PWS.pdf

PWS File No: FD2030-15-02637

PERFORMANCE WORK STATEMENT (PWS)

for the

F108 MODULE 14 (LPT SHAFT ASSEMBLY) NAVY

PURCHASE REQUEST NUMBER:

FD2030-15-02637

REV. 0

PREPARATION DATE: 09 September 2016

PREPARING ORGANIZATION:

Navy E6B ISS Propulsion Engineering Team

Technical Element (Navy Code 4.4.3.3)

TINKER AFB, OK 73145-3031

File Number: FD2030-15-02637 1

TABLE OF CONTENTS Page

TABLE OF CONTENTS 1

SECTION I

1.0 DESCRIPTION OF SERVICES 2

1.1 Receiving 2

1.2 Overhaul/Repair 2

1.2.1 Overhaul/Repair Procedures 2

1.2.1.1 Levels of Repair 3

1.2.1.1.1 Repair (Light) 3

1.2.1.1.2 Repair (Medium) 3

1.2.1.1.3 Repair (Heavy) 3

1.2.1.2 Overhaul 3

1.2.2 Build Policy 3

1.2.3 Overhaul/Repair Deviations 3

1.2.4 Designated Engineering Representative (DER) Processes and Procedures 3

1.2.5 Disassembly 4

1.2.6 Cleaning 4

1.2.7 Assembly 4

1.2.8 Testing 4

1.3 Quality System and Quality Assurance 4

1.4 Deficiency Report (DR) Investigation 4

1.5 Item Unique Identification (IUID) 4

1.6 Condemned Assets 4

1.7 Reporting 4

1.8 Contractor Manpower Reporting 5

1.9 Document Storage 6

1.10 Packaging and Handling 6

1.11 Shipping and Transportation 6

1.12 Contractor Identification to Government Employees 6

1.13 Safety 6

1.14 Mission Essential Services 7

SECTION II

2.0 SERVICE SUMMARY (SS) 7

2.1 Service Summary Requirements 7

2.1.1 Performance Objective(s)/Threshold(s) 7

2.1.2 Surveillance Methods 7

2.2 Module 14 (LPT Shaft Assembly) Service Summary 8

2.3 Contractor Performance Evaluation 8

SECTION III

3.0 GOVERNMENT PROPERTY 8

3.1 Government Furnished Material (GFM) 8

3.2 Government Furnished Property (GRP) 8

APPENDIX “A”

ACRONYMS 9

File Number: FD2030-15-02637 2

SECTION I

1.0 DESCRIPTION OF SERVICES

The purpose of this PWS is to define the Overhaul/Repair requirements for the F108 Module 14 (LPT Shaft Assembly) that apply to the following National Stock Numbers (NSN) and Part Numbers (P/N).

F108 Module 14 LPT SHAFT ASSEMBLY

Input P/N Output P/N Input NSN Output NSN_______

301-316-158-0-2A 301-316-158-0-2A 2840-01-483-8785PN 2840-01-483-8785PN

The instructions stipulated are brief, concise statements providing general requirements for overhaul/repair of the F108 Module 14 (LPT Shaft Assembly). The contractor shall maintain a Federal Aviation Administration Part 145 rated repair facility rated to overhaul/repair CFM56-2A engine components; contractor must have the overhaul/repair capabilities to include appropriate technical data, overhaul/repair documents, and license agreements, required to accomplish overhaul/repair of F108 Module 14 (LPT Shaft Assembly). The contractor is responsible for the production, overhaul/repair and scheduled delivery of a quality product.

1.1 Receiving: The contractor shall perform a receiving visual inspection upon receipt of each Module 14 (LPT Shaft Assembly) for any shipping or packaging damage. The contractor shall report to the Procurement Contracting Officer (PCO) any received assemblies which are misidentified, misdirected, or incomplete (missing parts); the contractor shall obtain disposition instructions from the PCO. Discrepant shipments shall be processed In Accordance With (IAW) the contract’s Appendix B, “End Item and Commercial Asset Visibility for Air Force (CAVAF) System (CFM) Statement of Work”. The contractor shall initiate a Supply Discrepancy Report (SDR) IAW CDRL (A005) for any assets received in other than the contracted packaging.

