J85 PWS.pdf

PR# FD2030-10-26763 Page 1

APPENDIX “A”

PERFORMANCE WORK STATEMENT (PWS)

FOR THE

REMANUFACTURE OF J85-GE-5/-21

MISTR Components

Follow-on Contract

421 Supply Chain Management Squadron (SCMS)

Program Management Flight (GUMDA)

TINKER AFB, OK 73145-3031

PREPARATION DATE: 15 June 2011

PREPARING ORGANIZATION: OC-ALC/GKGDC/421 SCMS/GUMDA

TINKER AFB, OK

PR# FD2030-10-26763 Page 2

TABLE OF CONTENTS_______________________________________________Page

SECTION I – DESCRIPTION OF SERVICES………………………………………

1. Background………………………………………………………

1.1 Workload Scope…………………………………………………

1.2 Government Contract……………………………………………

1.3 Mission Essential…………………………………………………

1.4 Program, Data Bases, & Websites…………………………………..4

1.5 Management and Logistics Requirements………………………

1.6 Forecasting and Requirements Reviews……………………..……...4

1.7 Contract Phases……………………………………………………...5

1.8 General Program and Management Requirements…………………..6

1.9 Quality Management and Management Systems……………………7

1.10 Material Management………………………………………………..8

1.11 Reporting Requirements……………………………………………..9

1.12 Preservation and Inspection Requirements………………………….11

1.13 Remanufacture Requirements……..………………………………...12

1.14 Foreign Military Sales (FMS) Repair and Return…………………..12

1.15 Handling of Condemned Parts………………………………………12

1.16 Materiel Review Board ……………………………………………..13

1.17 Technical Library Maintenance……………………………………..14

SECTION II SERVICE SUMMARY……………………………………………………..16

2.0 Service Summary

2.1 Service Summary Requirements

2.2 Performance Objectives and Thresholds

2.3 Surveillance Methods

2.4 Contractor Performance Evaluation

SECTION III – Government Furnished Property/Services..…………………………………18

3.0 Government furnished Property

3.1 Government Services

ATTACHMENTS

Attachment I Acronyms

Attachment II Definitions

Attachment III J85 Bearing Save List

Attachment IV Applicable Documents

PR# FD2030-10-26763 Page 3

SECTION I – DESCRIPTION OF SERVICES

1. Background

The General Electric J85 is a compact high thrust, lightweight, afterburning turbojet engine comprising an 8-stage axial flow compressor coupled directly to a 2-stage axial turbine. It incorporates a thru-flow annular type combustion system, controlled compressor inter stage bleed, variable inlet guide vanes, and an afterburner with a variable area exit nozzle. The J85 is used primarily to power the Air Force’s primary trainer, the T-38 aircraft. The lead command for the J85 is the Air Education and

Training Command (AETC) at Randolph AFB, Texas. In addition, two other commands fly J85: Air Combat Command (ACC) and Air Force Material Command (AFMC). J85 engines are inspected and repaired at various USAF Engine Regional Repair Centers

(ERRC). Individual components on the J85 engine are also replaced at one of several T-

38 operating bases. Since the introduction of the J85 into the USAF inventory in the

1960’s, the J85 management of items subject to repair (MISTR) components has been repaired through contract support.

1.1. Workload Scope

This PWS provides the minimum technical, logistics management, and remanufacture requirements for the return of unserviceable J85 components to a serviceable condition.

The workload includes remanufacture of US Air Force, US Navy, Foreign Military Sales

(FMS), National Aeronautical & Space Administration (NASA) J85 components. The following chart indicates the engine model and user.

1.2. Government Contract

Work shall be accomplished in accordance with the latest version of the repair TO, TM, specification, regulation or instruction, or Government approved commercial practice unless specifically stated otherwise in this PWS. The applicable T.O.’s are listed in

Attachment IV. This list may not be all inclusive and is subject to change. Reference to the Enhanced Technical Information Management System (ETIMS) is required to ensure the most current document is acquired to perform work. A modification to the PWS is not required for any T.O. change and changes are to be implemented in accordance with paragraph 1.17. and its subparagraphs.

Engine User

AF USN FMS NASA

J85-GE-5 * * * *

J85-GE-21 * *

PR# FD2030-10-26763 Page 4

1.2.1. This contract does not allow for Commercial Packaging.

1.3. Mission Essential Services

N/A

1.4. Programs, Databases & Websites.

The contractor shall obtain and maintain accounts necessary to access programs, databases & websites. Some databases will require a Public Key Infrastructure (PKI) certificate.

a. Joint Deficiency Reporting System (JDRS)

b. Commercial Asset Visibility AF (CAVAF)

c. Comprehensive Engine Management System (CEMS)

d. Enhanced Technical Information Management System (ETIMS)

1.5. Management and Logistics Requirements

The contractor shall perform management and logistics efforts to include management requirements, quality, material management and reporting requirements. The contractor shall deliver all correspondence and documents required by this PWS, including forms, CDRLs, and required notifications in electronic format via e-mail, unless otherwise authorized by the PCO.

1.6. Forecasting and Requirements Reviews

The contractor shall be required to participate in Forecasting and Requirements Reviews.

Forecasting and Requirements Reviews is a process which enables the contractor and the

Government to collaborate and share information in an effort to better support the customer’s needs and improve the forecasting of future requirements. These reviews will be conducted in accordance with the clause in Section H of the basic contract.

1.6.1. Requirements Data

The contractor may use Government provided historical consumption data, future requirements, and inventory status for forecast planning. The contractor may use the data for the lay-in of inventory sufficient to meet required contract delivery requirements and to minimize any gaps in end user support. Projections based on

Government furnished data will not bind either party but may be used for planning purposes only. The Government will not be held liable for the accuracy of or decisions made using this data.

1.6.2. Criteria for Forecasting

Forecasting will be considered for all items; especially any CFM parts that would constrain or result in work stoppage of repair production and will be reviewed on a quarterly basis. The contractor shall forecast and maintain ample inventory to promote minimal production disruption to meet delivery requirements.

