F139 PWS DEC 2020.pdf

PWS for F‐139 Sustainment Engineering Contract

AIRFORCE LIFE CYCLE MANAGEMENT CENTER

PROPULSION DIRECTORATE

PROPULSION SUSTAINMENT DIVISION

AFLCMC/LPA

WRIGHT PATTERSON AFB, OH 45433

PERFORMANCE WORK STATEMENT

(PWS)

For F139 Engine, Engineering Sustainment Support

PREPARATION DATE: 17 December 2020

PWS No: 01: AFLCMC/LPA

RFP No: FA8124-20-R-0001

Contract No: FA8124-20-R-0001

PREPARING ORGANIZATION: AFLCMC/LPA K, TINKER AFB, OK 73145-3020

Page

SECTION 1 – Description of Services/Scope of Work

1. ...................................................................................................................................... Scope

1.1. General

1.2. Services

1.3. Period of Performance (PoP)

1.4. Assumptions

1.5. Quality Control.……….………………………………………………………………..7

1.6. Post Award Conference/Periodic Progress Meetings…...…………………………...8

1.7. Key Personnel……………...…………………………………………………………...9

1.8. Identification of Contractor Employees………...…………………………………….9

1.9. Contractor Travel………………………………………………………………………9

1.10. Data Rights or Intellectual Property………...………………………………………9

1.11. Organizational Conflict of Interest…………………………………………………..9

1.12. Phase In/ Phase out Period…...……………………………………………………..10

2. Program Management

2.1. Financial Management

2.2. Unscheduled Engine Removal Projection

2.3. War Readiness Engine (WRE)/Ready For Installation(RFI) Definition

2.4. Build Policy

2.5. Configuration Management

2.6. Parts Usage Report

2.7. Government Furnished Property (GFP)

2.8. Financial Improvement Audit Readiness (FIAR)

2.9. Quality

2.10. Meetings, Reviews, and Teleconferences

2.11. Surge Support

2.12. Maintenance Awareness Program (MAP)

2.13. Depot Maintenance Activation Working (DMAWG) Group

2.14. Data Accession List (DAL)

2.15. Title 10 Support

2.16. Service Contract Report (SCR)

2.17. Maintenance Training………………...….…………………………………………18

3. Scheduled Engineering Support

3.1. Engineering Support

3.2. Sustaining Engineering Services to be Provided

3.3. Operational Safety, Suitability, and Effectiveness (OSS&E)

3.4. Engine Health Monitoring

3.5. Customized Engine Management Plan (CEMP)

3.6. Reliability and Maintainability

3.7. Engine Life Management Plan (ELMP)

3.8. Counterfeit Parts

3.9. Obsolescent or Diminishing Manufacturing Source and Material Shortage (DMSMS) Items

4.0 General Requirements ………………………………………………………………..26

4.1 Technical Data Support……………………………………...…………………..…

4.2 Engine Mission Usage Study……………………………………………...……..…

4.3 Part life limits………………………………………………………..………….……...28

4.4 Mishap and Safety Investigations ………………………………………………

4.5 Durability and Damage Tolerance Life Update …………………..……………

4.6 F139 Performance Upgrade, Mods and Improvements…………………………

4.7 Additional Tasks ……………………………………………………………….……..31

4.8 ECPs …………………………………………………………………………...…

4.9 Fuel Savings Enhancements ……………………………………………………

4.10 Contractor Provided Tooling / Support Equipment………………………….....…32

4.11 Government Furnished Equipment ………………………………………………..32

4.12 Test, Measurement, and Diagnostic Equipment (TMDE) ………………..……

4.13 Assigned Engineering Tasks ……………………………..……………..…………..33

4.14 Emergency Engineering Field Support …………………..…………………....…..35

4.15 Records Maintenance …………………………………………………………...…..36

4.16 Parts Cannibalization……………………………………………………………

4.17 Packaging, Handling, Storage, and Transportation ……………………….....…...37

4.18 Precious, Critical and Strategic Metals …………………………………….…...…37

4.19 Materiel Sourcing ……………………………………………………………...……37

4.20 Disposal ………………………………………………………………………………37

5. Unscheduled MRO Activities

5.1. Engine Build-Up, Repair, Overhaul, and Test Services

5.2. Repair Management

5.3. Depot Level Material and Material Management

5.4. Workscopes/File Orders

5.5. Engine Test Run

5.6. Test, Teardown, and Evaluation (TT&E)

5.7. EBU Component Repair/Overhaul

5.8. QEC

5.9. Warranty

5.10. Reports

5.11. Production Reporting

5.12. Shipping Documents

5.13. Packaging ..................................................................... Error! Bookmark not defined.

5.14. Preservation

5.15. Transportation

5.16. Deficiency Reports

6. Administrative

6.1 Propulsion Working Group Meetings………………………………………..……….49

6.2. Government Quality Assurance Surveillance

6.3. Uses and Safeguarding of Information

6.4. Contractor Personnel at Government Facilities

6.5. Foreign Object Damage Prevention Program

6.6. Green Procurement Program (GPP)

6.7. Contractor Identification

6.8. Contractor Travel

6.9. Holidays and Facility Closings

6.10. Security Requirements

SECTION 2 – Services Summary

SECTION 3 Attachments:

