AppendixA.pdf

APPENDIX A

FILE NUMBER: OC/5960/001/448 ACSG

DEPARTMENT OF THE AIR FORCE

HEADQUARTERS OKLAHOMA CITY AIR LOGISTICS CENTER (AFMC)

TINKER AIR FORCE BASE, OKLAHOMA 73145

PR NO: FD2030-07-01532

AF CONTRACT NO: DATE: 09-11-2007

Performance Work Statement (PWS)

TYPE OF WORK: Overhaul / Remanufacture of Klystron Power Amplifier (KPA)

POINTS OF CONTACT

Production Management Specialist Pam Watkins (405) 736-5256

Logistic Manager Justin Pollard (405) 736-2191

Item Manager Calvin Austin (405) 736-2192

Engineer Solomon Tamirat (405) 736-5255

Equipment Specialist Kevin Massucci (405) 736-4433

Common Fax (405) 736-5412

CONTENTS

Page

PREFACE SHEET.......................................................................................................................... ii

REVISION SHEET ....................................................................................................................... iii

SECTION

I. GENERAL

II. WORK REQUIREMENTS

III. TECHNICAL ORDERS, DIRECTIVES, AND OTHER TECHNICAL GUIDANCE

FILE NUMBER: OC/5960/07/448 ACSG ii

PREFACE SHEET

END ITEM END ITEM

RECEIVED AS: TO BE DELIVERED AS:

END ITEM

NO

NATIONAL

STOCK NO(S)

PART NO(S)

NOUN

NATIONAL

STOCK NO(S)

PART NO(S)

0001 5960-01-343-5912AW 587R258H01

L-5865-50

Wide Band

KPA(Oxide Type)

5960-01-343-5912AW 587R258H01

0002 5960-01-343-5912AW 587R258H02 Wide Band KPA

(Dispenser Type)

5960-01-343-5912AW 587R258H02

FILE NUMBER: OC/5960/07/448 ACSG iii

REVISION SHEET

When a revision is received, it should be inserted into this (PWS). The superseded pages should be retained as a record.

Note: The portion of the text of this specification affected by the current revision is indicated by a black underscore for figures, words, or phrases within a given paragraph, and by a black vertical line in the outer margin where the change constitutes a whole paragraph.

After the revised pages have been inserted into the PWS, the revised title page should be inserted in front of the existing title page. This revision page is placed under the basic title page.

REVISION NUMBER PAGES DATE

FILE NUMBER: OC/5960/07/448 ACSG 1

SECTION I GENERAL

1.1 DEFINITIONS

1.1.1 The following definitions are applicable to this PWS:

a. End-Item. An end-item is a complete piece of Government equipment as listed in government supply catalogs and suitable for government storage and issue.

b. Initial Production Evaluation. An initial production evaluation (IPE) is a planned

Government review of early production items and processes to evaluate a contractor’s capability to complete the work stipulated in the contract. Work to be completed in accordance with (IAW) the technical order (TO).

c. Overhaul. The term overhaul covers both essential repair and remanufacturing as defined in FAR 22.1003-6. The determination of what will be required (essential repair or remanufacturing) will be based on the tech data for the end-item.

d. Initial Inspection. This inspection shall include visual, mechanical and functional testing to determine the condition of the tube. Upon completion of this task, the tubes will fall into one of four categories: serviceable, minor repair, major repair or total rebuild.

e. Minor Repair. Inspect and replace as necessary any non-vacuum external component or assemblies to bring the tube to like new condition.

f. Major Repair. Inspect and replace as necessary any major vacuum assemblies other than the input body section and output body section to bring the tube to like new condition. All external casings, hoses, and covers shall be cleaned, painted, and/or refinished as required.

g. Total Rebuild. Inspect and replace as necessary any major vacuum assemblies including the input body section and output body section to bring the tube to like new condition.

All external casings, hoses, and covers shall be cleaned, painted, and/or refinished as required.

h. Dispenser Conversion. Replace the oxide cathode electron gun with a dispenser cathode electron gun. Inspect, replace, and rework any major vacuum assemblies to bring the tube to the latest L-6075-50 configuration and to a like new condition. All external casings, hoses, and covers shall be cleaned, painted, and/or refinished as required.

