shall have 180 deg adjustment side to side to aim them towards the front or back of the aircraft.

All lighting shall be designed for outdoor storage.

Compressed Air.

Each stand shall have compressed air connections and infrastructure.

Compressed air supply to the forward stands shall be from existing facility connections. Compressed air outlet connections shall be to existing tools. Design shall ensure connections are compatible.

Non-flexible metal pipe infrastructure on the stands for compressed air supply shall be 1.5” size metal pipe. A valve with full metal construction shall be used on the compressed air infrastructure before all male couplers to eliminate large releases of compressed air when disconnecting couplers.

The forward stand on each side of the aircraft shall connect to the facility compressed air supply and distribute to the other stands on the same side. Enough hose shall be provided on the forward stands such that both can connect to the facility supply.

Each forward stand shall have an extra female line out to supply the opposite forward stand, i.e. forward left stand can connect to forward right stand and vice versa.

Compressed air supply hose from the stands to the facility shall be industrial duty and 3/4” size or larger if required. Compressed air connection between stands shall be 3/4” size or larger if required. Enough hose length shall be provided to connect the stands in all configurations. A dedicated hanger shall be provided on each stand to store the hoses when not in use or during transport.

Each stand shall have compressed air hose reels with full metal construction and sealed precision bearings, Coxreels P/N P-LP-330 or equivalent if approved by cognizant AMXG Engineer. Entire fall protection set shall have 16 reels with location to be determined during iterative design process. Hose on all compressed air reels shall be 3/8” size and over 30’ long.

Compressed air hose connecting the hard pipe to the reels shall be industrial duty and 1/2” size or larger.

Workstation.

Each stand shall have a flat-top workstation with space for two (2) users to comfortably use their laptops. The workstation shall be a full metal folding tabletop solution or equivalent if approved by the cognizant AMXG Engineer. The workstation shall attach to the stand structure or safety railings and be accessible while standing on the stand platform. The tables shall be suspended over the dock space outside the platform area.

The workstation shall not take up platform space when in use and shall fold up and down outside the platform area.

Folding down the workstation shall be required before transport and securing mechanism shall ensure workstation does not rattle during transport. Folding up and down the workstation shall be accomplished by one (1) user.

To the greatest extent possible, all components and materials shall be COTS items and secured using metal fasteners, welding and adhesives are prohibited.

DESIGN MILESTONES

Execution of the collaborative and iterative design process shall be an ongoing activity from Kickoff to Pre-Final Design submission. Additional coordination is anticipated to be required for minor design changes identified from Factory Acceptance Testing through the Final Design Submission or TDP milestones. Design milestones shall be completed by the timeframes specified in Table 1.

Contractor shall fully support the following design milestones:

Kickoff Meeting: Kickoff Meeting shall take place within 24 hours of executed contract award notification by CO. Location shall be via Teams or similar telecon-type medium. The intent of this meeting is to ensure all parties are on the same page as to project requirements, expectations and goals; participating government and contractor personnel; contact information; schedule; etc.

SLEP Concept : SLEP Concept shall be concluded no later than 15 calendar days after Kickoff Meeting. Location shall be a combination of Teams (or similar telecon-type medium), via email and shall include travel by the contractor to the F-16 facilities at HAFB. Contractor shall support at least three (3) full on-site business days at Hill’s facilities during this phase. Contractor’s licensed PE shall be present for all on-site meetings. The intent of this milestone is to ensure the contractor has access to the dock space dimensions, facility and on-dock work currently being conducted; ability to inspect and interact with personnel working on the current configuration; ability to ask questions of all government stakeholders; and ability to collaborate one-on-one with the cognizant AMXG Engineer about the concept design and design attributes that will meet SLEP production needs.

The SLEP Concept deliverable of meeting minutes shall be submitted in accordance with CDRL A001 (reference SOW Table 1 above, the Exhibit Summary at SOW paragraph 10 and Section J of the purchase order award).

The meeting minutes submitted as CDRL A001 shall include design solutions discussed during this milestone. Any approved design attributes and specifications including approved additions and/or deletions to design attributes in the SOW shall be included in the meeting minutes and specifically identified as “added”, “deleted”, “changed” or “no change” relative to the SOW.

In the event the cognizant AMXG Engineer determines CDRL A001 contains any inaccuracies or omitted information, a revision with completed corrections shall be submitted within two (2) calendar days of government notice.