Attachment A, List of QEC Parts from Boeing

Attachment B, Agenda for Contractor Hosted Meetings…………………………………….61

Attachment C, Government Property Physical Inventory Count…………………………..62

Attachment D, Transportation and Shipping

Attachment E, Technical Issue Briefing Packages

Attachment F, ADEM, Advanced Diagnostics Engine Monitoring…………………………66

Attachment G, Maintenance and Workscope Definitions……………………………………66

Attachment H, Technical Reports Deliverables

Attachment I, Leading Health Indicators……………………………………………………..68

Attachment J, Customized Engine Maintenance Plan or (CEMP)………………………….70

Attachment K, Key Personnel Listing………………………………………………………...71

Attachment L, Shop Visit Report, repairs/overhauls………………………………………...71

Attachment M, Deficiency Report, DR and Final Letter Closure…………………………...72

Attachment N, Contractor Saftey Program…………………………………………………..75

Attachment O, CDRL Correlation, Contractor Products in lieu of CDRL or DIDs……

SECTION 1 – Description of Services/Scope of Work

1. Scope

1.1. General

The term Contractor refers to Pratt & Whitney (P&W), a Division of United Technologies Corporation (UTC), and its partners, subcontractors, and/or authorized agents. The term USAF refers to the United States Government (USG), including the United States Air Force (USAF) and its authorized agents. The USAF will hold Cognizant Engineering Authority (CEA) for any and all decisions regarding the F139-PW-100 engine and any associated KC-46 components.

The USAF will be the final authority for decisions regarding engine and component configuration. For the purposes of this Engine, Engineering Sustainment Support (EESS) document, the term “F139” will be used to refer to the F139-PW-100 (PW4062-3). Should a separate and distinct F139 configuration (F139-PW-101 or similar) be developed during the period of performance for this contract, the USAF reserves the right to negotiate any additional work necessary to support the new configuration as part of an assigned engineering task using the process defined in Section 4.14 of this Performance Work Statement (PWS).

1.2. Services.

The Contractor shall provide the following general services:

Program Management (PM)

Scheduled and Unscheduled Engineering Support

Flightline Support in technical service advisory services or Field Service Representative (FSR)

Maintenance Repair and Overhaul (MRO) activities

Quick Engine Change (QEC) Material/Part Support

QEC Repair

QEC Engineering Support

Material, Material Management, and Material Reporting

Under the terms of this contract, USAF will send USAF F139 equipment for disassembly, inspection, repair, assembly, and testing. Foreign Military Sales (FMS) interest has not yet occurred but scope of this contract will include FMS. The Contractor shall be responsible for MRO of the Engine Build-Up (EBU) and other items as identified in the Contract Line Item Number (CLIN) list.

The Contractor shall furnish to USAF the labor and material necessary to accomplish the overhaul and/or repair of the P&W F139-PW-100 (F139) EBU, excluding select QEC items;

defined in Attachment A (List of QEC Parts from Boeing) of this PWS, for USAF and FMS customers. The Contractor shall build up engines into a complete EBU power-plant package configuration, tested and ready for immediate installation and use on the KC-46 Aircraft.

1.3. Period of Performance (PoP).

The PoP for this planned effort is June 2022 – May 2032 including options.

Base period: June 2022 – May 2027

Option 1: June 2027 – May 2030

Option 2: June 2030 – May 2032

1.4. Assumptions

The Contractor is expected to enter into a relationship with the QEC Original Equipment Manufacturer (Boeing) or other party to ensure adequate insight and material for any QEC work that arises during an engine shop visit (Contract Data Requirements List or CDRL A004, DI- ILSS-80620, Government Furnished Equipment Repair Status Report). This relationship shall allow for required program management coordination, technical collaboration, logistics management, and technical and program data exchange to continue supporting sustainment of the KC-46 Propulsion System. The Contractor shall concurrently release data required by both the F139 Program Office and Boeing.

1.5 Quality Control

The contractor shall develop and maintain an effective quality control program to ensure services are performed in accordance with this EESS. The contractor shall develop and implement procedures to identify, prevent, and ensure non-recurrence of defective services. The contractor’s quality control program is the means by which they ensure that their work complies with the requirement of the contract. The Quality Control Program (QCP) should be delivered within 30 days after contract start date. After acceptance of the quality control plan the contractor shall receive the contracting officer’s acceptance in writing of any proposed change to the QCP system. If there are any proposed changes to the QCP, the contractor should propose any changes during program meeting updates. (CDRL A011 DI-QCIC-81722, Quality Program Plan)

1.6 Post Award Conference/Periodic Progress Meetings

The Contractor agrees to attend any post award conference convened by the contracting activity or contract administration office in accordance with Federal Acquisition Regulation Subpart 42.5. The contracting officer, Contracting Officers Representative (COR), and other Government personnel, as appropriate, may meet periodically with the contractor to review the contractor's performance. At these meetings the contracting officer will apprise the contractor of how the government views the contractor's performance and the contractor will apprise the Government of problems, if any, being experienced. Appropriate action shall be taken to resolve outstanding issues. These meetings shall be at no additional cost to the government.

1.7 Key Personnel

The following contractor personnel are considered key personnel by the government, contract manager and alternate. Listing of key personnel and qualifications need to be agreed upon. See Attachment K, (Key Personnel Listing).

1.8 Identification of Contractor Employees

Contractor employees will identify themselves as Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishing badges or other visible identification for meetings with Government personnel. In addition, Contractor personnel will appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence. If the Contractor requires access to the flightline on any USAF Base or commercial airport maintenance area, they will secure proper access.

