PWS_10112013.doc

APPENDIX A

APPENDIX A

DEPARTMENT OF THE AIR FORCE

AIR FORCE SUSTAINMENT CENTER

TINKER AIR FORCE BASE, OKLAHOMA 73145

Performance Work Statement (PWS) TYPE OF WORK: Overhaul of B-52 Bypass Ducts

PURCHASE REQUEST: FD2030-12-00911

DATE: 23 Apr 2013

CONTENTS

Page

PREFACE SHEET

ii

REVISION SHEET

iii

SECTION

I. DESCRIPTION OF SERVICES/GENERAL INFORMATION

II. SERVICE SUMMARY

III. GOVERNMENT FURNISHED PROPERTY OR SERVICES

ATTACHMENT A: DEFINITIONS

ATTACHMENT B: APPLICABLE DOCUMENTS/PUBLICATIONS

ATTACHMENT C: SPECIFIC WORK REQUIREMENTS

PREPARED BY: 424 SCMS/GUEA

PREFACE SHEET

END ITEM

RECEIVED AS

END ITEM

TO BE DELIVERED AS

STOCK NO(S)

STOCK NO(S)

PARTS NO(S)

35-8275-518

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 The superseded pages should be retained as a record.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.

DATES OF ISSUE FOR ORIGINAL AND CHANGED PAGES ARE:

23 Apr 13

1. DESCRIPTION OF SERVICES/GENERAL INFORMATION

1.1. Purpose

1.1.1. The purpose of the Performance Work Statement (PWS) is to define the overhaul requirements for the B-52 By-pass Ducts noted with National Stock Numbers (NSNs) specified on page ii of the PWS. The work encompasses the disassembly, cleaning, inspection, maintenance, reassembly, and testing and finishing actions required to return the items to an overhauled condition. The Contractor is responsible for the overhaul of the B-52 By-Pass Ducts with support of appropriate technical data, overhaul documents, and license agreements required to accomplish this overhaul. The Contractor is responsible for the scheduled delivery of a quality product.

1.2. General Information

1.2.1. Contractor employees shall 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 shall appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence.

1.3. Pre-Award Survey (PAS) Requirements

1.3.1. A Pre-Award Survey is not required.

1.4. Initial Production Evaluation (IPE) Requirements

1.4.1. IPE is not required.

1.5. Reporting Requirements

1.5.1. Data requirements are specified in the Contract Data Requirements List (CDRL DD Form 1423) found in Part 1, Section B, The Schedule of the Basic contract.

1.5.2. In addition, the Contractor shall maintain a document package, in Contractor format, containing the following documentation for each item produced for the contract period:

a. Quality Acceptance Documentation

1.6. Quality Program and Inspection System Requirements

1.6.1. 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 will be in accordance with the requirements documented on the AFMC Form 807 (Recommended Quality Assurance Provisions and Special Inspection Requirements). Each end-item identified as serviceable shall be delivered to the Government defect free.

1.6.2. When a Deficiency Report is received for an end item overhauled under the terms of this contract, the Contractor shall comply with the Administrative Contracting Officer’s (ACO) directions. Guidance is provided in TO 00-35D-54, USAF Deficiency Reporting, Investigation, and Resolution.

1.6.3. The Contractor shall report any Government Furnished Material (GFM), for the work accomplished as outlined in this PWS, that is damaged or otherwise unsuitable for use to the ACO using a Report of Discrepancy (ROD) (referred to as Supply Discrepancy Report (SDR)), SF Form 364 within 30 calendar days of discovery.

1.6.4. 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 before production of the next end item.

1.6.5. The Contractor shall support quality assurance reviews to be conducted at the site of overhaul at the request of the DCMA throughout the contract period.

1.6.6. The Contractor shall support a quality acceptance review by the Defense Contract Management Agency (DCMA) representative at the site of overhaul for each end item generated under the terms of this contract.

1.6.7. The Contractor shall submit requests for deviation / waiver to the Procurement Contracting Officer (PCO) through the ACO In Accordance With (IAW) 1.17.2. Work shall not be initiated on assemblies / components affected by deviation / waiver pending approval / disapproval. Requests shall include the contract number, NSN and P/N of end item and lowest part / assembly affected, effect on cost / price and delivery schedule, description of deviation / waiver, justification for deviation / waiver, and proposed corrective action taken.