PR# FD2030-10-26763 Page 5

1.6.3. Source of Supply

The contractor shall procure all parts required to complete the USAF requirements.

All CFM parts shall be of new condition and may be procured from the Defense

Logistics Agency (DLA) and/or Government/Original Equipment Manufacturer

(OEM) approved sources available per the T.O. requirements. To enhance CFM supportability the contractor may employ the DLA supplier collaboration program to share supply plans, forecast orders and improve demand planning efforts.

1.7. Contract Phases

The contract shall have three phases, Transition Phase, Production Phase and Exit Phase.

1.7.1. Transition Phase

Transition will begin when a funded task order is issued. During this phase the

AFGLSC Program Manager, contractor personnel and other government J85 team members will form together as an Integrated Process Team (IPT). The IPT will conduct initial requirements and forecasting review and address the contractor’s milestone schedule and production plan provided in the proposal which will be implemented to maintain Contractor Furnished Material (CFM) supportability. The contractor shall establish TO Library (1.17), Access to data systems (PWS 1.4) within thirty days after award. The contractor shall also establish process to be employed for

Root Cause Analysis of failures, TDRs, and production delays on or before the end of three month transition phase.

1.7.2. Production Phase

Production Phase shall begin at the end of the three month transition. However, delivery of orders may occur during the transition phase. The contractor shall meet the required delivery schedules. Delivery requirements will be incremental to accommodate capacity and quarterly demands. There are a few NSN’s that require a longer turnaround time and their delivery will also be incremental to accommodate capacity and quarterly demand rates. Items that are identified under Forecasting and

Requirements Reviews may be negotiated as needed. Deliveries not meeting the contractual delivery schedule shall require the contractor to notify the ACO/PCO and submit a corrective action plan to the PCO within three business days of the missed delivery. The contractor shall maintain a process developed for Root Cause Analysis of failures, TDRs, and production delays throughout the production phase. If delivery requirements are negotiated and changed during the course of the contract it does not require an amended PWS.

1.7.3. Exit Phase

The contractor and government IPT shall coordinate an exit schedule for an orderly transition of assets. PCO will provide disposition instructions for any remaining inventory in CSI and CRI.

PR# FD2030-10-26763 Page 6

1.8. General Program and Management Requirements

The contractor shall have and maintain a program management structure to accomplish administrative planning, coordination of program requirements, and to optimize workflow by organizing, directing, controlling actions. The contractor shall notify the

PCO, PM and PMS in writing within two working days in the event of a part problem or technical problem that is anticipated to cause a work stoppage or production delay and provide a get-well plan to mitigate work stoppage.

1.8.1. Program and Status Reviews

The contractor shall travel to participate and support USAF reviews between contractor, major commands, and OC-ALC as requested. At these meetings the contractor shall brief their risk assessment along with mitigation plans and other appropriate briefings during meeting. At a minimum, the contractor shall travel to attend and support the annual J85 USAF Maintenance Planning Working Group

(MPWG) /Users Conferences (at Tinker), J85 USAF Mini MPWG/Users Conferences

(at Tinker by Invitation), J85 Component Improvement Program (CIP) Conferences

(in Boston), and the semi-annual J85 Production Management Reviews (PMRs) alternating between contractor and Tinker locations. The contractor shall provide the government the points of contact and presentations for review 45 days prior to scheduled meetings IAW with CDRL (A012).

1.8.2. Bi-Weekly Teleconference

The contractor shall develop and present issues during bi-weekly teleconferences to resolve any program problems that concern production, technical issues and parts constraints to include get-well plans. The contractor shall also provide forecasted delivery schedules, by delivery order and modification, for the current month (actual production) as well as the two following months projected schedule.

1.9. Quality Management and Management Systems

1.9.1. ISO Quality Management

All parts identified as serviceable shall be delivered to the Government defect free.

At contract award the contractor shall have in place and maintain a quality management system in compliance with ISO 9001:2000/AS9100 or equivalent

Quality systems – Model for quality assurance in production, installation and servicing. The quality system procedures, planning, and other documentation and data that comprise the quality system shall be made available to the Government for review upon request. The Government will, at their discretion, perform any inspections, verifications, and evaluations to ascertain conformance to the ISO

9001:2000/AS9100 requirements and the adequacy of implementing procedures.

1.9.2. Corrective Action

The Government reserves the right to issue corrective actions against the contractor’s quality system as a result of audits or inspections. The contractor shall implement appropriate corrective actions to bring the quality system into compliance.

PR# FD2030-10-26763 Page 7

1.9.3. Maintaining Quality Management

Under this contract the contractor is responsible for maintaining its quality management systems and/or registration that complies with the requirements of

International Standards Organization (ISO) 9001:2000 or /AS9100 or equivalent and shall provide the government access to all third party audits as necessary.

1.9.4. Product Audits

The contractor shall support product audits, at the determination of the Government on overhauled MISTR components. The Government may select at random such quantities of end items as may be necessary to determine quality of workmanship and materials.

1.9.5. Request for Deviation/Waiver

The contractor shall submit all J85-5/-21 requests for deviation on form DD Form

1694, per MIL-STD-481B to PCO.

1.9.6. Repair and Manufacturing Qualification

The contractor shall ensure all repairs and spare parts are provided by government qualified sources to maintain Operational Safety, Suitability, and Effectiveness

(OSS&E) integrity.

1.9.7. Source Approval Requirements (SAR)

The contractor performing the work shall be source approved for master NSNs in

Section B of the contract prior to award. All repair processes are subject to substantiation of specific repair procedures, process control, and the specialized testing of samples through Initial Product Evaluations (IPEs). IPEs may be waived at the discretion of the Cognizant Engineering Authority (CEA) based on the offeror’s experience with the specific parts/procedures under review. Any changes to internal repair processes or subcontractors after contract award must be presented to and approved by the CEA prior to implementation to ensure compliance with the Repair

Qualification Requirements (RQR) for the NSN. These proposed changes shall be submitted through the PCO. For NSNs added after contract award via the Additional

Requirements Clause, the contractor will be required to meet RQRs for the new NSN prior to incorporation.