Intermediate Design: Intermediate Design shall be concluded no later than 33 calendar days after SLEP Concept. The general direction and details of the F-16 SLEP Fall Protection Work Stands design shall be firmly established and clearly indicated in the drawings at the Intermediate Design Submission. This submission of drawings is intended to permit the cognizant AMXG Engineer a review of the intermediate stand design while also providing feedback to the contractor. Continued collaborative design during this phase shall be used as the basis to make appropriate design changes by the contractor. Communications including questions and feedback shall be conducted via Teams (or similar telecon-type medium) and/or via email.

In coordination with the cognizant AMXG Engineer, contractor shall support at least three (3) full on-site business days at Hill’s facilities that must be completed no later than submission of the Pre-Final Design, i.e. travel on-site to HAFB may occur anytime between Intermediate Design and submission of Pre-Final Design but coordination with AMXG Engineering must occur as to the specific dates.

The Intermediate Design deliverable of meeting minutes shall be submitted in accordance with CDRL A002 (reference SOW Table 1 above, the Exhibit Summary at SOW paragraph 10 and Section J of the purchase order award).

The meeting minutes submitted as CDRL A002 shall include design solutions discussed during this milestone. Any approved design attributes and specifications including approved additions and/or deletions to design attributes in the SOW shall be included in the meeting minutes and specifically identified as “added”, “deleted”, “changed” or “no change” relative to the SOW.

In the event the cognizant AMXG Engineer determines CDRL A002 contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

The Intermediate Design deliverable of drawings shall be submitted in accordance with CDRL A003 (reference SOW Table 1 above, the Exhibit Summary at SOW paragraph 10 and Section J of the purchase order award).

Digital copies of the deliverable shall be provided on two (2) CD-R/DVD-R in pdf file format compatible with Adobe Acrobat and CAD files of the work stands around the airframe in Solidworks file format. File format for CAD files must be compatible with Solidworks 2019 or earlier.

Deliver one (1) complete printed copy of the drawings in a bound book to the cognizant AMXG Engineer.

In the event the cognizant AMXG Engineer determines CDRL A003 contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

Pre-Final Design: Pre-Final Design shall be concluded no later than 29 calendar days after Intermediate Design. At this submission milestone all design work should be complete. This submittal is intended to provide the Government with a thorough review of the design and drawing package in preparation for Government final approval of the TDP. Communications including questions and feedback shall be conducted via Teams (or similar telecon-type medium) and/or via email. The contractor shall not proceed with fabrication of the prototype until written approval by the cognizant AMXG Engineer has been received.

The Pre-Final Design deliverable of meeting minutes shall be submitted in accordance with CDRL A004 (reference SOW Table 1 above, the Exhibit Summary at SOW paragraph 10 and Section J of the purchase order award).

The meeting minutes submitted as CDRL A004 shall include design solutions discussed during this milestone. Any approved design attributes and specifications including approved additions and/or deletions to design attributes in the SOW shall be included in the meeting minutes and specifically identified as “added”, “deleted”, “changed” or “no change” relative to the SOW.

In the event the cognizant AMXG Engineer determines CDRL A004 contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

The Pre-Final Design deliverable of drawings shall be submitted in accordance with CDRL A005 (reference SOW Table 1 above, the Exhibit Summary at SOW paragraph 10 and Section J of the purchase order award).

Digital copies of the deliverable shall be provided on two (2) CD-R/DVD-R in pdf file format compatible with Adobe Acrobat and CAD files of the work stands around the airframe in Solidworks file format. File format for CAD files must be compatible with Solidworks 2019 or earlier.

Deliver one (1) complete printed copy of the drawings and BOM in a bound book.

In the event the cognizant AMXG Engineer determines CDRL A005 contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

Factory Acceptance Testing (FAT): Capabilities demonstrated at FAT shall include, but not be limited to, the structural integrity of the stands, safety attributes, COTS/commercial components and subcomponents, ease of use attributes and mechanisms, welding, etc. To the maximum extent possible, the demonstration shall evidence that the prototype meets the requirements of the SOW along with any additional design features agreed upon during the iterative design process. The Government will conduct FAT of the prototype using the accepted pre-final drawings as the baseline. Any deficiencies identified during the test shall be corrected prior to shipment of the prototype to HAFB. In the event it is not possible to demonstrate the full capability at the contractor’s facility, FAT will be concluded at HAFB after Facility Install.

The contractor shall host the cognizant AMXG Engineer and other government stakeholders at their facility to demonstrate the capabilities of the F-16 SLEP Fall Protection Work Stand prototype on two (2) separate occasions.