1.9 Contractor Travel

The Contractor may be required to travel within the continental United States and overseas during the performance of this contract to provide engineering services. The contractor may travel to attend meetings, conferences, and provide training. The contractor may be required to travel to locations to provide training and to ship training aids to these locations in support of this

PWS.

1.10 Data Rights or Intellectual Property

The Government has unlimited rights to all documents/material produced under this contract.

All documents and materials, to include the source codes of any software, produced under this contract shall be Government owned and are the property of the Government with all rights and privileges of ownership/copyright belonging exclusively to the Government. These documents and materials may not be used or sold by the contractor without written permission from the Contracting Officer. All materials supplied to the Government shall be the sole property of the Government and may not be used for any other purpose. This right does not abrogate any other Government rights.

1.11 Organizational Conflict of Interest

Contractor and subcontractor personnel performing work under this contract may receive, have access to or participate in the development of proprietary or source selection information (e.g., cost or pricing information, budget information or analyses, specifications or work statements, etc.) or perform evaluation services which may create a current or subsequent Organizational Conflict of Interests (OCI) as defined in FAR Subpart 9.5. The Contractor shall notify the Contracting Officer immediately whenever it becomes aware that such access or participation may result in any actual or potential OCI and shall promptly submit a plan to the Contracting

Officer to avoid or mitigate any such OCI. The Contractor’s mitigation plan will be determined to be acceptable solely at the discretion of the Contracting Officer and in the event the Contracting Officer unilaterally determines that any such OCI cannot be satisfactorily avoided or mitigated, the Contracting Officer may affect other remedies as he or she deems necessary. This includes prohibiting the Contractor from participation in subsequent contracted requirements which may be affected by the OCI.

1.12 Phase In/ Phase out Period

To minimize any decreases in productivity and to prevent possible negative impacts on additional services, the Contractor shall have personnel on board, during the [sixty (60) day] phase in/ phase out periods. During the phase in period, the Contractor shall become familiar with performance requirements in order to commence full performance of services on the contract start date.

2. Program Management The Contractor shall manage, direct, and control requirements and processes to achieve the performance requirements of the contract. The Contractor shall establish a single point of contact to communicate with the USAF F139 Program Manager and provide a monthly program report.

The USAF anticipates collaboration between the Contractor and the Government USAF F139 Program Office and KC-46 System Program office (SPO) to develop and implement a joint partnership to manage the sustainment of the F139 engine and achieve safety, reliability, and readiness goals. The contractor shall provide a monthly report no later than 15 days after the previous month. (CDRL A001 DI-MGMT-80933A, Repair/Modification/Overhaul Status Report)

2.1. Financial Management

2.1.1. Budgetary Support

The Contractor shall support the USAF analysis of budgeting exercises and drills as mutually agreed to by both parties, for work covered under the scope of this contract.

2.1.2. Contract, Invoicing and Payment Report

The Contractor shall report invoicing and payment information associated with CLINs and Accounting Classification Requirements Numbers (ACRNS) within the contract period of performance. Contractor shall also provide written notice to the Primary Contract Officer (PCO) when funding for any CLIN has reached eighty-five percent of available amount per CLIN.

Notification shall include Contractor's assessment of whether or not the effort can be completed within the remaining funds (CDRL A036, DI-MGMT-81651, F139 Contract Invoicing and Payment Report).

2.2. Unscheduled Engine Removal Projection

The Contractor shall provide a forecast for unscheduled engine removals. This forecast shall be for planning purposes only based on mission type and similar use commercial data. The

Contractor shall provide a life cycle forecast for overhaul predictions based on the PW4062-3 lifing studies. Unplanned engine removal events, USAF cycle assumptions, and/or known fleet movements will be assessed for year by year unscheduled engine removals out to the year 2045.

The USAF will make a best effort to provide any known changes and data to assist in developing unscheduled modeling.

2.3. War Readiness Engine (WRE)/Ready For Installation(RFI) Definition An EBU is deemed a WRE/RFI when it is accepted at the receiving location and is identified in Comprehensive Engine Management System (CEMS) system as Condition Code “RB.” which is raw build-up IAW USAF Technical Order 00-25-254-1. USAF will accept engine as WRE/RFI within two (2) business days of arrival at destination.

2.4. Build Policy

The Contractor shall provide repair maintenance for engines to meet the USAF Build Goal of 13,800 low cycle fatigue cycles to meet a Mean Time Between Removal (MTBR) of 14,300 Engine Flying Hours (EFH) on new engines. The Contractor shall deliver repaired / overhauled EBU engines in a fully tested and Ready for Installation (RFI) condition. Regardless of need for off-wing maintenance, engines shall meet the Exhaust Gas Temperature (EGT) Margins outlined in the Attachment G, (Maintenance and Workscope Definitions) and Attachment J (CEMP, Customized Engine Maintenance Plan). The USAF reserves the right to direct an engine be repaired to a shorter build policy. The Contractor shall submit a Request for Waiver (CDRL A030, DI-SESS-80640E, Request for Variance) for any technical variance for formal documentation of an engine built or repaired for short-term use.

2.5 Configuration Management

2.5.1 Configuration Control: The Contractor shall provide support to the F139 Configuration Management Plan (CMP) (CDRL A016, DI-SESS-80858C, Supplier’s Config. Mgt. Plan) to the USAF as required. The configuration control process is documented in the P&W engineering services manual, PW4000 Engine Manual (part number 50A605, Chapter 5), shall follow the configuration management processes outlined in International Organization for Standardization ISO 9001, Aerospace Standard AS9100 and/or AS9110.