1.9.8. Work Standard

Work shall be performed to T.O. instructions. In the instance where Air Force TO’s do not identify specific parameters for the required procedures, the supplier or sub-vendor shall establish a written procedure in accordance with applicable commercial standard. The procedure shall be submitted via email to CEA for final approval through the PCO. The contractor may submit Value Engineering Change Proposals

(VECP) for consideration in accordance with FAR 52.248.

1.9.9. Government Sources

All source controlled replacement components must be manufactured by government approved sources. Any new sources must submit SAR packages for the items they

PR# FD2030-10-26763 Page 8 wish to manufacture and/or become a source of supply in order to be considered for future procurements.

1.9.10. Over and Above (O&A)

Contracts for the performance of the remanufacture of various items generally contain over and above work requirements. The procedures for submission of O&A work requests are detailed in the contract. Items to be classified as O&A are as follows:

Condemnation Processing (Para 1.15.3), Teardown Deficiency Report (TDR) (Para

1.11.3.A.), Technical Order/Technical Order Time Compliance changes (Para 1.17.1 thru 1.17.4.), Product Audits (Para 1.9.4.), Supply Discrepancy Report (SDR)/Report of Discrepancy (ROD) (Para 1.11.7.), Beyond Economical Repair (BER) (Para

1.15.4.), and Reclamation (Para 1.15.6.) as determined by government.

1.10. Material Management

The contractor shall be responsible for providing all support equipment and all material required to repair and maintain the support equipment needed to accomplish the engine component remanufacture. Calibration of support equipment shall be in accordance with the most current prescribed technical data and accomplished per the International

Organization for Standardization (ISO) 10012 and ANSI/NCSL Z504-3. The contractor shall be responsible for furnishing petroleum, oils and lubricants used for remanufacture and testing. The contractor shall be responsible for the disposal of contaminated fuels and oil in accordance with local, state and federal regulations.

1.10.1. Consolidated Reparable Inventory (CRI)

The contractor shall establish and maintain a consolidated reparable inventory (CRI) at the contractor’s facility [upper limit of 5000 each and a lower limit of 0 (“zero”) each]. In the event the CRI maximum level is exceeded, the contractor shall notify the PCO, PM and PMS within 5 working days of occurrence. The contractor shall store reparable items shipped from designated field units, Air Logistics Center

(ALC), and other contractor facilities. The contractor shall induct assets using the

First-in First-Out (FIFO) concept. The contractor shall report asset receipt and induction into CAVAF in accordance with Appendix B.

1.10.2. Consolidated Serviceable Inventory (CSI)

The contractor shall establish and maintain a consolidated serviceable inventory (CSI) at the contractor’s facility [upper limit of 900 each and a lower limit of 0 (“zero”) each]. In the event the CSI maximum level is exceeded, the contractor shall notify the

PCO, PM and PMS within 5 working days of occurrence. The contractor shall store completed serviceable items and ship them directly to a designated user at a Field

Unit, Air Logistics Center (ALC), or other contractor facility based upon a prioritized demand. The contractor shall report asset storage and shipment information into

CAVAF in accordance with Appendix B.

PR# FD2030-10-26763 Page 9

1.10.3. End Item Shipment

Upon completion of assets the contractor shall request shipping instructions from the

PCO or his/her authorized representative. Disposition instruction will be provided for direct shipment through the government. If the government does not reply within three work days of the request, the items shall be shipped to the address cited in the basic contract (Tinker AFB). Upon shipment of the assets the contractor shall provide tracking information for each document number. All correspondence shall be via email to the POC determined by the program office.

1.10.4. Segregation of Material

The contractor shall ensure that USAF components received for remanufacture or modification are to be accounted for, and kept segregated from other orders (FMS, USN, etc.) during storage and the process of remanufacture.

1.11. Reporting Requirements

Reporting requirements shall be detailed in attached DD form 1432-1, Contract Data

Requirement Listing.

1.11.1. Product Quality Deficiency Report (PQDR)

Using the Joint Deficiency Reporting System (JDRS), the contractor shall investigate and document PQDR findings on all design and quality control (material) deficiencies found IAW the procedures of T.O. 00-35D-54. The contractor shall review the reported discrepancy from the field and schedule PQDR exhibit for investigation.

The contractor shall investigate returned PQDR within 30 days from time of exhibit receipt. Substantiation of root cause on failure against reported field failure shall be provided in close out report. Upon completed PQDR investigations, the contractor shall request disposition of exhibit through the PCO to PM and PMS for material induction into current delivery order or next delivery order submission. Disposition action request on completed PQDR exhibits shall not exceed 45 days. Reports shall be submitted IAW (CDRL A001).

1.11.2. US Air Force Technical Manual Change Recommendation and Reply (TMCRR)

(AFTO Form 22)

The contractor shall prepare a TMCRR using an AFTO Form 22 when a technical data deficiency is discovered or to propose a revised repair process or alternate material which is presently covered in repair manual. The contractor shall accomplish a TMCRR IAW TO 00-5-1. TO changes shall be submitted in accordance with (CDRL A002).

1.11.3. Teardown Deficiency Report (TDR)

A. CAT I and II material deficiency report (MDR) Teardown Deficiency Report

(TDR) will be authorized using a Specific Statement of Work (SSOW) through the PCO. SSOW shall be used for pricing request from the contractor and response shall be sent to the PCO within 7 working days. CAT I and CAT II

MDRs shall be inducted for TDR upon receipt of exhibit and approved funding.