1.2 INITIAL PRODUCTION EVALUATION REQUIREMENTS

1.2.1 Determination for the requirement/non-requirement of an IPE will be made at the award of the contract.

1.2.2 The IPE will be conducted on three total rebuild units. The condition of the items at

IPE will be as follows: 1 each open and ready to be disassembled to follow the entire overhaul procedure, 1 each fully disassembled, cleaned, and ready for assembly and testing, 1 each

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assembled and ready for functional testing. The Contractor shall furnish a written notice to the

Procuring Contracting Officer (PCO) through the Administrative Contracting Officer (ACO) within fifteen workdays after the required quantity of end items are available for the IPE. The

PCO will notify the Contactor of the projected dates that the Government IPE Evaluation Team will arrive at the Contactor’s facilities to conduct the IPE. The Contractor shall permit entrance into its facilities to the Government’s IPE Evaluation Team members. This includes access to

Contractor telephones and other communication devices that will allow the Government IPE

Evaluation Team members to consult with appropriate Government personnel in the accomplishment of the IPE evaluation. Under no circumstances will the Contractor accomplish overhaul on any other quantity of items on order or through any Induction-at-Risk /Early

Induction contractual provisions, other than the three IPE units that will by evaluated by the

Government IPE Team members prior to the accomplishment of the IPE. Only after the approval of the IPE by the cognizant Engineer and/or Equipment Specialist (the Government IPE

Evaluation Team Leader) will the Contractor proceed with overhaul on the remaining items on order or items under Induction-at-Risk/Early Induction provisions. The Government’s delivery schedule will be held in abeyance until approval of the IPE by the Government IPE Evaluation

Team Leader.

1.3 REPORTING REQUIREMENTS

1.3.1 Data requirements are specified in the contract: Part I, Section B, The Schedule.

1.3.2 The contractor shall maintain a document package containing the following documentation for each item produced:

a. Maintenance Data Sheet

b. Test Data Sheet

c. Quality Acceptance Review Documentation

d. Parts replaced listed by each serial numbered end item overhauled

1.4 DEFICIENCY REPORTING AND INSPECTION SYSTEM REQUIREMENTS

1.4.1 When a Deficiency Report is received for an end item overhauled under the terms of this contract, the Contractor shall comply with the ACO’s directions. Guidance is provided in TO

00-35D-54, USAF Deficiency Reporting and Investigating System.

1.4.2 Any Government material furnished for the overhaul of the end item that is damaged, or otherwise unsuitable for use, shall be reported by the Contractor to the ACO within in 30 days of receipt of unsuitable item. In the event that the furnished material is damaged or malfunctions during or after installation, the Contractor shall determine and record the probable cause and the necessity for withholding the material from use.

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1.4.3 Quality Audit. The Contractor shall support quality audits as required by the ACO.

These audits could require that one or more end items be removed from the production line and subjected to any combination of inspection, testing, disassembly, or assembly, to determine that the standards of performance and technical conformance meet the requirements of this PWS.

The Contractor shall be required to correct a deficient process to eliminate the cause(s) of any defects as directed by the ACO.

1.4.4 Quality Assurance Reviews. The Contractor shall support quality assurance reviews to be conducted at the site of overhaul at the request of the government throughout the contract period.

1.4.5 Quality Acceptance Reviews. The Contractor shall support quality acceptance reviews by the Defense Contract Management Agency (DCMA) representative at the site of overhaul for each end-item generated under the terms of this contract.

1.5 CONDEMNATION

1.5.1 Reparable items whose overhaul cost will exceed 75% of the stock listed price (beyond economical repair), shall be reported as condemnation candidates by the Contractor to the PCO through the ACO. The Contractor will not condemn reparable or recoverable items without prior approval of the PCO through the ACO. The disposition of condemned items will be determined on a case by case basis by the ACO. Non-reportable items will be disposed of IAW the

Contractor’s approved property procedures.

1.6 TOOLS AND SUPPORT EQUIPMENT

1.6.1 The support equipment (SE) required to accomplish the scope of work to be completed on end-items under this contract, is listed in T.O.’s or original equipment manufacturer (OEM) overhaul procedures listed in Section III of this PWS. If the equipment specified in the T.O.’s is not designated as Government furnished in this contract, the Contractor is responsible for furnishing identical or substitute SE from commercial sources.

1.6.2 If the Contractor intends to substitute SE, a list of the proposed substitute SE must be provided to the PCO with the proposal. At the time of the pre-award survey (PAS) conference, the Contractor must demonstrate to the PAS team that suitable substitute SE can be acquired and the SE meets the standards stipulated in the technical data by the following actions:

Note: This demonstration may have been included in the Source Approval Request(SAR) submitted for qualification as a new source. The PCO will get concurrence from engineering on whether suitable equipment was covered in the SAR and then can waive this portion of the PAS.