2.5.2 The Contractor shall use configuration management functions to establish and maintain consistency of product/system attributes with requirements and configuration information throughout the entire life cycle. The Contractor shall use configuration management processes for product and system characteristics, including components, key processes, and methods used to verify compliance with design and performance requirements. Configuration management requirements for configuration control must be documented and performed to meet Federal Aviation Administration (FAA) commercial requirements.

2.5.3 The Contractor shall initiate and maintain a tracking program for Original Equipment Manufacturer (OEM) Service Bulletins (SBs), and FAA Airworthiness Directives (ADs).

Tracking of this information shall be reported in the Program Monthly Report (CDRL A001, DI- MGMT-80933A, Repair/Modification/Overhaul Status Report).

2.5.4 The Contractor shall maintain configuration control over in-service F139 engines, subassemblies and components I.A.W. the approved CMP, the most recent revisions of the List Of Applicable Documents (CDRL A016, DI-SESS-80858C, Configuration Management), Time Compliance Technical Orders (TCTO), USAF-approved FAA ADs and OEM SBs. Only OEM approved Category I Parts Manufacturer Approval (PMA) parts and approved OEM Designated Engineer Representative (DER) components/repairs will be installed in the F139.

2.5.5 The Contractor shall identify F139 configuration control issues, recommendations and corrective actions to the F139 CEA for approval through the applicable manuals, ADs, SBs, and other pertinent information outlined in this EESS.

2.6 Parts Usage Report

2.6.1 The Contractor shall provide the USAF with insight into critical parts list that may affect WRE requirements or will impact production. The Contractor shall continue to deliver the critical parts list and add the Program Management Office on the distribution detailing all parts which may impact production, root cause, and possible mitigation or corrective actions. This shall be delivered in the weekly action item report and with the critical parts list.

2.6.2 The Contractor shall provide rights to F139 component repair rates and factors, and scrap report to include reason for scrapping that is sufficient to support a supportability analysis. The Contractor shall provide in Contractor format rates for all engine parts and factors for eighty percent of the engine parts excluding consumables. Rates and factors shall include items sent to repair, scrapped at MRO facility, serviceable from vendor. (CDRL A009, DI-ILSS-81226, ICS Parts Usage and Maintenance Data Collection Report).

2.7 Government Furnished Property (GFP)

2.7.1 The Government will furnish negotiated GFP without cost to the Contractor to support F139 Engine Sustainment. The Contractor shall ensure all GFP is safeguarded and secured at the close of each workday. This GFP shall only be used for the performance of this contract. GFP shall remain property of the Government during contract performance, completion, and/or termination. The GFP shall be managed in accordance with 48 CFR Part 45, Government Property, plus supplements, applicable contract clauses, and this PWS for Government and prime contractor facilities. For commercial overhaul facilities, the Contractor is responsible for inventory control and reporting in the GFP module of Procurement Integrated Enterprise Environment (PIEE).

2.7.2 The Contractor shall safeguard Government property provided as GFP or GFE. GFP/GFE inventory, location, and condition shall be reported as directed in (CDRL A033, DI-MGMT- 80441D, Government Property Inventory Report) NOTE: GFP includes Government Furnished Equipment (GFE), Government Furnished Facilities (GFF), and Government Furnished Material (GFM).

2.7.3 The Contractor shall be responsible for managing and maintaining any GFP Special Tooling and Support Equipment in a serviceable condition during the contract period, including replacement of unserviceable items.

2.7.4 Reporting loss of GFP, the Contractor shall use the PIEE website as directed in the Financial Improvement Audit Readiness (FIAR) - (Section 0 of this PWS) and applicable supplements and shall be in compliance with all applicable guidance and clauses listed in the contract. The reporting requirement does not change any liability provisions or other reporting requirements that may exist under the contract/order. Unless otherwise provided for in this contract, the requirements of FAR 52.245-1, paragraph (b) (1) do not apply to normal and reasonable inventory adjustments, i.e., losses of low-risk consumable material such as common hardware, as agreed to by the Contractor and the Government Property Administrator. Such losses are typically a product of normal process variation. The Contractor shall ensure that its property management system provides adequate management control measures, e.g., statistical process controls, as a means of managing such variation.

2.7.5 The Contractor shall report losses of GFP outside normal process variation, e.g., losses due to theft, inadequate storage, lack of physical security and “Acts of God”. This reporting requirement does not change any liability provisions or other reporting requirements that may exist under this contract.

2.7.6 At contract completion, the Contractor shall return to USAF any GFP Special Tooling and Support Equipment provided to assist the Contractor in supporting this contract. The Contractor shall return those items that were originally received in a serviceable condition (with consideration for normal wear and tear) back to USAF in serviceable condition. For items that were received originally by the Contractor in an unserviceable condition, as annotated on the DD1149, the Contractor may return these items in an unserviceable condition.

NOTE: The Contractor shall be responsible for all costs related to making the GFP available for use, such as installation at his site or rehabilitation costs necessary to upgrade any currently unserviceable equipment to a serviceable status.