PR# FD2030-10-26763 Page 10

Using TO 00-35D-54 as a reference, final CAT I MDR TDRs shall be submitted to the PCO NLT 45 days after exhibit induction and authorization. Final CAT II

MDR TDRs shall be submitted to the PCO NLT 90 days after exhibit induction and authorization. Investigate exhibit to disclose failure mode(s). If failed components require additional lab analysis, contractor may use independent agencies for analytical evaluation. Contractor may request support from CEA for additional guidance and disposition via PCO. TDR may be written in contractor format. TDR will be input to JDRS. (CDRL A003)

B. TDR investigations for T5 Motors, NSN 2915-01-538-1154OK and Main Fuel

Pump NSN 2915-01-572-2557OK. When an item fails and is reported in the Joint

Deficiency Reporting System (JDRS) a TDR investigation will be accomplished on these items that have not been previously repaired under the basic CLINs of the contract. These items will be sent to the contractor and will have a DD Form

1575, Suspended Tag-Materiel, attached to the component. Contractor shall separate these assets from other Condition F material located at their facility.

Contractor shall notify the program office upon receipt of assets and request funding. Contractor shall perform a teardown inspection to determine or verify failure mode as described in the discrepancy description. Upon authorization through a funded modification to the contract the contractor will have 20 working days to complete teardown, inspection and submit TDR. If further investigation is required a specialized statement of work will be prepared and provided to the contractor for pricing and the firm fixed price will be adjusted to include this requirement. Contractor shall contact the PCO with findings as soon as a failure mode is identified and/or teardown investigation is complete. Contractor shall submit TDR. (CDRL A003)

1.11.4. Comprehensive Engine Management System CEMS Reporting, (CEMS/D042)

The contractor shall report into CEMS database for accurate Overhaul/Time Since

Shop Visit/Total Time status on time tracked MISTR components in accordance with

(CDRL A004).

1.11.5. Commercial Asset Visibility Air Force (CAVAF) Government Furnished

Material Reporting

The contractor shall provide GFM reporting into Commercial Asset Visibility Air

Force Government Furnished Material Report. Contractor reporting requirements into CAVAF require each asset be identified by actual NSN. CAVAF reporting requires corresponding CLIN submission as detailed on the basic contract. Each end item MISTR/component NSN of this PWS shall be properly registered within

CAVAF system. (CDRL A005)

1.11.6. Government Industry Data Exchange Program (GIDEP)

The contractor shall participate in the GIDEP process IAW www.gidep.org and submit reports. The contractor shall be responsible for preparing and responding to

ALERTs. (CDRL A006)

PR# FD2030-10-26763 Page 11

1.11.7. Supply Discrepancy Report (SDR)/Report of Discrepancy (ROD)

The contractor shall submit a SF-364 (Standard Form) IAW T.O. 00-35D-54 upon discovery of discrepancies for items of supply received for overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damage or improperly packaged shipment. (CDRL (A007)

1.11.8. Remanufacture Maintenance History Records

The contractor shall accumulate and store all records and paperwork associated with the engine and component remanufacture for the life of the contract. The contractor shall convert all records and paperwork to scanned digital format and stored on CD in

DVD format. The contractor shall include an index of each component package. The contractor shall provide this information each quarter. (CDRL A008)

1.11.9. Remanufacture Production Report

The contractor shall provide an updated weekly/monthly production report to the government IAW (CDRL A009).

1.11.10. Government Property Physical Inventory Count or Custodial Balance Report

This report enables the Government to track Material Review Board holding area contents. (CDRL A011)

1.12. Preservation and Inspection Requirements

The contractor shall be responsible for preservation and inspections processing as defined below.

1.12.1. Preservation

The contractor shall comply with a MISTR component pre-induction preservation inspection prior to overhaul/shop visit. The contractor shall refer to applicable

MISTR component technical data for proper preservation. If during the pre-induction inspection, the MISTR component is found to have been preserved incorrectly or is missing preservation caps and/or plugs, the contractor shall immediately email the

PCO with discrepancies that were noted during the pre-induction preservation inspection. The contractor shall maintain shipping containers IAW TOs 2J-1-18 and

35E20-3-1-103.

1.12.2. Inspection

The contractor shall inspect scheduled incoming components and GFM for missing parts, any damage associated with improper handling and shipping, and damage other than normal failures. For components with missing parts or damage, the contractor shall provide the PCO, PM and PMS with the estimated parts list required for the remanufacture and submit a SDR (PWS 1.11.7). The contractor shall contact the

PCO, PM and PMS for disposition instructions within two days of receipt. The contractor shall not induct these components without PCO disposition instructions.

1.13. Remanufacture Requirements

PR# FD2030-10-26763 Page 12

The contractor shall overhaul MISTR items IAW remanufacture manuals and documents as listed in (PWS 1.17-1.17.4), Table 1.17-1 and RQR.

1.13.1. Item Unique Identification (IUID)

IUID part-marking compliance is a DoD mandate for items contained within government inventory systems and as identified by DoD criterion requirements.

Repair contracts that result in the delivery of tangible personal property to the government shall follow the latest DoD instructions to install IUID compliant marks in accordance with policy as stated in DFARS 211.274.

1.14. Foreign Military Sales (FMS) Repair and Return

Assets received shall be processed and repaired under terms of contract. If assets fail to complete repair, assets shall be segregated and request for specific disposition from the

PCO, PM and PMS.

1.15. Handling of Condemned Parts

1.15.1. Condemned Parts Staging

The contractor shall provide secure locations for condemned part storage. The contractor shall sort parts by ELIN, for Government personnel inspection and disposition. The contractor shall keep USAF and FMS parts segregated from each other.

1.15.2. Low Cycle Fatigue (LCF) Parts without History

The contractor shall establish a holding area and separate all LCF life limited components for which the operating history cannot be established pending disposition by the PCO.

1.15.3. Condemnation Processing

The contractor shall condemn engine components determined by the Quality

Assurance Representative (QAR) to be beyond economical repair to MRB holding area after ACO approval. The contractor shall place recoverable engine components condemned during the course of overhaul in the MRB hold area pending disposition from the PCO. The contractor shall accomplish MRB actions and DEMIL of parts condemned, including condemnation resulting from NDI and LCFC, within 60 days after receipt of disposition instructions from the PCO. This Over & Above CLIN in accordance with O&A procedures must be funded for authorization. The contractor shall ensure condemned parts containing critical alloys and precious metals are processed IAW TO 00-25-113 and the contractor’s MRB procedures approved by the

Government property administrator.