1.7. Condemnation Candidates

1.7.1. The Contractor shall report end items that have been determined to be Beyond Economical Repair (BER) in which the overhaul cost will exceed 75% of the stock listed price. The Contractor shall report condemnation candidates to the PCO through the ACO within 30 calendar days of discovery. The Contractor shall not condemn reparable or recoverable items without prior approval of the PCO through the ACO. The Contractor shall ensure non-repairable items are demilitarized and disposed according to the Contractor-developed, Government-approved property procedures.

1.7.2. Contractor shall not continue overhaul of item exceeding BER until approval is received from ACO/PCO.

1.7.3. As specified in the Contractor-developed, Government-approved property procedures, the disposition of condemned items will be determined on a case-by-case basis by the ACO.

1.7.4. On units approved to be condemned by the Government, the Contractor is authorized to retain serviceable parts scrapped from the condemned unit. The cannibalized parts shall be retained by the Contractor for further use in overhaul of the same type end item. These parts will not be replenished when used up. The non-useable, scrapped parts shall be condemned IAW the Contractor-developed, Government-approved property procedures.

1.8. Special Tools (ST) and Support Equipment (SE)

1.8.1. The SE required to accomplish the scope of work to be completed on end-items under this contract is listed in the TOs and overhaul procedures listed in Attach. C of this PWS. If the equipment specified in the TO or OEM overhaul procedures is not designated as Government furnished in this contract, the Contractor shall furnish identical or substitute SE from commercial sources.

1.8.2. If the Contractor intends to substitute SE, a list of the proposed substitute SE shall be provided to the PCO with the proposal for Government approval. The Contractor shall demonstrate that substitute SE can be acquired and meets the standards stipulated in the technical data by the following actions:

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

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

1.8.2.3. 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 as approved by the cognizant engineering activity.

1.8.3. The Contractor shall show certification documents of all calibrated SE to the ACO prior to work performed as outlined in the PWS.

1.8.4. Support Equipment Calibration Requirements. The Contractor shall ensure documentation certifying the accuracy of all calibrated SE is made available to the ACO prior to work performed. The Contractor shall ensure SE calibration is maintained throughout performance of this contract. Upon request, the Contractor shall provide certification documents (DI-QCIC-80798B) to the ACO for each SE item as follows:

a. SE part number and serial number

b. Date calibrated

c. Calibration due date

d. Calibration source

e. Calibration procedure used

f. Before and after calibration data

g. Facsimile of the current stamped calibration sticker affixed to SE item

h. Verification of full performance compliance IAW this PWS for SE items not requiring calibration.

i. Traceability to the National Institute of Standards and Technology

1.9. Precious Metals Recovery Program

1.9.1. The Precious Metals Recovery Program is not applicable to this PWS.

1.10. Parts Control Program

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

1.10.2. The Contractor shall establish the Parts Control Program for an end-item from the applicable Illustrated Parts Breakdown (IPB) TO and OEM assembly drawings.

1.10.3. Approval from the PCO is required for the Contractor to use any parts not contained in the IPB, OEM drawings or Attachment C (Specific Work Requirements). 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.

1.10.4. The Contractor shall use the Boeing engineering drawings and the Government Engineering Orders against those drawings as the current baseline for an end item or system.

1.10.5. The Contractor shall only use replacement parts purchased directly from the end-item OEM or purchased from Defense Logistics Agency (DLA), except as follows. The Contractor is authorized to manufacture replacement parts in accordance with the OEM drawings and Government provided technical data packages. Materials and processes used in the manufacture shall have certification documentation traceable to the original manufacturer or process source. All consumable items (bolts, rivets, nuts, paint, etc.) will be new manufactured items with traceability back to the original manufacturer with original material certifications.

The OEM drawings and technical orders for the Bypass Ducts are subject to export-control regulations. Distribution of this technical data is limited to those suppliers qualified through the Joint Certification Program (JCP). Information on acquiring JCP certification is available at the world wide web address http://www.dlis.dla.mil/jcp. JCP certified contractors who receive technical data pursuant to their DD form 2345 certification may not further disseminate such data unless further dissemination of the technical data is expressly permitted by DODD 5230.25.

1.10.6. In the instance that surplus components are available, the cognizant engineering activity reserves the right to approve or disapprove the material. Written authorization for its usage shall be obtained from the cognizant engineering activity via the PCO.

1.10.7. 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.