2.8 Financial Improvement Audit Readiness (FIAR)

2.8.1 The Contractor shall transition and maintain compliance with DoD Financial FIAR requirements associated with all reportable F139 GFP. This effort will include inventory verification, valuation, validation, reconciliation and audit assistance, cataloging of parts, material, National Stock Number (NSN) and/or part number cross reference research, database entry, GFP Accountable Property System of Record (APSR) or successor system, and production of all FIAR mandated reports. The Contractor shall maintain an inventory tracking system with 100% GFP inventory. See Attachment C, (Government Property Physical Inventory Count) of this PWS to list GFP. The Contractor shall provide an updated inventory and discrepancy listing to the PCO and IAW the (CDRL A003, DI-ADMN-81505, Report, Record of Meeting Minutes).

2.9 Quality

2.9.1 The Contractor shall provide and maintain a quality and inspection program in accordance with common commercial practices meeting FAA standards effective at the time of repair/overhaul. The Contractor’s standard commercial procedures meeting FAA standards will apply. The Contractor shall maintain a quality assurance management system and a quality plan IAW Title 14 Code of Federal Regulations Part 145 (14 CFR 145). The Contractor shall also hold certification for any one of the following: ISO9001, AS9100 or AS 9110. The Contractor shall provide a copy of their quality management plan 60 days after contract award. The Contractor shall report changes to the quality management plan. The Contractor shall identify their Quality point of contact at post award conference. CDRL A011 will apply, (CDRL A011, DI-QCIC-81722, Quality Program Plan) which is the Quality methodology.

2.9.2 The Contractor shall be an authorized FAA Repair Facility and hold a FAA Repair Facility Certificate Number for PW4000 Series Engine and rated for PW4062-3 (USAF F139 or equivalent) series maintenance.

2.9.3 The Contractor shall collect and report on program quality related data. The data should include significant quality deficiencies and corrective action taken. This information shall be made available via a shared data resource and shall be presented by the Contractor at each periodic Attachment B (Agenda for Contractor Hosted Meetings) PMR and documented in the Joint Deficiency Reporting System (JDRS).

2.9.4 The Contractor shall implement processes and procedure to reduce the risk of Category I deficiencies resulting from F139 sustaining engineering and supply chain management services.

The Contractor shall provide a monthly Quality Report (contractor format) addressing quality issues to include narrative of issue, date of occurrence, location of occurrence, root cause, corrective action, estimated completion date and justification if estimated completion date will not be met. (CDRL A011, DI-QCIC-81722, Quality Program Plan)

2.10 Meetings, Reviews, and Teleconferences

2.10.1 The Contractor shall, with the guidance of the PM, develop and coordinate agendas for Contractor-hosted meetings. Completed agendas will be presented to the Program Manager no less than fifteen working days prior to meeting date. Upon approval by the Program Manager, the Contractor shall distribute the agendas.

2.10.2 The Contractor shall provide Contractor hosted meeting minutes to the PM for approval no more than five working days after the meeting (CDRL A003, DI-ADMN-81505, Report, Record of Meeting Minutes). The Contractor has five working days after receipt of USAF comments to prepare and deliver the final minutes.

2.10.3 The Contractor shall establish a call-in number in order to participate in telecom meetings with the USAF program office.

2.10.4 The Contractor shall participate on the F139 Engine Management Team (EMT) and the Propulsion Sustainment Integrated Program Team (IPT).

2.10.5 Repair Management Cooperation

The USAF and Contractor shall participate on the Engine Management Team along with Boeing.

Boeing and the Contractor will continue to co-chair the EMT, following the guidelines enumerated below, to provide sustainment for the F139 engines to accomplish the goals of improving aircraft availability and reducing costs to their USAF and FMS customers. These guidelines recognize that the USAF has ultimate decision authority and may not always include Boeing and the Contractor in the decision making process regarding engine removals and maintenance. However, when Boeing and the Contractor are included in the decision making process, the following general guidelines will be used:

2.10.5.1 When an aircraft is on-ground or an engine may be removed outside Technical Order (T.O.) limits:

The Contractor will participate in concurrent discussion with Boeing and the Customer on any engine issue including AFTO 95 historical documentation and interpretation of Technical Manual.

2.10.5.2 The Contractor will participate in concurrent discussion with the Customer and Boeing on:

Items that affect engine serviceability

Where an engine should be stationed when technical issues or field service campaigns, etc. may make it more advantageous to keeping an engine at a main operating base

2.10.6 Propulsion IPT Engine Management Teleconference

The Contractor shall support the weekly IPT telephone call with the USAF program manager to discuss:

Supportability of the program

Contract compliance

Metrics

Requirements

Other essential elements pertaining to the Contract

2.10.6.1 The Contractor shall support scheduled IPT teleconferences. The Contractor shall be prepared to discuss:

Pending unscheduled removals where the Contractor has been requested to provide a recommendation

Validity of proposed Deficiency Reports (DR) before a DR is submitted on an engine and/or component. Documenting a problem on a DR and its possible solutions will not infer, demand, or hold P&W responsible to provide or perform corrective action unless an applicable root cause is identified. Issues that cannot be resolved will be raised up to KC-46 and F139 management for resolution.

2.10.7 The Contractor’s representatives may suggest alternate maintenance methods for engines that will be removed based on corporate commercial experience. The Contractor shall coordinate any engine maintenance recommendations outside of current T.Os. with Boeing prior to submitting a proposal to the USAF.