The first occasion shall be after completion of the first stand section and the second occasion shall be after completion of the entire prototype set. Scheduling of the FAT trips shall be initiated by the contractor; both trips are anticipated to require three (3) full business days to complete. FAT for the entire set of stands comprising the prototype shall be concluded 14 calendar days before shipment of the prototype set. Contractor shall provide sufficient advance notice to support timely government travel.

The FAT deliverable of meeting minutes shall be submitted in accordance with CDRL A006 (reference SOW Table 1 above, the Exhibit Summary at SOW paragraph 10 and Section J of the purchase order award).

The meeting minutes submitted as CDRL A006 shall include all deficiencies identified during FAT, status of corrections, and method of how corrections will be executed.

In the event the cognizant AMXG Engineer determines CDRL A006 contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

Facility Install & Maintainer Training: This milestone shall be concluded on or before the goal date listed in the Table 1 schedule. The intent of this milestone is to complete install of the prototype and on-site maintainer training in accordance with SOW 7 and 8, respectively. In addition, the Government will independently vet the prototype while in use by production personnel in order to assess any needed design changes. Communication of the identified changes including questions and feedback shall be conducted via Teams (or similar telecon-type medium) and/or via email. The cognizant AMXG Engineer will provide a comprehensive list of changes or deficiencies to be made to the design. The identified design changes and corrected deficiencies shall be incorporated into the TDP. The contractor shall not proceed with the TDP until written approval by the cognizant AMXG Engineer has been received.

Post-Installation (Final) Design (TDP): This milestone shall be concluded on or before the goal date listed in the Table 1 schedule. The Operation & Maintenance (O&M) Manuals and TDP shall be submitted in accordance with CDRLs A007 and A008, respectively (reference SOW Table 1 above, the Exhibit Summary at SOW paragraph 10 and Section J of the purchase order award).

O&M Manuals (CDRL A007). Operation and Maintenance manuals shall be prepared and delivered on electronic media in pdf file format compatible with Adobe Acrobat and on 8 ½ by 11 inch bond paper and presented in appropriately sized three ring binders. Operation Manual and Maintenance Manual shall be in separate binders. The contractor shall provide three (3) hardcopy O&M manuals and one (1) CD-R ROM/DVD-R digital copy. The manual shall include, but is not limited to, the following:

Operation Manual – This manual is intended for the user.

Illustrated Parts Breakdown (IPB) with a full bill of materials (BOM) with all components, parts numbers, NSNs, and associated manufacturers and vendors.

Prior-to-Use Inspection Instructions. These instructions shall be performed by the user to inspect the stands prior-to-use.

Operating Instructions. These instructions shall be performed by the user to set-up and operate the stands in each configuration.

Maintenance Manual – This manual is intended for maintenance personnel.

Illustrated Parts Breakdown (IPB) with a full bill of materials (BOM) with all components, part numbers, NSNs, and associated manufacturers and vendors.

Maintenance Instructions. These instructions shall be performed by maintenance personnel and cover items/components that will require sustainment to include all materials and consumables required for maintenance and step by step instructions to complete required tasks.

Schematics for electrical and compressed air systems shall be included.

Recommended Preventative Maintenance Schedule. These instructions shall be performed by maintenance personnel.

In the event the cognizant AMXG Engineer determines CDRL A007 contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

Final Design Technical Data Package (TDP) (CDRL A008). The engineering drawing package, or TDP, shall be prepared per ASME Y14.100 and shall be provided to the Government with unrestricted rights--no proprietary markings of any kind shall be included on the TDP. The final design, or TDP, shall be comprehensive and ensure that the Government can reproduce and modify the design. The TDP shall represent the AMXG Engineering approved design of the stands after Production Assessment has been completed. TDP data includes, but is not limited to, CAD data, CAD models, Bill of Materials (BOM) and parts list, schematics, wiring diagrams, and engineering drawings. The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement and manufacture of an interchangeable item that duplicates the physical and performance characteristics of the original product without additional design engineering effort or recourse to the original design activity. For any third party items procured for this effort, the contractor shall provide the OEM’s original nomenclature, key characteristics, and data sheets as part of the TDP. The engineering drawing package shall be certified and stamped by the contractor’s state licensed Professional Engineer (PE).

The contractor shall deliver two (2) complete printed copies of the final engineering drawing package on 11 by 17 inch bond paper and presented in appropriately sized bound presentation booklets with plastic covers.

Digital copies of the engineering drawings shall be provided on two (2) CD-R/DVD-R in pdf file format compatible with Adobe Acrobat.