1.15.4. Beyond Economical Repair (BER)

“Economically Reparable End Items” are defined as end items which can be restored to a serviceable condition, in accordance with the applicable requirements, when costs of remanufacture of any end item received will not exceed 75% of the Stock

PR# FD2030-10-26763 Page 13

List Price (SLP) specified in the contract. BER are categorized as components under this contract which exceed repair values over 75% of the SLP. If the Contractor estimates the total cost of the remanufacture of any end item received will exceed the above percentage of the SLP, the Contractor shall promptly notify the ACO/PCO in writing and shall not perform further services on any such items except at the direction of the ACO/PCO. Once written notification is received from the ACO/PCO that a particular item is considered BER and not reparable, the Contractor shall dispose of the unit in the manner directed by the ACO/PCO. The ACO/PCO may authorize the Contractor to exceed the percentage of the SLP when an item is in critical supply status. Work performed on BER items will be determined by the

ACO/PCO to be Government economic overhaul. Once this determination is made the contractor services and direct materials furnished in the amount as set forth in the

Work Request to be performed will be only for the amount exceeding the normal repair cost.

1.15.5. End Item Repair Condemnation Compensation

The contractor shall submit to the PCO, PM and PMS, IAW the provision in contract

Section H entitled Over and Above Work Procedures, and a compensation for payment within 60 days for work performed on reparable that are subsequently condemned.

1.15.6. Reclamation Processing

The contractor shall accomplish reclamation of recoverable engine components as directed by the PCO.

1.16. Material Review Board (MRB) Reviews

When assets being remanufactured are beyond T.O. Limits the contractor shall segregate subject asset for future MRB review and if available an additional asset is to be inducted to complete open order. Once the USAF completes MRB review disposition will be provided in writing by the USAF Technical Office by the PCO. The contractor shall not condemn asset(s) without prior approval by the PCO through the ACO. The contractor shall make all dispositions of the condemned items in the manner directed by the ACO.

1.16.1. Contractor MRB Support

The contractor shall support as a minimum, quarterly inventory material count report of unserviceable Government USAF, Navy and FMS property placed in holding store room. The government ACO will inform the contractor of pending scheduled material scrap reviews. Prior to material scrap reviews, the contractor shall provide list of material in scrap hold area to government and will support during reviewing of material.

1.16.2. Disposition - Consumable Material

The contractor shall condemn all unserviceable consumable items XF3 and XB3-

ERRC Codes P and N respectively. All unserviceable recoverable items (XD2-

ERRC Code T) shall be held in the MRB hold area pending J85 Technical Office

PR# FD2030-10-26763 Page 14 review. The contractor shall ensure proper DEMIL actions are taken to prevent condemned material re-entering into government service or from being used from its intended purpose. A bearing Hold List, Attachment III, will be used to recover bearings for shipment as instructed by the ACO as part of this PWS.

1.17. Technical Library Maintenance

The contractor shall maintain all TOs, TMs, TCTOs and other technical directives listed in this PWS in an updated and current status IAW TO 00-5-1. If a conflict arises between the requirements of this PWS and the Technical Documents, the contractor shall notify the PCO.

1.17.1. Review Of Change

The contractor shall review all updates to the TO’s, TM’s, TCTO’s and other directives within five days of receipt. Safety of Flight changes shall be reviewed within one day of receipt.

1.17.2. Cost Impact of Changes

If the contractor determines the changes will result in remanufacture cost change, the contractor shall notify the PCO in writing of estimated cost impact within 30 days for non-safety of flight changes and 15 days for safety of flight changes.

1.17.3. Implementation of Changes

The contractor shall implement all no cost changes within 5 days of review. Safety of

Flight changes shall be implemented within one day regardless of cost and notification shall be provided to the PCO that changes have been incorporated. Non-safety of flight changes having cost impact shall not be implemented without PCO direction.

1.17.4. Time Compliance Tech Order Incorporation

The contractor shall ensure that all engine components inducted for remanufacture has all outstanding technical directives listed in Table 1.17-1 incorporated in their remanufacture processes. Deletions and/or additions to this list will not require a contract modification.

PR# FD2030-10-26763 Page 15

Table 1.17-1 J85 Time Compliance Tech Orders

TCTO NUMBER DATE TITLE

2J-J85-989 15Apr02 Upgrade Configuration to J85-5R

2J-J85-989C 19Jul02 Supplement

2J-J85-989G 01Feb05 Supplement

2J-J85-989H 03Oct05 Supplement

2J-J85-989J 28Oct05 Supplement

2J-J85-992 20Oct03 One Time Inspection, Second Stage

Compressor Disk, P/N 37D401312P101

And P/N 5045T88P01

2J-J85-992C 15Jun04 Supplement

2J-J85-993 20Oct03 One Time Inspection of Third Stage

Compressor Disk

2J-J85-993C 15Jun04 Supplement

2J-J85-994 20Oct03 One Time Inspection of Fourth Stage

Compressor Disk

2J-J85-994C 15Jun04 Supplement

2J-J85-995 20Oct03 One Time Inspection of Fifth Stage

Compressor Disk

2J-J85-995C 15Jun04 Supplement

2J-J85-996 17Oct03 Replacement of Exciter Ignition Lead

2J-J85-1000 10Feb05 One Time Inspection, Comp/Rotor Assy

2J-J85-1002 28Feb 06 One Time Inspection, IGV Clips

2J-J85-1003 17Jan06 Life Limit Reduction Plan (LLRP), Compressor Disks Stgs 1 thru 4