2.11 Surge Support

2.11.1 Surge Plan

The Contractor shall maintain a Surge Plan, (CDRL A007, DI-MGMT 80969, Production Surge Plan), to support Air Force surges, exercises, and contingency requirements and make available to USAF upon request IAW 48 CFR 252.237-7024. The Contractor shall maintain and update its plan as necessary and adhere to its requirements throughout the contract term. The Contractor shall not alter the plan without the PCO’s consent. In the event the Contractor anticipates not being able to perform any of the essential Contractor services identified in this EESS during a crisis situation, the Contractor shall notify the PCO and use its best efforts to cooperate with the USAF to maintain the continuity of operations.

2.11.2 Surge Support

The Contractor shall support Air Force surge, contingency, and reporting requirements as directed by the USAF PCO. The Contractor shall also provide support to USAF during Surge, Aircraft On Ground (AOG), Mission Capable (MICAP), and/or Engine Non-Mission Capable Status (ENMCS) situations to provide critical status updates on parts shipments. The Contractor shall take reasonable actions to expedite the repair and/or procurement of parts, as appropriate, to meet the requirements of the KC-46 Fleets. The Contractor shall provide daily status to USAF during these times of crisis.

2.12. Maintenance Awareness Program (MAP)

Contractor shall implement a MAP (or meet intent of Program) to address engine health, maintenance, and safety related issues. The program will provide Maintenance Awareness Briefings (MAB) yearly at F139 bases worldwide as coordinated with the USAF F139 Program Office. Contractor shall price 3 CONUS and 1 OCONUS briefings per year. The Contractor will develop briefings based on Unscheduled Engine Removal (UER) and In-Flight Shut Down (IFSD) drivers and current field related issues (See Attachment I). Contractor shall support consistent maintenance practices throughout the F139 fleet, through increased communication and feedback of operational problems, address maintenance induced incidents, recognition of support equipment issues, and clarification of procedures in Technical Data (See Attachment I).

The Contractor shall allow the Contracting Officer Representative (COR) or his designated Government representatives to accompany them during these base visits and briefings.

2.13 Depot Maintenance Activation Working (DMAWG) Group

2.13.1 The Contractor shall participate and provide support as outlined in AFMCI 21-101 for the OC-ALC Depot activation of the F139 engine (CDRL A027, DI-ILSS-80739, Depot Maintenance Study).

2.13.2 The Contractor shall provide input into the F139 strategic depot activation plans (ramp-up plans) and schedules in a joint effort with the USAF DMAWG representative(s).

2.13.3 Gap Analysis Report. When so tasked, the Contractor shall perform an evaluation of existing USAF depot facilities to identify shortfalls in the depot’s facilities and equipment necessary to support organic MRO activities. The Contractor shall provide a gap analysis report that will contain results from the on-site capabilities assessment starting when two years into the contract (CDRL A027, DI-ILSS-80739, Depot Maintenance Study). The tasking report and analysis will be negotiated at the time.

2.13.4 The Contractor shall assist in the development of funding requirements and business case analysis for support of ALC depot activation and will provide recommended execution priorities.

2.13.5 The Contractor shall provide assistance to the IPT for components in support of a depot activation study as requested or when tasked in (CDRL A027, DI-ILSS-80739, Depot Maintenance Study).

2.14 Data Accession List (DAL)

The Contractor shall maintain and make available (during the contract performance period and upon request by the Government) data listed in the DAL. The DAL shall specify internally generated data or other working papers prepared by the Contractor to document compliance with the PWS requirements in developing, testing, and managing the program. (CDRL A029, DI- MGMT-81453B, Data Accession List).

NOTE: The DAL may be developed as part of the Contractor’s ISO certification and quality systems. The DAL does not include the Contractor’s working papers or sticky notes. The purpose of the DAL is to provide a medium for identifying Contractor deliverable data which has been generated by the Contractor in compliance with the work effort described in the EESS. The DAL is an index of the generated data that is made available upon request.

2.14.1 Generated Materials

All material generated and delivered under this contract becomes the property of the USAF and shall be returned to the USAF upon completion of the contract/order. All Department of Defense (DoD) Form 1423-1, deliverables become the property of the USAF upon receipt. The Contractor shall not report more than one document late per quarter and no document shall be received later than five business days. The Contractor shall not submit reports that require more than two corrections per report per quarter.

2.15 Title 10 Support

The Contractor shall provide information as required to support reporting of 50/50 law, 10 USC Sec 2466, as directed in (CDRL A031, DI-MGMT-81749B, 50/50 report). The Contractor shall evaluate OC-ALC infrastructure, capacity, and capability to support Core and 50/50 workloads.

2.16 Service Contract Report (SCR)

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

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

Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and Contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the Contractor name and contract number associated with the data.

User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for Government personnel and Contractors are available at the Army CMRA link at http://www.sam.gov .

2.17 Maintenance Training

When required, the Contractor shall develop KC-46 engine maintenance system training in accordance with USAF Instructional Systems Development procedures and the Air (Air Material Command) Aircraft MTS Concept of Operations for unrestricted Government use.

2.17.1 Organizational Level (O-Level) Maintenance Training: When required, the contractor shall develop and conduct Type 1Training for engine maintenance personnel and tailor to each skill level.

3. Scheduled Engineering Support

3.1. Engineering Support

The Contractor shall perform Scheduled (this Section) and Unscheduled (Section 5 of this PWS) engineering and technical services required to support Operational Safety, Suitability & Effectiveness (OSS&E) and sustaining engineering of the F139 engine. Contractor shall provide the required information needed for USAF OSS&E and sustaining engineering compliance outlined IAW AFI 63-101/20-101. The contractor shall utilize Attachment E for Technical Issue briefing packages and Attachment H for Technical Reports as applicable.