1.10.8. When a particular overhaul is constrained for lack of materials that are not, and will not be immediately available, the Contractor shall request authorization from the PCO to cannibalize subassemblies or parts between inducted unserviceable assets in order to expedite overhaul. Cannibalization requests will be subject to the review and approval of the cognizant engineering activity. Such cannibalization actions will only be considered upon exhaustion of all other sources of materials. The Contractor shall not initiate any cannibalization action unless such action will satisfy all material requirements for the item in question. The Contractor shall not remove any piece parts from serviceable units. The Contractor shall replace, at the Contractor’s expense, all cannibalized subassemblies with overhauled or new subassemblies and replace all cannibalized parts with new parts. The Contractor shall ensure the contract delivery schedule is not negatively affected by the removal of any subassemblies or parts from any inducted end item.

1.11. Ozone Depleting Substances (ODS)

1.11.1. 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.

1.12. Technical Order Maintenance

1.12.1. 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, and TO 00-5-3, Technical Order Life Cycle Management. The Contractor shall evaluate 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 business days after receipt of updated TO and directives. The Contractor shall not incorporate these technical order changes until approved by the PCO.

1.13. Work Requirements

1.13.1. The Contractor shall overhaul the items specified on page ii of this specification. The work encompasses the disassembly, cleaning, inspection, maintenance, reassembly, and testing and to finishing actions required to return the items to an overhauled condition. The work shall be accomplished IAW documents as specified in Attachments B and C. In the event that a situation develops where the instructions conflict with the pertinent manual, this PWS shall take precedence. Additional TOs, directives and other publications listed in Attach. B will be used as guidance to support the overhaul stipulated in this PWS.

1.14. Specific Work Requirements

1.14.1. Basic overhaul requirements: The end item shall be cleaned, disassembled, components inspected, assembled, and tested according to Attachment C, TOs and OEM specifications. Any component parts that do not meet specified inspection requirements, or if there is any doubt as to its serviceability or longevity shall be replaced at the Contractor’s expense. This includes any part requiring replacement due to catastrophic failure, fatigue failure, or normal deterioration. The Contractor is advised to include the cost of replacing a percentage of each recoverable part in their overhaul cost proposal.

1.14.1.1. If the TO does not address the repair of a recoverable part, this part shall be replaced with a new or repaired by approved Contractor’s developed procedures. In case of utilizing a developed repair for salvaging a part, Contractor may propose their repair procedure along with substantiating documents for evaluation and possible approval. This request for evaluation must be submitted to the cognizant engineer office through the PCO for approval. The Government will not be responsible for any costs associated with development of any repair procedures unless it has been negotiated and approved by the PCO.

1.14.2. Over and Above.

1.14.2.1. Over and above will be considered for missing components or for work out of scope of this PWS. Identification of missing part(s) must be revealed within 2 business days after induction for repair and reported to the PCO through the ACO in the form of a Supply Discrepancy Report using SF 364. The Contractor shall obtain approval from the PCO prior to performing over and above.

1.14.2.2. Development and Manufacturing of Special Tools and/or Materials not identified or covered in any TOs or in the Attachment of this PWS may be required to overhaul the end items. The Contractor shall provide a cost estimate to the PCO if it is determined additional tools and/or materials are needed to overhaul end items under this contract. Any special tools developed by the Contractor and paid for by the Government, shall become the property of the Government at the end of the performance period of this contract.

1.14.3. End Item Identification and Marking:

1.14.3.1. Permanently and legibly mark each overhauled end item with the Contractor's identification. This identification shall include the Contractor's CAGE and the date of overhaul. The identification shall be permanently affixed to the end item by stamp, stencil, or similar means.

1.14.3.2. Item Unique Identification (IUID) will be added to the end item in accordance with the following:

a. Specification requirements for IUID marking will be contained in the applicable overhaul technical order, Specific Work Requirements appendix, approved engineering drawing, or a Government provided Engineering Order (EO) (AF Forms 3925, 3926 and 3927) as applicable.

b. IUID markings are required for the end-item only. IUID for subcomponents is only required if specifically identified in the applicable overhaul technical order, Specific Work Requirements appendix, approved engineering drawing, or a Government provided EO.

c. For items that do not have IUID marking specifications as stated in paragraph b., the Contractor shall develop the marking specifications in accordance with the current revision of MIL-STD-130. Location and marking method shall be approved by 424 SCMS engineering before implementation. If the Contractor cannot meet the terms and conditions in the contract for IUID, the Contractor will contact the PCO/ACO for determination.