The equipment must be in possession of the contractor prior to the IPE team visit.

a. Displaying drawings, schematics, or specifications which illustrate that the prospective Contractor understands the exact nature of the work to be performed and the SE required to perform the tasks.

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b. Explaining the capabilities of substitute SE to ensure that it is adequate to perform the specified testing requirements.

c. Defining how substitute SE will be designed, built, and calibrated without assistance from the Government, by an internal engineering capability, or the services of a recognized outside engineering agency.

1.6.3 Documentation certifying the accuracy of all calibrated SE shall be furnished to the

ACO prior to overhaul of the first end-item.

1.7 PRECIOUS METALS RECOVERY PROGRAM

1.7.1 The Precious Metals Recovery Program is not applicable for this PWS. The handling and control of precious metals shall be IAW AFM 23-110, USAF Supply Manual.

1.8 NUCLEAR HARDNESS REQUIREMENT

1.8.1 Normally, nuclear hardness of the system will not be degraded if the work is accomplished IAW the applicable technical data. The PCO must be notified if the work will degrade the nuclear hardness of the item; maintenance actions will not continue until

Government approval is obtained from the PCO.

1.9 PARTS CONTROL PROGRAM

1.9.1 The Contractor will establish, document, and maintain a parts control program for the work associated with this PWS.

1.9.2 The Contractor shall establish the Parts Control Program for an end-item from the applicable Illustrated Parts Breakdown (IPB) TO.

1.9.3 Approval from the PCO is required for the Contractor to use any parts not contained in the IPB. The Contractor shall maintain configuration of items worked under the scope of this contract as identified in the applicable end-item or system IPB TO. The Contractor shall notify the PCO via fax or e-mail of any configuration discrepancies noted between the applicable IPB, the engineering drawings, and the current configuration of the end-item. The Contractor shall obtain written authorization from cognizant engineering activity via the PCO for deviations from the IPB prior to implementation. The Contractor shall report any TO improvement recommendation to the PCO via e-mail or fax.

1.9.4 The IPB shall serve as the current baseline for an end item or system.

1.9.5 The contractor shall only use replacement parts purchased from the OEM for the end item or purchased from DLA. In the event that parts are not available from either of these two sources for a pending overhaul operation, the contractor must receive written authorization from

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the cognizant engineering activity via the PCO for any deviations from the aforementioned sources. In the instance that surplus components are available, the cognizant engineering activity reserves the right to approve the material. Written authorization for its usage must be obtained from the cognizant engineering activity via the PCO.

1.9.6 The contractor shall keep records to allow traceability of the sourcing of replacement parts for each end item overhauled and shall be furnished for inspection upon government request.

1.10 OZONE DEPLETING SUBSTANCES (ODS)

1.10.1 This PWS is not explicitly requiring the use of a Class 1 ozone depleting substance

(ODS) in the performance of the contract. The contractor is authorized to use a suitable substitute for any Class 1 ODS, which may be required by the specifications or Technical Data of this PWS. The contractor shall immediately identify the substitute by written notification to the PCO.

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SECTION II WORK REQUIREMENTS

2.1 GENERAL

2.1.1 The work performed under this contract is for minor, major, and total rebuild of the specified end-items. The work must be accomplished IAW the TOs listed in Section 3.1.1.

Additional TOs, directives and other publications listed in Section III will be used as guidance to support the overhaul stipulated in this PWS.

2.2 TECHNICAL ORDER MAINTENANCE

2.2.1 The Contractor shall maintain all TOs and other technical directives applicable to the work requirements in an updated and current status according to TO 00-5-1, AF Technical Order

System. The Contractor shall consider the impact of a TO change on costs, schedules, and any other pertinent factors. A written evaluation, along with specific backup data for those changes which impact the Contractor’s performance, shall be provided to the PCO within 10 workdays after receipt of updated TO and directives. The Contractor shall not incorporate these technical order changes until approved by the PCO.

2.3 SPECIFIC WORK REQUIREMENTS

2.3.1 All records of overhaul and acceptance tests shall be maintained by the Contractor and shall be made available for inspection upon request by Government

Representatives.

2.3.2 End-Item Identification and Marking

The Contractor shall permanently and legibly mark each overhauled end-item with the

Contractor’s identification. This identification shall include the Contractor’s CAGE code, the contract number, and the date of overhaul. The identification shall be permanently affixed to the end item by decal, stamp, stencil, or similar means IAW the applicable TO. The applicable part number shall be permanently and legibly marked on each overhauled end- item.