3.2. Sustaining Engineering Services to be Provided

The Contractor shall provide engineering services for Sustaining Engineering and Investigations.

Sustaining Engineering support shall include:

3.2.1. Provide engineering expertise to respond to technical inquiries such as operational and maintenance procedures, engine to aircraft interface, Electronic Engine Control (EEC) and Full Authority Digital Engine Controller (FADEC) logic understanding, and engine limits. These services are limited to current, day-to-day operational issues or maintenance documentation (non-conformance support, deviation requests, and engine configuration changes) and excludes engineering studies and airframe upgrade activities.

3.2.2. Operational Level Response

Contractor shall provide completed responses to Engineering/Technical Support Inquires/ Questions within the allotted time for Urgent/Safety and Routine. Urgent/Safety related instructions shall be completed within a monthly average of twenty four (24) hours, with no responses taking longer than fourteen (14) calendar days. Routine related instructions shall be completed within a monthly average of three business days, with no responses taking longer than thirty calendar days. The Contractor shall provide Engineering Support Reports quarterly (CDRL A026 DI-MISC-80508A, Technical Report – Study/Services) that contain technical inquiry narrative/request type, technical inquiry identification number, date of formal request, answer due date, message close date, issue close date, engine type, message status, initiator, problem type, MRO facility/base location and justification for delinquent response time if not completed within required timeframe. The USAF will determine the category of support (Urgent/Safety and Routine) with input from the Contractor and collaborate with the contractor to determine a mutually agreed upon start and due date.

3.2.3. Depot-Level Response

The Contractor shall maintain a goal for providing disposition recommendations in reporting methods or commercial equivalent from MRO repair facilities within ten business days for non-work stop issues and three business days for work stoppage issues. The Contractor shall provide the USAF with a copy of the Engineering Authorizations Summary, that affect the design or maintenance of the F139 engine or its components to the USAF as outlined in this EESS.

3.2.4. The Contractor shall provide status of on-going USAF initiated projects (CDRL A026 DI- MISC-80508A, Technical Report – Study/Services) related to the F139 engine.

3.2.5. The Contractor shall support preliminary fact finding investigations as requested by USAF. This support shall be limited to review of field reports, engine records (CDRL A008, DI- ALSS 81610, Scanning/Digitizing Data), preliminary data, and consultation with other engineering groups.

3.2.6. The Contractor shall evaluate Aircraft Maintenance Manual, (AMM). Changes to the manual or a Publication Change Requests (PCR) deemed to have an impact to engine operation or maintenance manual limits. Initial response shall be within 5 business days from receipt of a T.O. change/PCR by the Contractor. Response shall include an initial evaluation of the T.O.

change/PCR and a forecast date for the final approval or disapproval recommendation if Contractor determines additional time is needed to evaluate the PCR. The final recommendation will include a rationale for any disapproval recommendation, or if approved, a forecast date for the delivery of appropriate source documentation of any updates to engine operation or maintenance manual limits. Source documentation shall meet the intent of an FAA certified engineering process.

3.2.7. Contractor shall deliver at no charge to the USAF F139 Program Office the following F139 commercial engine Technical Data:

Pratt & Whitney Interactive DVD Eagle Disk (PN 1B8138) which includes PN 50A605 Engine Manual (PW4062-3), PN 50A607 Illustrated Parts Catalog, and F139 Service Bulletins.

Access to Pratt and Whitney’s parts catalog, with appropriate level drawings

PN 52A509 Commercial Maintenance Manual

PN 585005 Standard Practices Manual

PN 51A357 Cleaning, Inspection, Repair Manual

PN 1B8536 F139 Component Maintenance Manuals

PN 1B8617 Manual and Parts Catalog Index for P&W F139

3.2.8. The Contractor shall be responsible for maintaining access to and controlling all applicable Technical Documentation. USAF will assist the Contractor with Technical Order Distribution Office (TODO) authorization and/or Digital Technical Order System (DTOS) access and Interactive Electronic Technical Manual (IETM) updates.

3.3. Operational Safety, Suitability and Effectiveness (OSS&E Contractor Interface)

3.3.1. The contractor shall provide the common commercial services required support needed for USAF OSS&E and sustaining engineering compliance outlined in AFI 63-101/20-101. The Contractor may be tasked to provide support beyond standard commercial engineering services that is not defined in other sections using the Assigned Engineering Task Process of Section 0 of this PWS.

3.3.2. The Contractor shall provide agreed to technical data as required for OSS&E compliance.

3.3.3. The Contractor shall provide the USAF access to technical data and assist the USAF in OSS&E compliance. The technical data provided by the Contractor may include technical manuals and component level data. Component level data is defined as data required for validating OEM recommendations, such as Level III drawings, failure analysis, and stress analysis. The technical data provided by the Contractor will only be used for USAF requirement compliance and shall not be disclosed outside of the USAF unless previous written authorization from the Contractor is granted.

3.3.4. System Safety

3.3.4.1. Safety Plan

The Contractor shall develop a system safety approach plan (CDRL A020, DI-SAFT-81626, System Safety Plan) that adheres to MIL-STD-882E requirements and Propulsion Center of Excellence (PCOE) Best Practice (BP) 99-06.

3.3.4.2. Non-Recoverable In-Flight Shut-Down (NRIFSD)

The Contractor shall manage to Director of Propulsion (DoP) safety thresholds defined in Air Force Manual (AFMAN) 20-116 for NRIFSD and Engine Related Loss of Aircraft (ERLOA) for the F139 fleet.