d. IUID markings currently in place on items undergoing overhaul shall be protected from damage or removal during overhaul. Verify 2-D matrix IUID markings are readable per TO 00-25-260. Should IUID marking be rendered unreadable during repair, the Contractor shall notify 424 SCMS engineering and the PCO/ACO for determination of how to replace the IUID mark.

e. The Contractor shall submit the required and applicable contingent data for Legacy items (Bypass Ducts) to the IUID Registry per the data submission procedures at http://www.acq.osd.mil/dpap/pdi/uid/data_submission_information.html.

f. The Contractor shall submit IUID data for new manufactured items that require IUID based on the DFARS clause 252.211-7003, Item Identification and Valuation (AUG 2008), as prescribed in DFARS Subpart 211.274

1.14.4. Quality Acceptance and Processing:

1.14.4.1. The Contractor shall support quality acceptance inspections 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.

1.14.4.2. Following quality acceptance by the DCMA, the Contractor shall notify the Production Management Specialist (PMS) via email or fax of the completion of overhauled end- items. The PMS will provide ship-to addresses/instructions to the Contractor via email or fax for each item produced. Within one business day of shipment, the Contractor shall provide proof of shipment through delivery of an accepted WAWF Receiving Report to the PMS. The Receiving Report shall include the carrier and tracking number.

1.14.5. Shipping Documentation:

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

a. Serviceable tag is DD Form 1574/1574-1 (Yellow).

b. Unserviceable (repairable) tag is DD Form 1577-2/1577-3 (Green).

c. Unserviceable (condemned) tag is DD Form 1577/1577-1 (Red).

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

1.14.5.3. The Contractor shall reimburse the Government for packaging and shipping costs for items returned to the contractor for correction of quality deficiencies.

1.15. Surge/Mission Essential Services

1.15.1. In the event that the Department of Defense (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 shall work to meet and sustain this demand for quantity levels above and beyond normal peacetime requirements. After being notified by the PCO 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 shall implement their procedures to support the surge demand.

1.15.2. The PCO shall be notified in advance 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 of basic contract. The schedule and surge requirements shall be on a best-effort basis.

1.15.3. The Contractor shall prepare for the continuation of essential DoD services during crisis IAW Defense Federal Acquisition Regulation Supplement (DFARS) 252.237.7023. In a state of emergency, if the Government deems necessary, the Contractor shall provide all services necessary to ensure mission accomplishment. On occasion, services may be required to support an activation, or exercise of contingency plans outside normal duty hours. IAW DFARS 252.237.7023, the contractor shall be responsible to perform those services identified as essential contractor services during crisis situations (as directed by the Contracting Officer).

1.16. Delivery Schedule

1.16.1. The Contractor shall meet the contractual delivery schedule.

1.17. Customer Service Requirements

1.17.1. Information Requests: The Contractor shall ensure responses to requests for information and data are only provided to customers authorized by the PCO in the performance of official duties. All requests between the Government and the Contractor shall go through the Procuring Contracting Officer (PCO). Exceptions are found in 1.17.1.2.

1.17.1.1. Information requests shall contain a subject line, nature of the request and an expected/requested response date and time. The request must be identified as “EMERGENCY”, “URGENT” or “ROUTINE” IAW paragraph 1.17.2 of this PWS so that a response is provided within the specified timeframes. A log will be maintained by the PCO or an appointed Government Representative. The log will be used to track all requests and evaluate response times.

1.17.1.2. Contractor requests for engineering and/or technical related problems or issues shall be submitted on an AFMC Form 202, Nonconforming Technical Assistance Request and Reply. All AFMC Form 202s shall be sent directly to 424 SCMS Cognizant Engineering with an information copy to the ACO and PCO.

1.17.2. Response Times for Information Requests: All requests for information initiated by the Government or Contractor shall be in writing and submitted electronically via e-mail or fax. Requests for information shall be answered within the following timeframes:

a. Emergency and Work-Stoppage- Respond within two (2) business days.

b. Urgent- Respond within five (5) business days.

c. Routine- Respond within ten (10) business days.

NOTE: Federal Holidays will not be counted in evaluating the response times. Only normal business days and hours will be counted when evaluating the response time for requests. Normal business days are Monday through Friday, except Holidays. Business hours are 0800 to 1600 Central Standard Time.

1.18. Contractor Manpower Reporting

1.18.1. The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the Overhaul of B-52 Bypass Ducts via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

1.18.2. 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 CMRA help desk.”