1.2 Overhaul/Repair: The contractor shall overhaul/repair the Module 14 (LPT Shaft Assembly) as follows.

1.2.1 Overhaul/Repair Procedures: Module 14 (LPT Shaft Assembly) shall be disassembled to piece part level, cleaned, inspected, piece parts repaired or replaced and reassembled. Piece parts shall not be intermixed with any other Type Model Series (TMS).

Life limited parts shall be replaced IAW Navy Build Policy of paragraph 1.2.2. Module 14 shall be overhauled/repaired preserved IAW the procedures outlined in the CFM56-2A Engine Shop Manual (ESM) 72-55-00 thru 72-55-20 and any Temporary Revisions. The latest revision of the CFM56-2A Service Bulletins listed below shall be incorporated.

Overhaul/repair for Module 14 requires 100% incorporation of these CFM56-2A Service Bulletins:

• 72-507: #4 bearing with New Outer Race Material

• 72-464: Introduction of New Center Vent Tube Supports

• 72-338: Reidentification of LPT Stub Shafts (Serial Number dependent)

Incorporate the following Service Bulletin as required:

• 72-275: Introduction of a Thicker Center Vent Tube

For the level of visual and dimension inspections required, Repair 001: Replacement of Aluminum Paint IAW ESM 72-55-01 is required on all reused Module 14 shafts.

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1.2.1.1 Levels of Repair

1.2.1.1.1 Light: No Life Limited Components replaced. Repairable and Non- Repairable Item scrap rates are anticipated at typical levels for components in Module 14 with approximately 20,000 hours, and 5,000 cycles of use.

1. Disassemble Module 14 to piece part level

2. Inspect piece parts (Including striping LPT Shaft to perform NDI, Visual and dimensional Inspections)

3. Clean and inspect all parts. Repair parts as required.

NOTE

With respect to SB 72-0338, the requirement to re-identify an LPT Stub-Shaft is dependent on its S/N. If a stub-shaft’s S/N is not one of those affected by SB 72-0338, enter a statement on FAA Document, in paragraph 1.6, to reflect this.

4. Comply with CFM56-2A Service Bulletins 72-0507, 72-0464 and 72-0338

5. Center Vent Tube shall be inspected for cracks. If Center Vent Tube (CVT) fails inspections for cracks, or is unserviceable for some other inspection criteria, incorporate S/B 72-275

6. Replace all unserviceable components.

7. Reassemble Module 14

8. Perform Long Term preservation of Module 14

1.2.1.1.2 Medium: Perform paragraph 1.2.1.1.1 Light requirements plus replace Stub Shaft

1.2.1.1.3 Heavy: Perform paragraph 1.2.1.1.1 Light requirements plus replace LPT Shaft

1.2.1.2 Overhaul: Perform paragraph 1.2.1.1.1 Light requirements plus replace Stub Shaft and LPT Shaft

1.2.2 Build Policy: Build Policy for life limited parts in the CFM56-2A Navy Module 14 is 5100 cycles.

1.2.3 Overhaul/Repair Deviations: Prior to contractor’s use in overhauling /repairing of Module 14 (LPT Shaft Assemblies), the contractor shall obtain written approval from the PCO for any deviations from the processes, materials, material processes or procedures outlined in CMM, required Service Bulletins (SB). The contractor’s request for deviation must show that the intent of process, materials, material process or procedures conform to processes required by the ESM and the Performance Work Statement (PWS). Navy Propulsion Engineering reserves the right to approve or disapprove any processes or procedures when they fail to meet intended configuration requirements of the Module 14 (LPT Shaft Assembly).

1.2.4 Designated Engineering Representative (DER) Processes and Procedures: Prior to contractor’s use of a DER repair in overhauling/repair of Module 14 (LPT Shaft Assembly) or component parts, the contractor shall obtain written approval from the PCO for all DER processes and procedures.

File Number: FD2030-15-02637 4

1.2.5 Disassembly: The Contractor shall fully disassemble Module 14

1.2.6 Cleaning: All grease, oil, dirt, corrosion and moisture must be removed prior to inspecting, repairing or re-assembling of Module 14

1.2.7 Assembly: Assembly of Module 14 shall be in accordance with appropriate technical procedures

1.2.8 Testing: Module 14 shall be tested to ensure that all operational and performance requirements are met

1.3 Quality System and Quality Assurance: Each Module 14 identified as serviceable shall be delivered to the Government defect free. The contractor shall develop and maintain a system that adheres to the requirements of International Standard Organization (ISO) 9001-2000/ANSI/ASQC Q92, Quality Systems Model for Quality Assurance in Design/Development, Production, Installation, and Servicing and supplement requirements imposed by this contract. Develop and implement procedures to properly maintain measuring and test equipment in accordance with ANSI/NCSL 2340-

1. The quality system will include a clear and complete set of work documents for all maintenance required by this contract. The quality program shall be designed to promptly detect and correct conditions adverse to quality.

