PWS - KC135R-10 Appendix A

APPENDIX A

DEPARTMENT OF THE AIR FORCE

HEADQUARTERS OKLAHOMA CITY AIR LOGISTICS CENTER (AFMC)

TINKER AIR FORCE BASE, OKLAHOMA 73145

PR NO: FD2030-11-36333

AF CONTRACT NO:

DATE: 16 Nov 2010 Performance Work Statement (PWS)

TYPE OF WORK: KC135R IDG ROTOR ASSEMBLY REPAIR AND/OR REWIND AS REQUIRED.

CONTENTS

Page

PREFACE SHEET

ii

REVISION SHEET

iii

SECTION

I. GENERAL

II. WORK REQUIREMENTS

III. TECHNICAL ORDERS, DIRECTIVES, AND OTHER TECHNICAL GUIDANCE

PR NO: FD2030-11-36333

PREPARED BY: OC-ALC/422SCMS/GUMD/JAMES H. BARNES JR. /DSN 884-8344

PREFACE SHEET

END ITEM

END ITEM

RECEIVED AS

TO BE DELIVERED AS

END ITEM

NO

NATIONAL

STOCK NO(S)

STOCK NO(S)

PART NO(S)

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 The superseded pages should be retained as a record.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

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 and in accordance with (IAW) the technical order (TO), or other guidance stipulated in this PWS, or both the TO and other guidance stipulated in the PWS.

c. Repair and/or Rewind as required consists of end item disassembly to facilitate cleaning and visual inspection of component parts: replacement of all soft-parts and non-reusable parts; repair, refurbishment or replacement of all components not meeting inspection parameters: reassembly of assemblies subassemblies; lubrication in accordance with (IAW) the applicable technical orders (T.O.’s), performance of all adjustments, alignments, and modifications; teat and calibration of assemblies and subassemblies; and final inspection )e.g., safety wiring, painting, affixing of decals etc.) to restore the end item to a serviceable condition.

1.2 INITIAL PRODUCTION EVALUATION REQUIREMENTS

1.2.1 The IPE requirement will be waived if the contract is awarded to the OEM Hamilton Sunstrand.

1.2.2 An IPE is required within 30 days after receipt of delivery order and assets. The IPE will be conducted on three units of each line item. The condition of the items at IPE will be as follows: Prior to the IPE date, one (1) unit will be torn down, cleaned, inspected, completely repaired, tested and ready to be shipped; one (1) unit will be torn down, cleaned, inspected, and ready to be reassembled in the presence of the IPE technical team. During the course of the IPE, the second unit will be assembled and the third unit will go through the entire Technical Order and O.E.M. drawings and procedures. The second and third unit will be functionally tested in the presence of the evaluators. The Contractor shall furnish a written notice to the Procuring Contracting Officer (PCO) through the Administration Contracting Officer (ACO) with seven business days after the required quantity of end items are available for the IPE. Within seven (7) business days of notification that the required quantity of end items are available for the IPE, (which shall not exceed a total of 37 days from receipt of a contract, funded delivery order and reparable assets) the PCO will notify Contractor of the projected dates that the Government IPE Evaluation Team will arrive at the Contractor’s facilities to conduct the IPE. The Contractor shall permit entrance into and access by the Government’s IPE Evaluation Team members to its facilities. 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 modification/repair/overhaul on any other quantity of items on order or through any Induction-at-Risk/Early Induction contractual provisions other that the three IPE units that will be evaluated by the Government IPE Team members prior to the accomplishment of the IPE. Only after the approval of the IPE by cognizant Engineer and/or Equipment Specialist (the Government IPE Evaluation Team Leader) will the Contractor proceed with modification/repair/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.

1.4 QUALITY PROGRAM AND INSPECTION SYSTEM REQUIREMENTS

1.4.1 The Contractor shall establish, document, and maintain a quality system as a means of ensuring that the end item conforms to specified requirements. The quality system may be either ISO 9001:2000 compliant or an equivalent quality system incorporating the intent of the following ISO elements: 4.1 Management Responsibility, 4.5 Documentation Control, 4.6 Purchasing, 4.9 Process Control, 4.14 Corrective and Preventive Action, and 4.17 Internal Quality Audits.

a. When a Deficiency Report is received for an end item manufactured, repaired, or 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 Material Deficiency Reporting and Investigating System.

b. Any Government material furnished for the overhaul or repair of the end item that is damaged, or otherwise unsuitable for use, shall be reported by the Contractor to the ACO. 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.