1.18.2.1. Reporting Period: Contractors are required to input data by 31 October of each year.

1.18.2.2. 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.

1.18.2.3. 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.ecmra.mil.

2. SERVICE SUMMARY

2.1. Service Summary

2.1.1. Contractor performance shall be measured and assessed, using the Performance Requirements listed in Table 2-1. The Contractor service requirements are summarized into performance requirements that relate directly to the mission essential items. The performance threshold requirements describe the minimum acceptable levels of service for each requirement. In the event the performance requirement is not met, the Contractor shall be given time after notification to correct the unacceptable performance, if such correction is possible. The Contractor shall immediately take corrective action in accordance with the performance threshold(s). In cases where the Contractor fails to implement corrective action, the PCO will take appropriate measures.

2.1.2. Service Summary (SS) Requirements: The Contractor shall ensure the performance and threshold requirements are achieved as identified in Table 2-1.

2.1.3. Surveillance Methods: The PMS, DCMA Quality Assurance Representatives (QAR) and PCO will exercise surveillance over the performance requirements. The absence of any contract requirement from the SS shall not detract from this enforceability nor limit the rights or remedies of the Government under any other provision of the contract. The Contractor shall support the PMS, DCMA QAR, and PCO surveillance methods as identified below:

a. Periodic Inspection of Process or Output

b. Random Sampling of Recurring Service Output

c. 100 Percent Inspection of Output

d. Customer Observation or Complaint.

2.1.3.1. The Government will use the methods contained in the Quality Assurance Performance Plan (QASP) to evaluate the Contractor’s performance for the listed program objectives. The PMS, DCMA QAR, and/or PCO will monitor Contractor performance to determine if it meets the contract thresholds as set forth in the performance measures and this PWS.

2.1 SERVICE SUMMARY TABLE

Requirements

Urgent Requests – respond within 5 business days Routine Requests – respond within 10 business days

95 percent of all ducts shall perform without defect for one year after overhaul

GFM.

2.1.4. Contractor Performance Evaluation: The Contractor shall understand that the evaluation of performance will occur when the PMS evaluates the service of the Contractor to determine whether or not it meets the performance measures of the contract.

a. SS-1through SS-5: The Contractor's failure to meet the requirement for this item shall result in the possibility of an unsatisfactory or marginal rating under the Contractor Performance Assessment Review (CPAR) and remedies as allowed under Federal Acquisition Regulation (FAR) 52.246-4 Inspection of Services-Fixed Price.

3. GOVERNMENT PROPERTY

3.1. Government Property

3.1.1. The Contractor shall furnish all material, support equipment, tools, test equipment, and services except as listed below. No Government Furnished Property will be provided other than the units to be overhauled. Government Furnished Material will not be provided.

3.1.1.1. The following support equipment will be provided by the Government:

FAJ35-8271

Floor Assembly Jig

FAJ35-8272

FAJ35-8270-501

FAJ35-8270-502

FAJ35-8275-1

FAJ35-8275-2

3.2. Disposition of Government Property

3.2.1. These instructions apply to all Government owned property. Within 90 calendar days prior to contract expiration, the Contractor shall submit a letter to the managing ALC requesting disposition instructions in the transfer of Government furnished property (GFP). A listing identifying GFP shall include the NSN, part number/CAGE, noun, quantity, condition code, and dollar value, and the list shall be submitted through the ACO to the PMS for disposition instructions.

3.2.2. If a follow-on contract is being awarded or, is in the negotiation or solicitation stage, the existing GFP may be retained to the extent required to phase support on the current contract and/or the follow-on contract.

3.2.3. The Contractor shall comply with preservation, packaging, and packing instruction as specified in the basic contract and/or on the AFMC Form 158 (Packaging Requirements).

3.2.4. The Contractor shall comply with the Transportation Data on the DD Form 1653 and Transportation Appropriations Form when returning government property.

3.3. Discrepancies Incident to Shipment:

3.3.1. The Contractor shall report discrepancies incident to shipment which include misidentified items, variations in quantity, non-requisitioned items, lost or damaged parcel post, and items in dubious condition within 5 business days of discovery. The Contractor shall report and resolve the discrepancies using the DoD web-based application WebSDR link located within the CAV AF system described in the CAV AF SOW. This system of reporting a Supply Discrepancy Report (SDR), formerly called a Report of Discrepancy (ROD), has been developed in compliance with DoD regulations 4140.1-R and 4000.25-M Volume 2, which requires automated SDR processing. In those situations where the SDR initiator is unable to gain access to the AF WebSDR, continued use of manual forms (SF Form 364) is permitted. A copy of the form shall be forwarded through the PCO and QAR activity for corrective action.