2J-J85-1004 18Dec 06 LLRP Comp Disk Stgs 1 thru 4

2J-J85-1005 01Oct07 Fleet Replacement T-5 Mtr

2J-J85-1006 31Mar08 AB Manifold Clamp Replacement

2J-J85-1007 06Nov08 Legacy 5M Engines with Overflown GE recommended Life Limit

2J-J85-1008 17Nov08 Removal Compressor/Turbine Disks with Overflown

GE recommended Life Limit

2J-J85-1009 14Oct09 Removal of Compressor Rotor Assemblies with

Non-Conforming Compressor Rotor Rear Spools

Part Number 5126T37P03, J85-5 Propulsion

Modernization Program (PMP) Engines

2J-J85-1011 01Dec09 Life Limit Reduction Program (LLRP), Removal

Of Stage 2 Turbine Wheel, P/N 4036T24P01, and

Torque Ring, P/N 37D401014P101, from J85-GE

-5 Series Propulsion Modernization Program (PMP)

Engines

PR# FD2030-10-26763 Page 16

SECTION II- SERVICE SUMMARY

2. Service Summary

The contractor shall be aware that the absence of any contract requirement in the Service

Summary does not detract from its enforceability nor limit the rights or remedies of the

Government under any other provision of the contract. The contractor shall ensure the

SS requirements are accomplished.

2.1. Service Summary Requirements.

The contractor shall ensure the performance objectives, performance thresholds, and support for surveillance methods are achieved as follows:

2.2. Performance Objectives and Thresholds.

The contractor shall achieve performance thresholds identified in Table 2.4 of this PWS.

NOTE: The performance thresholds are designed to:

a. Align contractor performance with objectives.

b. Focus on critical success factors in meeting performance objectives.

c. Reflect performance goals.

d. Promote continuous improvement in performance.

e. Support minimum mission requirements.

f. Provide cost savings/cost avoidance to the Government.

g. Maximize efficiencies.

Defense Contract Management Agency (DCMA)/Administrative Contracting Officer

(ACO) and/or Quality Assurance Representative (QAR) will exercise surveillance over the performance thresholds.

2.3. Surveillance Methods

The contractor shall support the surveillance methods as identified below:

a. Customer complaints

b. Periodic Inspections

Note: The method of surveillance may include one or more of the methods defined above. The Government will use the methods contained in the Performance Plan (PP) to evaluate the contractor’s performance for the listed program objectives.

2.4. Contractor Performance Evaluation

The contractor shall be aware that the evaluation of performance will occur when the

QAR and/or Contracting Officer Technical Representative (COTR) evaluate the service

PR# FD2030-10-26763 Page 17 of the contractor to determine whether or not it meets the PP objectives of the contract.

In the event the performance objective is not met, the QAR will issue written notification to the contractor. In cases where the contractor fails to implement corrective action, the

PCO will take appropriate measures.

TABLE 2.4 Service Summary Elements

Reference Performance

Objective

PWS

Paragraph

Performance Threshold

SS-1 The contractor shall meet the required delivery schedule

1.7.2.2 Excellent = Meets all scheduled

deliveries with 10% ahead of schedule

Satisfactory = Meets 90% of all scheduled deliveries

Unsatisfactory = Meets < 90% of all scheduled deliveries

SS-2 Quality, all parts identified as serviceable shall be delivered to the Government defect free

1.9.1 Excellent = Defect rate< 0.5%

Satisfactory = Defect rate 1.0%

Unsatisfactory = Defect rate

>1.0%

PR# FD2030-10-26763 Page 18

SECTION III-GOVERNMENT FURNISHED PROPERTY/SERVICES

3. Government Furnished Property

The contractor shall furnish all material, support equipment, tools, test equipment, labor and services. Government Furnished Material shall not be provided with the exception of

Air Force managed repairable parts called out in Appendix “B”.

3.1. Government Furnished Services

N/A

PR# FD2030-10-26763 Page 19

ATTACHMENTS

ATTACHMENT I

Acronyms

Acronym Definition

ACI Analytical Condition Inspection

ACO Administrative Contracting Officer

AFMC Air Force Materiel Command

AFB Air Force Base

AFTO Air Force Technical Order

ALC Air Logistics Center

ANSI American National Standards Institute

BER Beyond Economical Repair

BEQ Best Estimated Quantity

CAVAF Commercial Asset Visibility Air Force Reporting

CDRL Contract Data Requirement List

CEA Cognizant Engineering Authority

CEMS Comprehensive Engine Management System

CFE Contractor Furnished Equipment

CFM Contractor Furnished Material

CID Change in Design

CIP Component Improvement Program

CLIN Contract Line Item Number

CRI Consolidated Reparable Inventory

CSI Consolidated Serviceable Inventory

DCMA Defense Contract Management Agency

DEMIL Demilitarization

DOD Department of Defense

EISP End Item Sales Price

ELIN Exhibit Line Item Number

ERRC Engine Regional Repair Center

ERRC Expandability, Recoverability, Reparability Category

FAA Federal Aviation Administration

FAR Federal Acquisition Regulation

FMS Foreign Military Sales

GE General Electric

GFM Government Furnished Material

GIDEP Government Industry Data Exchange Program

GLSC Global Logistics Supply Center

HAZMAT Hazardous Material

IAW In Accordance With

IPT Integrated Product Team

ISO International Organization for Standardization

PR# FD2030-10-26763 Page 20

JDRS Joint Deficiency Reporting System

LCF Low Cycle Fatigue

LCFC Low Cycle Fatigue Cycle

MDR Monthly Demand Rate

MFC Main Fuel Control

MISTR Management of Items Subject to Repair

MRB Material Review Board

MRRL Material Requirements Repair List

NASA National Aeronautics & Space Administration

NCSL National Conference of Standards Library

NDI Non Destructive Inspection

NHA Next Higher Assembly

OC-ALC Oklahoma City Air Logistics Center

NSN National Stock Number

O/H Overhaul

ODC Office of Defense Cooperation

OSG Over speed Governor

PCO Procurement Contracting Officer

PGM Program Manager

PKI Public Key Infrastructure

PM Program Manager

PMS Production Management Specialist

PN Part Number

PQDR Product Quality Deficiency Report

QAR Quality Assurance Representative

QDR Quarterly Demand Rate

ROD Report of Discrepancy

SDR Supply Discrepancy Report

SWP Sub Work Package

TCTO Time Compliance Technical Order

TDR Teardown Deficiency Report

TMCRR Technical Manual Change Recommendation and Reply

TM Technical Manual

TO Technical Order

USAF United States Air Force

WP Work Package

PR# FD2030-10-26763 Page 21

ATTACHMENT II

Definitions

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.