2.3.3 Quality Acceptance and Processing

a. Quality acceptance of each end item shall be performed prior to packaging and transportation. Quality acceptance will be performed by DCMA at the overhaul site. Quality acceptance documentation for each end-item shall be maintained by the Contractor as part of the item document package.

b. Following quality acceptance, the Contractor shall notify the Production Management

Specialist (PMS) via email or fax of overhauled end- items. The PMS will provide shipping instructions to the Contractor via email or fax for each item produced. Within one day of shipment, the Contractor shall provide proof of shipment through delivery of a signed DD Form

250 to the PMS. The DD Form 250 shall include the carrier and tracking number.

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2.3.4 Shipping Documentation

a. The Contractor shall insure that a serviceable tag is attached to each serviceable end-item generated.

b. Shipments under this contract shall be by Commercial Bill of Lading (CBL) by the fastest traceable means.

c. Items overhauled as a result of a quality deficiency shall be shipped at the

Contractor’s expense.

2.4. SURGE

2.4.1 In the event that the DoD experiences an unplanned spike or sudden increase in demand, due to major theater warfare or a national emergency (also known as surge), and invokes surge: The Contractor is willing to work to meet and sustain this demand for quantity levels above and beyond normal peacetime requirements. After being notified of the surge demand in writing, the Contractor may see additional orders and/or will see the priority status elevated on current orders. The Contractor may do one or more of the following to fill the demand:

a. Add additional shifts to increase production within the Contractor and with suppliers.

b. The Contractor will work with the approved component part manufacturers to expedite production.

DoD will be notified in advance of, and be given the opportunity to negotiate, any expedite charges that might apply at the time of surge. Contractual requirements for production of this contract are addressed in Part I. The schedule and surge requirements will be on a best-effort basis.

FILE NUMBER: OC/5960/07/448 ACSG 8

SECTION III TECHNICAL ORDERS, DIRECTIVES, AND TECHNICAL GUIDANCE

3.1 REQUIRED TECHNICAL ORDERS

3.1.1 SPECIFIC TECHNICAL ORDERS

PART NUMBER OVERHAUL

MANUAL/TO

NUMBER

TCTO NUMBER TCTO TITLE

587R258H01 / L-5865-50 NNone

587R258H02 / L-6075-50 None

All levels of repair shall be IAW OEM specifications and data. All levels of repair shall be tested to L-3 Communications EDD test procedure PT-1100 Rev. G and comply with Northrop

Grumman PDS 23947 Rev. K.

3.1.2 GENERAL TECHNICAL ORDERS

TO NUMBER DATE TITLE

00-5-1

CHG 1

15 Sep 03

01 Mar 04

AF Technical Order System (Incorporates TO 00-5-2, which was rescinded)

00-20-1

30 Apr 03 Aerospace Equipment Maintenance General Policies and

Procedures (Incorporates TO 00-20-5, which was rescinded)

00-20-2 01 Mar 03 Maintenance Data Collection

00-20-3 01 Mar 03 Maintenance Processing of Reparable Property and Repair Cycle

Asset Control System

00-35D-54 01 May 07 USAF Deficiency Reporting and Investigating System

3.2 REFERENCE TECHNICAL INFORMATION

The following manuals and instructions are for reference only and can be applied where necessary.

3.2.1 Air Force Manuals

NUMBERS DATE TITLE

AFJMAN 23-215 6 Aug 01 Reporting of Supply Discrepancies

AFMAN 23-110 01 Apr 07 USAF Supply Manual

3.2.2 Air Force Material Command Instructions and Manuals

AFMCI 21-113 2 Jun 05 Contract Maintenance Programs for Depot Maintenance

Business Area (DMBA)

AFMCI 21-301 6 Oct 05 Air Force Materiel Command Technical Order System

Implementing Policies

FILE NUMBER: OC/5960/07/448 ACSG 9

NUMBERS DATE TITLE

AFMC 21-150 Draft Commercial Asset Visibility Air Force (CAVAF) - Reporting

Procedures for Contractors

AFMCI 24-201 14 Apr 04 AFMC Packaging and Materials Handling Policies and

Procedures

3.2.3 Military Specifications, Standards, Handbooks, and Non-Government Standards

ISO 9001:2000 2000 Quality Systems – Model for Quality Assurance in Productivity, Installation, and Servicing

MIL-STD-2073-1D 15 Dec 99 Standard Practice for Military Packaging

MIL-HDBK-6870A 28 Aug 01 Inspection Program Requirements Nondestructive for Aircraft and Missile Materials and Parts

ISO 10012:2003 14 Apr 03 Measurement management systems -- Requirements for measurement processes and measuring equipment

(Replaces ISO 10012-1:1992, which was withdrawn by ISO)