3.3.2. Transportation discrepancies and item transaction discrepancies shall be coordinated with the DCMA Property Administrator and ACO within 2 business days upon discovery for corrective action utilizing the AF WebSDR submittal.

3.3.3. The Contractor shall process a SDR (SF Form 364) for contract line items received with missing components (Missing On Induction, (MOI)) within 2 business days upon discovery in accordance with AFJMAN 23-215. An electronic copy of MOI SDR form shall be submitted to the ACO and PCO within 2 days of discovery.

3.3.4. Misdirected shipments of GFP shall be reported by written notification to the Property Administrator (PA) within 2 business days. The PA will issue disposition instructions for the misdirected items. Misdirected items received by the Contractor which are not part of this contract will not be receipted into CAV AF.

3.4. Other

3.4.1. The Contractor shall not obtain GFP through the utilization of requisition codes assigned exclusively to this contract for any other contracts.

3.4.2. The Contractor shall not transfer or use GFP charged to this contract to any other contract, Contractor, or activity without the advance approval of the PMS through the PCO.

3.4.3. The Contractor shall replace GFP that has been removed by the USAF to fulfill other more urgent requirements. If any item so removed by the government is still required to complete the contract, the Contractor shall take appropriate action to replace the removed item.

ATTACHMENT A - DEFINITIONS

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 (IPE): An 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), and other guidance stipulated in this PWS.

c) Overhaul: Overhaul is the restoration of an item to a completely serviceable condition as prescribed by maintenance serviceability standards. An overhaul will allow the item to be fixed repeatedly as it is driven by specific serviceability standards.

d) Cannibalization: Authorized removals of a specific assembly, subassembly, or part from one weapon system, system, support system, or equipment end-item for installation on another end-item to meet priority mission requirements with an obligation to replace the removed item.

e) Administrative Contracting Officer (ACO): A contracting officer assigned the responsibility for the post award functions related to the administration of a government contract in the field. The ACO is normally located in the Defense Contract Management Agency (DCMA) office. The ACO is responsible for ensuring the Contractor performs in accordance with the terms of the contract.

f) Procurement Contracting Officer (PCO): The individual authorized to enter into contracts for supplies and services on behalf of the Government by formal advertising or negotiation and who is responsible for overall procurement of the contract.

g) Technical Order (TO): An Air Force publication that gives specific technical directives and information with respect to the inspection, storage, operation, modification, and maintenance of given items and equipment.

h) Support Equipment (SE): All equipment called out in applicable technical orders required for end item and component test, repair, and / or modification.

i) Serviceable: Capable of meeting the requirements and performing the function for which designed or modified, and meets all test requirements established by the technical order and PWS.

j) Repair: An end item repair is the action taken to return the end item to a serviceable condition by replacing all exposed consumable items and only the damaged recoverable parts that do not meet the TO inspection criteria. Repair consists of end item testing to determine deficiencies, disassembly as required to support maintenance actions required, thorough cleaning, refurbishment or replacement of all disturbed components not meeting inspection criteria, replacement of all soft parts (seal, gaskets, etc.) exposed during repair, re-assembly of assemblies and subassemblies, performance of all adjustments and alignments, test and calibration of subassemblies and end-items and final inspection (e.g., safety wiring, painting, affixing of decals) IAW the applicable TOs and approved test documents to restore the end item to a serviceable condition.

k) Defect: Any nonconformance of a characteristic with specified requirements.

l) Product Quality Deficiency: A defect or nonconforming condition. Included are deficiencies in design, specification, material, manufacturing, and workmanship.

m) Product Quality Deficiency Report: The SF 368 form or format used to record and transmit product quality deficiency data.

n) Consumable Part: Piece parts that are replaced 100% at each repair event

o) Recoverable Part: Parts that are not replaced at every repair event.