Beyond Economical Repair: When the cost of repair exceeds 75% of the stock list price.

Beyond Physical repair:

Calibration: Comparison of two instruments or measuring devices, one of which is a standard of known accuracy traceable to national standards to detect, correlate, report, or eliminate by adjustment any discrepancy in accuracy of the instrument or measuring device being compared

With the standard.

Depot Level or Maintenance Facility: An industrial type facility established to perform accessory overhaul functions or modifications and maintenance in support of field and using organizations. This includes AFMC assigned installations and commercial contractors who are engaged in performing depot level work on weapon systems or equipment under a contract issued and managed by AFMC.

Disassembly: Teardown of the item or parts sufficient to permit the type and amount of inspection and work required.

End Item: A final assembly of end products, component parts and materials, which is ready for its intended use.

Engine Accessories: All external items contained in the fuel, ignition, and control systems that are normally removed for rework or replaced without disassembly of the engine.

Engine Accessory Parts: All assemblies, sub-assemblies or components, and detail parts of engine accessories.

Engine Minor Overhaul: As applied to engine accessories, means to restore low time operated engine accessories, when extensive damage is not indicated, to serviceable status without accomplishing complete disassembly.

Engine Parts: All items of the basic engine, excluding engine accessories.

Inspect or Check: An examination of an item to determine identity, condition and proper assembly.

PR# FD2030-10-26763 Page 22

Joint Deficiency Reporting System (JDRS): provides a common, seamless solution for deficiency reporting and resolution management across the USN and USAF. JDRS is a cross-service web enabled automated tracking system designed to initiate, process and track deficiency reports from the War fighter through the investigation process.

MISTR (Management of Items Subject to Repair): Accessories or parts to be overhauled or modified, in support of MISTR programs.

Major Repair: consist of complete disassembly, inspection, repair, assembly and test in accordance with the requirements of the overhaul manual.

Minor Repair: test, adjustment, limited disassembly and repair or parts replacement sufficient to return a unit to a serviceable condition.

Modification: The performance of a change in the physical configuration or in the functional characteristics of an end item as required by TCTO, PPC or other directive.

Nondestructive Inspection (NDI): Methods of investigating the quality, integrity, properties and dimensions of material and components without damaging or impairing their serviceability.

Parts: Essential elements, components or sub-assemblies of an item.

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.

Product Audit: An inspection and evaluation of a repaired or modified item and its process for the purpose of Government verification that all work performed fully complies with contractual requirements.

Product Quality Deficiency: A deficiency attributable to substandard workmanship, errors or nonconformance to technical requirement.

Reclamation: The process of disassembly of end items to recover serviceable or economically repairable spare parts.

Remanufacture: The complete disassembling, cleaning, inspection, repair, or replacement of parts or components, reassembling and testing of any item or accessory in accordance with technical orders/Manuals, directives, and authorized manufacturer’s publications to provide an operationally safe and serviceable item. The restoration or replacement of parts or components of material as necessitated by wear and tear, damage, failure of parts or the like in order to maintain the specific item of material in serviceable operating condition.

Reparable: Pertains to status. An unserviceable item that can be repaired and restored to a serviceable condition.

PR# FD2030-10-26763 Page 23

Save List: A listing of engine parts, engine accessories or engine accessory parts to be removed from reclamation engines or engine accessories. Engine containers and other transportation devices are included on this list.

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

Shop Visit: Restore MISTR components, when extensive damage is not indicated, to serviceable status without accomplishing complete overhaul. MISTR components will be bench checked/disassembled/adjusted and tested only to the extent required to return the component to serviceable condition IAW applicable TO. Shop visit will be recorded into CEMS if applicable.

Support Equipment: All equipment called out in applicable technical orders required for engine and component test, remanufacture.

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

Teardown Deficiency Report: Report requested by the USAF and provided by the contractor that provides findings when a component needs to be disassembled to determine root cause failure or a failure mode.

Work Control Documents: Processing paperwork utilized by the contractor to document work accomplished during inspection, repair or overhaul of engine components.