Digital copies of the CAD models and engineering drawings shall be provided on two (2) CD-R/DVD-R in Solidworks file format compatible with Solidworks 2019 or earlier. CAD models shall be provided for all individual parts and components that make up the stands with appropriate sub-assemblies making up the final assembly for each stand Solidworks CAD files for parts, assemblies, and drawings shall be compatible with Solidworks 2019 or earlier.

In the event the cognizant AMXG Engineer determines CDRL A008 contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

PROTOTYPE FABRICATION

Upon written confirmation from the cognizant AMXG Engineer that the Pre-Final Design is approved, fabrication of the prototype shall commence. Fabrication shall be in accordance with the approved Pre-Final Design.

Fabrication of the prototype shall be wholly executed at the contractor’s facility by contractor’s staff, i.e. fabrication shall not be executed at an alternate location owned by any other entity than the contractor and labor associated with the fabrication shall not be executed by a subcontractor or individual employed via similar type arrangement but shall be a direct employee of the contractor’s firm.

The only exceptions to the prototype fabrication being wholly executed at the contractor’s facility are powder coating and signage may be executed by subcontractors.

Contractor shall have a sufficient number of AWS certified welders on staff to ensure timely fabrication of the prototype in accordance with the schedule detailed in Table 1 of 4.6 Design Milestones.

The contractor is responsible for the quality of the welds produced. All welding and welds shall comply with AWS D1.1 (for steel) and AWS D1.2 (for aluminum) standards. Welds will be inspected prior to acceptance for appropriate quality and penetration.

Welding must be done by staff in accordance with SOW 3.5.2.2 and 3.5.2.2.1.

DELIVERY of prototype Prototype shall be packaged for transport to ensure that no damage occurs to the structural integrity, subcomponents, finishes, etc. while enroute to HAFB. Prototype shall not contain dirt, burrs, cleaning oils, material shavings, etc. when received at HAFB for installation.

The delivery schedule and shipping address shall be in accordance with Section F – Deliveries of the purchase order award. Labels shall be affixed on exterior packaging that includes Name, Email and Phone of POC identified in Section F as well.

Notice of delivery shall be coordinated with the cognizant AMXG Engineer at least 7 calendar days prior to scheduled arrival at HAFB.

Contractor shall be on-site at HAFB to accept delivery of the prototype and immediately begin the installation process.

INSTALLATION

Contractor shall be responsible for installation and any assembly of final stand components to ensure that the prototype is fully functional, i.e. deemed operationally capable, by the cognizant AMXG Engineer upon final inspection and acceptance at AMXG facilities.

Contractor shall be responsible for all assembly at delivery site. All on-site assembly will be done in a controlled area. Visitors and all personnel working in the controlled area must be escorted by government personnel at all times. Assembly shall be outside, unless hangar space is available or is necessary due to weather conditions.

All tools or equipment necessary to assemble and install the prototype stands to a fully functional condition must be provided by the contractor.

Government-provided shop air and power is available with prior coordination with cognizant AMXG Engineer.

Contractor shall adhere to control procedures for any contractor-owned tools and equipment brought into AMXG facilities as well as FOD, see SOW paragraph 16.

TRAINING

The contractor shall provide on-site maintainer trainer upon completion of the prototype installation at HAFB. Training shall be provided for both day shift and swing shift personnel for three (3) consecutive business days. Training shall take place during core HAFB business hours and be pre-coordinated with the cognizant AMXG Engineer. Pre-coordination while the contractor is on-site for install is acceptable. Training shall cover the following, at a minimum:

Familiarization with all components and features.

Daily maintenance and prior-to-use inspections.

Explanation of safety features and how stands comply with applicable OSHA and DAFMAN 91-203 requirements.

Stand set-up for all configurations including height adjustments.

How to properly connect and disconnect electrical and compressed air.

Explanation of transport and storage of stands; storage details shall include procedures for outdoor storage and methods of storage in inclement weather.

WARRANTY

Warranty shall be a minimum of one (1) entire calendar year. The warranty period shall begin the day after acceptance of the TDP by the cognizant AMXG Engineer. If any repairs are needed during the warranty period, they shall be completed entirely on-site at HAFB by contractor’s direct staff. The warranty shall cover, and the contractor shall be wholly responsible for the replacement of any defective components, subcomponents or systems, the failure of which is due to faulty materials, workmanship, design, and/or selection of inadequate service life materials. The contractor shall perform repairs, including repair/replacement of any faulty materials within seven (7) calendar days. Any shipping or travel costs shall be entirely at the expense of the contractor.

DELIVERABLE SUMMARY

Contract data shall be delivered in accordance with the format and timeframe submission instructions of the applicable CDRL. Reference Table 2 below for a summary of data deliverables.

TABLE 2