ATTACHMENT B - Applicable Documents Technical Orders, Directives, And Technical Guidance USAF Technical Orders

00-5-1, Chapters 1-3

http://www.tinker.af.mil/technicalorders/index.asp

00-5-3

Chapters 1-4

http://www.tinker.af.mil/technicalorders/index.asp

00-35D-54

Chapters 1-4

http://www.tinker.af.mil/technicalorders/index.asp

http://www.robins.af.mil/library/technicalorders.asp

http://www.robins.af.mil/library/technicalorders.asp

Enhanced Technical Information Management System (Access through AF Portal)

http://www.tinker.af.mil/technicalorders/index.asp

http://www.tinker.af.mil/technicalorders/index.asp

Tinker Integrated Data for Maintenance (IDM) (Access though AF Portal

Tinker Integrated Data for Maintenance (IDM)

(Access though AF Portal)

Tinker Integrated Data for Maintenance (IDM)

(Access though AF Portal)

Tinker Integrated Data for Maintenance (IDM)

(Access though AF Portal)

Department of Defense Directives

http://www.dtic.mil/whs/directives/corres/pdf/523025p.pdf

Military Specifications, Standards, Handbooks, and Government Standards

Industry Publications

Integral Fuel Tanks and Fuel Cell Cavities, High Adhesion

Forms

http://www.e-publishing.af.mil/shared/media/epubs/AF3925.XFD

http://www.e-publishing.af.mil/shared/media/epubs/AF3926.XFD

http://www.e-publishing.af.mil/shared/media/epubs/AF3927.XFD

Other Publications For Information Purposes Only Note: These publications are for information purposes only.

Air Force Manuals

AFMAN 23-110

Vol 1 Part 4

Vol 6 Chap 4

http://www.e-publishing.af.mil/shared/media/epubs/afman23-110.pdf

http://www.e-publishing.af.mil/shared/media/epubs/AFJMAN23-215.pdf

ATTACHMENT C - SPECIFIC WORK REQUIRMENTS

1. SPECIFIC WORK REQUIREMENTS - Unless otherwise authorized by 424 SCMS Engineering, these bypass duct assemblies will be overhauled in strict accordance with these specific work requirements.

1.1. All FAJ fixtures shall be calibrated by vendors/sources who meet applicable calibration requirements, IAW the master “B52 Nacelle Engine Bypass Duct FAJ Tooling Initial Certification Procedure” and the applicable Initial FAJ Certification Reports. Measuring and test equipment shall be calibrated as specified in ISO 10012-1. Certification of calibration is required, utilizing equipment traceable to NIST standards, or other international or national measurement standards. Prior to use all FAJ fixtures and measuring equipment shall have been calibrated for use within one year or if the accuracy of a tool has become suspect at any time and recorded to ensure all inspected dimensions are accurate.

Following is the list of GFE Tooling required for calibration:

FAJ35-8271

FAJ35-8272

FAJ35-8270-501

FAJ35-8270-502

FAJ35-8275-1

FAJ35-8275-2

1.2. Disassembly – Disassembly is limited to that necessary to accomplish the required inspection, test, repair or replacement.

1.3. Cleaning – Cleaning will be accomplished as follows:

1.3.1. Wash the interior and exterior as required with solvent MIL-C-87937D, Type I, use nylon non-abrasive mat per A-A-3100 (see T.O. 1-1-8, Table A-2) to remove stubborn accumulations. Drain and dry with lint free cloth or blow dry with compressed air.

WARNING

Solvent, MIL-C-87937D, Type I, is toxic and flammable. Skin and eye protection is required. Adequate ventilation or respiratory protection is required.

WARNING

Use approved personal protective equipment (goggles/face-shield) when using compressed air. Air-pressure is restricted to less than 30 PSI. Provide protection from flying particles. Do not direct air stream towards self or other personnel.

1.3.2. Strip visible exterior finish per T.O. 1B-52H-23 section XI. Optional to strip finish by plastic media blasting (PMB method per T.O. 1-1-8, Type 1).

NOTE: T.O. 1B-52H-23, cleaners, strippers and other solvents may be revised due to environmental concerns.

1.4. Inspection – Upon receipt Contractor must inspect items for missing parts and any potentially damaging condition. Entire bypass duct assembly must be inspected and documented for:

a. Missing parts

b. Existing repairs

c. Correct configuration

d. Fit conformance

e. Defects

NOTE: Specific allowable limits are listed under the Maintenance and Repair section.