PR# FD2030-10-26763 Page 24

ATTACHMENT III

J85 Bearing Save List

Engine Location NSN PN number/CAGE Alternate PN/ CAGE T.O. fig and index

J85 #3 ENG

BEARING

3110-01-253-32360K

5014T13P06/99207 R1916E//2 //38443 2J-J85-54, 17/-36

* 3110-00-180-73070K 5014T13P02//99207 R1916E106//38443

*3110-01-038-98870K 5039T58P01

J85 PTO 3110-01-359-71430K 5045T46P02//99207 1916S104//38443 2J-J85-54, 13/-14

*3110-00-400-44090K 4004T19P02//99207 1916S103//38443 *3110-00-901-20900K 4004T19P01//99207 1916S102//38443

J85 PTO/G-BOX 3110-00-618-13880K 327B431P1 //99207 2J-J85-54, 13/-28

3110-00-763-63580K 4008T41 P01 //99207 106KS114 //38443

J85 PTO 3110-00-618-58800K 327B430P1 //99207 R106KC102 2J-J85-54, 13/-32

J85 AXIS D 3110-00-825-48690K 327B622P1 //99207 1903S103//38443 2J-J85-54, 15/-28

J85 AXIS A 3110-00-825-60480K 841B585P1 //99207 R104KD103//38443 2J-J85-54, 15/-101

J85 AXIS F 3110-00-826-50780K 841B772P1 //99207 R104KC10//138443 2J-J85-54, 15/-59

J85AXIS E 3110-00-834-96160K 327B619P1//99207 1904S106 //38443 2J-J85-54, 15/-51

J85 AXIS A 3110-00-847-51360K 37B201484P101 7105KRD4B //38443 2J-J85-54, 15/-99

3110-01-226-1535 5045T28P03//99207 MR40445B32 //83086 2J-J85-94, 12/-64

J85 AXIS B 3110-00-989-89320K 4002T82P01 //99207 R105KD104//38443 2J-J85-54, 15/-43

*3110-00-826-50790K 841B584P1 //99207 R105KD105//38443

3110-01-356-4191OK 5045T45P02 MR40173B432 2J-J85-54, 15/-82

J85 #2 ENG

BEARING

3110-01-053-89590K 5040T17P01//99207 5HTH215-44 //78118 2J-J85-54, 3/-44

*3110-00-928-22850K 4003T99P01 //99207 9215U116 //38443 3110-00-116-3993 4006T93P01//99207 9215U115 //38443

J85 #1 ENG

BEARING

3110-01-267-9019 6051T94P02//99207 5RUH109-A83//78118 2J-J85-54, 3/-8

J85 AXIS E 3110-01-295-57540K 5053T80P01//99207 100KS103//38443 2J-J85-54, 15/-53

J85 AXIS E 3110-00-825-30980K 841B773P1 //99207 100KSD2-44692 //38443 2J-J85-54, 15/-53

J85-21 ENG 3110-01-278-29450K 6051T94P01 //99207 5RUH109-83 1/78118 2J-J85-94, 3/-57

*3110-01-304-60860K 6051T60P01 //99207 AAV9109ROW2//21335

*3110-00-436-02160K 5020T26P01 //99207 AAV9309ROWS4//21335

PR# FD2030-10-26763 Page 25

ATTACHMENT IV

Applicable Documents

TO Number Short Title

00-5-1 AF TECH ORDER SYSTEM

00-20-1 AEROSPACE EQUIP MAINTENANCE INSPECTION & DOCUMENTATION

00-20-2 MAINT DATA DOCUMENTATION

00-20-3 MAINT PROC OF REPARABLE PROP

00-20-5-1-10 JET ENG PARTS TRKING/HIST DATA

00-25-113 CONS SEQ & DIS OF CRITICAL ALLOY

00-25-113-J85 CRITICAL ALLOYS & PREC METALS

00-25-254-1 USERS MANUAL - CEMS

00-25-254-2 USERS MANUAL - CEMS

00-35D-54 MATERIAL DEF REPORT SYSTEM

2J-1-13 CLEANING OF ENG PARTS

2J-J85-9 NDI

2J-J85-54 IPB-5

2J-J85-94 IPB-J85-GE-21

2J-J85-102 CORR CONTR THRU ORG/INTR AINT

2J-J85-111-2 DEPOT OPN & SVC INSTR

2J-J85-113-1 DEPOT MAINT INSTR

2J-J85-113-2 DEPOT MAINT INSTR

2J-J85-113-3 DEPOT MAINT INSTR-DIS

2J-J85-113-4 DEPOT MAINT INSTR-DIS SUB ASSY

2J-J85-113-5 DEPOT MAINT INSTR-CLN, IN

2J-J85-113-6 DEPOT MAINT INSTR-ASSY SUB ASSY

2J-J85-113-7 DEPOT MAINT INSTR-ASSY OF ENG

2J-J85-113-8 DEPOT MAINT INSTR-AB OVHL

2J-J85-113-9 DPT MNT INSTR-MINOR ACESS OVHL

2J-J85-113-10 DEPOT MAINT INSTR-ENG & AB ADJ

2J-J85-133-1 DEPOT MAINT INSTR-21

2J-J85-133-2 DPT MNT INSTR-SUPPORT EQUIP

2J-J85-133-3 DPT MNT INSTR-DISASSY OF ENG

2J-J85-133-4 DEPOT MAINT INSTR

2J-J85-133-5 DEPOT MAINT INSTR

2J-J85-133-6 DPT MNT INSTR-ASSY OF SUBASSY

2J-J85-133-7 DEPOT MAINT INSTR-ASSY OF ENG

2J-J85-133-8 A/B OVERHAUL

2J-J85-133-9 MINOR ACCES OVERHAUL

2J-J85-133-10 ENGINE & A/B ADJUSTMENT

2J-J85-133-11 ENGINE TEST, T/S & PRES

6-1-4 TEST FLUID-ACFT/ENG FL SYS COMP

6J1-2-16-13 OVHL INSTR-TEMP AMP AB CONTROL

6J1-2-16-14 IPB-TEMP AMP AB CONTROL

6J3-1-1 PREP FUEL ACCESS FOR SHIPMENT,

6J3-2-16-13 O/H INSTR-AB CONTROL

6J3-2-16-14 IPB

PR# FD2030-10-26763 Page 26

6J3-2-19-3 O/H INSTR-AB CONTROL

6J3-2-19-4 IPB

6J3-2-31-3 O/H INSTR-AB CONTROL

6J3-2-31-4 IPB

6J3-4-68-3 O/H INSTR-MAIN FUEL CONTROL

6J3-4-68-4 IPB

6J3-4-73-3 O/H INSTR-MAIN FUEL CONTROL

6J3-4-73-4 IPB

6J3-4-78-3 O/H INSTR-MAIN FUEL CONTROL

6J3-4-78-4 IPB

6J3-4-96-3 O/H INSTR-MAIN FUEL CONTROL

6J3-4-96-4 IPB

6J3-8-4-23 O/H NOZZLE ACTUATION POWER UNIT

6J3-8-4-24 IPB

6J3-8-13-3 OH INSTR-NOZ ACT HYD PWR UNIT

6J3-8-13-4 IPB-NOZ ACT HYD PWR UNIT

6J3-8-17-3 OVHL INSTR-VAR EX NOZ ACI

6J3-8-17-4 IPB-VAR EX NOZ ACT SUPPLEMENTS: -1,-2

6J7-6-23 OVHL INSTR-GOV ASSY

6J7-6-24 IPB-GOV ASSY

6J7-10-3 OVHL INSTR-GOV ASSY

6J7-10-4 IPB-GOV ASSY

6J7-15-3 OVHL INSTR-OVERSPEED CONT