1.4.2 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.

1.5 CONDEMNATION AND REPAIR

1.5.1 The Contractor will not condemn end 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.

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 TOs or original equipment manufacturer (OEM) repair procedures listed in Section III of this PWS. If the equipment specified in the TOs 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:

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 such tasks.

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 repair of the first end item.

1.7 PRECIOUS METALS RECOVERY PROGRAM

1.7.1 The Precious Metals Recovery Program is 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, and may use MIL‑HDBK‑965 as guidance.

1.9.2 The Contractor shall establish the Program Parts Selection List (PPSL) for an end item or system from the applicable documents in the following order of precedence:

a. Illustrated Parts Breakdown (IPB) TO 9H6-5-15-4 and or O.E.M. drawings and repair procedures.

b. OEM parts list

c. Current configuration of the end item or system.

Approval from the PCO is required for the Contractor to use any parts not contained in the PPSL.

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.

SECTION II WORK REQUIREMENTS

2.1 GENERAL

2.1.1 The work performed under this contract is to repair/rewind as required. The work must be accomplished IAW TO 9h6-5-15-3/4 and O.E.M. Drawings/repair procedures. In the event that a situation develops where instructions conflict, this PWS will take precedence. The work encompasses the disassembly, cleaning, inspection, maintenance, upgrade to the “C” configuration, reassembly, testing, and finishing actions required to return the items to a serviceable condition. Additional TOs, directives and other publications listed in Section III will be used as guidance to support the repair 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, 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 Pre-Disassembly

a. Insure external cleanliness of each item prior to attempted disassembly.

b. Inspect each end item for obvious damage beyond the limits of economical repair.

2.3.2 Inspection

a. Reuse all components of the end item determine serviceable IAW TO 9H6-5-15-3/-4 and O.E.M. drawings/repair procedures.

2.3.3 End Item Identification and Marking

a. Permanently and legibly mark each repaired end item with the Contractor's identification. This identification shall include the Contractor's name, the AF contract number, and the date of repair. The identification shall be permanently affixed to the end item by decal, stamp, stencil, or similar means. If size prohibits marking the end item, the information above will be marked on the item packaging.

SECTION III TECHNICAL ORDERS, DIRECTIVES, AND TECHNICAL GUIDANCE

3.1 APPLICABLE TECHNICAL ORDERS

3.1.1 TO dates listed in this section are current as of the date of this PWS. However, the work will be accomplished IAW with Sections II and III.

3.1.2 SPECIFIC TECHNICAL ORDERS

731114D

Change 5 9H6-5-15-3

20090601 Overhaul Instructions

731114D

Change 1 9H6-5-15-4

20080201 Illustrated Parts Breakdown

20070515 Standard Practices

3.1.3 GENERAL TECHNICAL ORDERS

00-20-2

20071025 Change 2 Maintenance Data Collection

00-20-3

20071025

Change 9 Maintenance Processing of Reparable Property and Repair Cycle Asset Control System

00-25-234

20080821

General Shop Practice for the Repair Maintenance and Test of Electrical Equipment

Change 4 USAF Material Deficiency Reporting and Investigating System

Preventative Maintenance Program/General Requirements and Procedures

Application and Removal of Organic Coatings, Aerospace and Non-aerospace Equipment

Aircraft Weapon Systems Cleaning and Corrosion Control

Change 7 Nondestructive Inspection Methods

Process Instructions, Metal Treatments

3.2 MANUFACTURER'S SPECIFICATIONS

731604C

OEM Drawings and Specifications

3.3 OTHER PUBLICATIONS FOR GUIDANCE PURPOSES ONLY

3.3.1 Air Force Instructions

3.3.2 Air Force Manuals

AFMAN 23-110

3.3.3 Air Force Material Command Instructions and Manuals

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

FILE NUMBER: FD2030-11-36333