1.5. Corrosion Control – Treatment of existing corrosion and corrosion prevention will be accomplished in accordance with the following:

1.5.1. Remove corrosion and treat reworked corrosion areas in accordance with T.O. 1B-52H-23 and 1-1-691. Corrosion removal limits are as follows:

a. 10% of original material thickness on all parts except duct vanes and angles.

b. 20% of original material thickness on any duct vanes or angle parts.

c. Apply corrosion protection finish to all reworked surfaces per T.O.1-1-691.

NOTE: References in T.O. 1B-52H-23 and 1-1-691 for cleaners, strippers and other solvents may be revised due to environmental concerns.

1.6. Maintenance and Overhaul – Boeing drawings, sub-drawings and called for specifications will be used for references. Unless otherwise authorized by 424 SCMS Engineering, all discrepancies documented during inspection will be corrected using depot level authorized procedures. All deviations from Boeing drawings, repair technical orders and these Specific Work Requirements will be documented and approved via AFMC Form 202.

1.6.1. Tooling/Replacement Parts – All new replacement parts shall be manufactured from approved electronic CAD data, aircraft part and assembly drawings (including referenced material and process specifications), and/or tooling certified by 424 SCMS Engineering or authorized representative prior to use in any part of the overhaul process.

Note: Authorized substitutions for fasteners called for in the bypass duct drawings are listed in Table 2.

1.6.2. Defects – All defects will require replacement of the affected components.

a. All damaged, loose, missing or incorrect fasteners will be replaced with the correct fasteners as called for in the appropriate drawing, or engineering authorized substitution.

b. Fasteners which are oversize from the drawing up to and including the next standard size fastener are authorized to remain installed or to be installed during the repair process. For previously installed repair fasteners (NAS1456 thru 1462) installed in place of a BACR15AZ, an NAS1456 thru 1462 may be used at that location if the part does not require replacement and the hole is clean round and within tolerance.

c. Any amount of oversize fastener is authorized for repair when the appropriate edge (margins) distance of material can be maintained. Do not exceed maximum material thickness vs. diameter limits.

1.6.3. Missing parts – All parts found to be missing upon acceptance and inspection will be replaced with serviceable parts as part of the overhaul process. All parts procured by the Contractor to be inspected and validated IAW ISO 9001 clause 7.4 using Government approved Computer Aided Design (CAD) data and or Government furnished drawings.

1.6.4. Existing repairs – No existing repairs are allowed to remain and must be fully corrected by authorized depot level repair and/or replacement of the affected part, to the condition as specified in the design drawings for that duct assembly.

1.6.5. Correct Configuration – Each duct assembly must be returned to the proper and complete configuration as specified in the design drawings for that specific duct part number or as otherwise required by 424 SCMS Engineering (see details in paragraph 1.5.4 below):

1.6.5.1. Convert by-pass duct part number 35-8275-518 to 35-8275-2 configuration as follows:

a. Remove the following parts from by-pass duct part number 35-8275-518:

39-16247-1 Angle

39-16247-2 Bracket

39-16247-4 Clip

39-16247-5 Radius filler

39-16247-801 Clip

39-16248-1 Angle

39-16248-2 Angle

39-16248-3 Clip

39-16248-801 Clip

b. Fill the following holes with MS20426DD rivets (diameter and length as required) in accordance with 1B-52H-3:

- 10 each holes in skin 35-8275-6 (countersunk on inside airflow skin surface).

- 8 each holes in channel 35-8275-176

- 8 each holes in channel 35-8275-18

c. Reidentify by-pass duct assembly part number 35-8275-518 to by-pass duct part number 35-8275-2.

1.6.5.2. Modify 35-10749-1 cowl support brackets on 35-8270-501 and 35-8270-502 by-pass ducts per Figure 1. (Cowl Support Rod Bracket Repair OC-ALC/LAHRH, 25 May 93).

1.6.5.3. P/N 35-8275-1 will be modified to incorporate chafe guards per T.O. 1B-52H-3 Chapter 5, Figure 5-40 (Nacelle Lower Inboard Bypass Duct Chafe Elimination).

NOTE: No magnesium skins are allowed to be installed or to remain on any duct.

1.6.6. Bifurcation Fitting Seal Attachment Holes - Seal rivet holes on bifurcation fittings must be welded closed and redrilled to proper size during overhaul when the holes have become oversized. See paragraph 1.5.7.a. for welding procedures.

1.6.7. Flush Fastener Criteria - All flush fastener applications to be installed such that the fastener completely fills the countersink area by visual inspection with no greater gap and not beyond the limits set forth in the 1B-52H-3, 1-1A-8 and Figure 2.