3.3.4.3. Fleet Safety

The Contractor shall provide support to improve F139 fleet safety and reliability. The required support includes safety analysis, hazard tracking, risk analysis (CDRL A021, DI-MISC-80508B, Technical Report – Study/Services), and closure status, as required, to meet or improve system performance. The Contractor shall provide analysis of safety hazards, failure causes and effects, reliability and maintainability trends, risk assessments, risk mitigations, position papers, T.O.s, ADs, and SBs. The Contractor will provide this information to F139 program office for concurrence (CDRL A020, DI-SAFT-81626, System Safety Plan) and F139 System Safety Program Plan (SSPP)).

3.3.4.4. Safety Risk Assessments (SRAs)

The Contractor shall thoroughly research, provide, coordinate SRAs, Investigation, events, Fault Trees, and safety related studies with the F139 program office. SRA reports shall contain issue description, executive summary, key inputs/assumptions, summary of results, references, supporting documentation identifying population at risk by serial number, releasable historical events, event severity, sample calculations, and aircraft hazard matrix. The contractor shall provide Risk Notifications IAW LPS OI 91-882 for Baseline (T0), Interim (T1), and Final (T2) risk assessments. The Contractor shall provide and coordinate recommendations and mitigations for managing risk (CDRL A020, DI-SAFT-81626, System Safety Plan).

3.3.4.5. Notifications

The Contractor shall provide the F139 Program Office with copies of final notifications and recommendations provided to commercial owner-operators in accordance with 14 CFR 21.3 for incidents involving the F139 and PW4000 series commercial fleets (CDRL A014, DI-SESS- 82018, Failure Modes, Effects, and Criticality Analysis Report).

3.3.5. Risk Management

3.3.5.1 The Contractor shall develop, provide, and maintain a risk management plan for the purpose of early identification of program risks and mitigation actions. The Contractor shall provide description of the cause of risk, risk levels, actions being taken, and any slips to the plan of action as required (CDRL A020, DI-SAFT-81626, System Safety Plan).

3.3.5.2 The Contractor shall analyze safety hazards, failure causes and effects and identify corrective actions and mitigations for risk events ensuring DoP thresholds are adhered to.

3.3.5.3 The Contractor shall report risk mitigations and formal risk assessment as directed by the USAF required AFIs and all pertinent documents/regulations for addressing safety related issues IAW MIL-STD-882E, AFMAN 20-116 and PCOE BP 99-06.

3.3.5.4 The Contractor shall provide a status report and provide briefings detailing risk resolution and mitigation status to the USAF during program reviews and other meetings as directed by the PCO. For safety related issues, the reports and briefings shall conform to the format designated by PCO.

3.3.6. Failure Modes, Effects, and Criticality Assessment (FMECA)

The Contractor shall provide an initial FMECA study as directed in (CDRL A012, DI-SESS- 80255B, Failure Summary and Analysis Report) Failure Modes, Effects, and Criticality Analysis Report. The USAF may request additional FMECA studies using the Assigned Engineering Task process defined in Section 0 of this PWS.

3.4. Engine Health Monitoring

3.4.1. Engine Trending and Diagnostics (ET&D)

3.4.1.1. The Contractor shall process, and interpret engine health and usage trend data.

3.4.1.2. The Contractor shall provide ET&D for the F139 fleet to reduce engine flight safety risk, improve reliability, and optimize life cycle costs by identify adverse performance trends to the total fleet and identify adverse trends and/or faulty Line Replaceable Unit (LRU) indications to individual aircraft/propulsion system(s) excluding QEC. When assigned as an Engineering Task per Section 0 of this PWS, the Contractor shall assist in the migration of all ET&D data from ADEM to USAF Maintenance Information System (CDRL A013, DI-SESS-81497B, Reliability and Maintainability Predictions Report).

3.4.1.3. The Contractor shall perform the following tasks applicable to the F139 Propulsion System defined as Engine Trending and Diagnostics:

Analyze engine data from Main Operating Bases (MOB), off-station deployments and en-routes. Assess fleet performance retention and identify individual engine health relative to the fleet average. The Contractor shall provide all core engine related data and performance information to the Integrated Process Team (IPT) as required. (CDRL A013, DI-SESS-81497B, Reliability and Maintainability Predictions Report.

Identify trends and diagnose system discrepancies based on data analysis.

Coordinate maintenance recommendations with the USAF IPT for Propulsion and with USAF Propulsion Engineers.

Review fleet trends with the USAF for root cause identification and potential corrective actions.

Participate on the Propulsion System IPT and shall support meetings and teleconferences as defined in Section 0 of this PWS.

The Contractor shall coordinate or provide the USAF access to the P&W Military Engine Portal and ADEM system for all F139 users to be used for configuration control, engine trending, diagnostics and technical services.

3.4.2. Advanced Diagnostics Engine Monitoring (ADEM) Service

3.4.2.1. The Contractor shall provide access to the F139 ADEM service to the USAF, KC-46 operators, and Boeing.

3.4.2.2. The Contractor shall provide appropriate access for USAF, KC-46 operators and Boeing as required to gain the appropriate information and input and retrieve data from the system.

Operation of ADEM shall be described in an ADEM User Manual.

3.4.2.3. Detail description of ADEM minimum requirements is in Attachment F, ADEM Monitoring. Specific parameters are listed in Attachment F.

3.4.2.4.