1.4 Deficiency Report (DR) Investigation: At the Government’s request, the contractor shall investigate and submit findings to include root causes and a corrective action against all Deficiency Reports submitted to contractor against items overhauled/repaired by this contract which are reported to be defective IAW Quality Deficiency Report (CDRL A004).

1.5 Item Unique Identification (IUID): 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. IUID requirements for the J85 MISTR components have not been identified at this time. When directed by the PCO, the contractor shall follow the latest DoD instructions to install IUID compliant marks. TOs and drawings will be complied with for any component where direction is currently called out in the TO or drawings.

1.6 Condemned Assets: Module 14 (LPT Shaft Assemblies) and assembly components that do not meet present overhaul/repair and inspection limits, shall be condemned at the contractor’s facility.

Requests for disposition instructions shall be submitted to the Contracting Officer and processed through Plant Clearance Automated Reutilization Screening System (PCARSS) at no additional cost to the government. Condemnations shall be reported to 421 SCMS/GUMBA, Global Logistics Support Center (GLSC) services to establish usage rates and cost planning. Condemned Module 14 shall be reported via CDRLs (A001) Commercial Asset Visibility for Air Force (CAVAF) System and (A002) Contract Depot Maintenance (CDM) Production Report.

1.7 Reporting: The contractor shall meet the delivery schedule. The contractor shall provide completed Certificate of Conformance documentation with each Module 14 (LPT Shaft Assembly) and its component parts that have been overhauled/repaired with the intent of returning these assemblies or component parts to service. This documentation shall have part number, serial number, work accomplished, Service Bulletins complied with, on serviceable tag DD Form 1574. The contractor shall ensure that all reporting as specified under the following Contract Data Requirements List (CDRL – DD Form 1423) is accomplished:

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A001: Commercial Asset Visibility Air Force (CAVAF) Reporting A002: Contract Depot Maintenance (CDM) Production Report A003: Comprehensive Engine Management System (CEMS) Reporting

A004: Quality Deficiency Report (QDR) – DI-ALSS-81535 A005: Supply Discrepancy Report (SDR) – DI-MGMT-80503

A001: CAVAF Reporting - The contractor shall input the data IAW CAV AF Statement of Work (SOW) guide and shall not be waived. For CAV AF reporting, the Contractor shall submit Supply Discrepancy Reports (SDRs) when required and IAW CDRL DD Form 1423-1.

A002: Contract Depot Maintenance (CDM) Monthly Production Reporting - Data in accordance with the CDRL report shall not be waived, although contractor’s format with all the same data elements as the production report may be accepted, if approved through the PCO.

A003: CEMS Reporting - Each Serial Number LPT Shaft assembly is loaded into Comprehensive Engine Management System (CEMS) system and all part number changes and TCTO accomplishment through Overhaul/Repair must have documentation accomplished. The point of contact for the Navy NSN: 2840-01-483-8785PN (CII: HG108G0) is Steven Gastineau, Equipment Specialist (405) 734- 5941, E6B ISS Propulsion Engineering Team Technical Element (Navy Code 4.4.3.3) email:

steven.gastineau@us.af.mil – IAW CEMS CDRL (A003)

A004: Quality Deficiency Report - Deficiency Reporting is initiated on the occurrence when deficient Government assets are received by the Contractor. Contractor shall refer to T.O. 00-35D-54 using SF Form 368 and IAW CDRL DD Form 1423-1 and shall process Deficiency Reports when required IAW Section 1.4 of this PWS.

A005: Supply Discrepancy Report - This report enables the contractor to notify the Government when freight contents do not agree with shipping documents and IAW CDRL DD Form 1423-1.

In addition, the contractor shall submit Supply Discrepancy Reports (SDRs) when required IAW the contract’s Appendix B, “End Item and Commercial Asset Visibility for Air Force (CAVAF) System, Contractor Furniture Material (CFM) Statement of Work.”

1.8 Contractor Manpower Reporting - Contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the United States Air Force via electronic Contractor Manpower Reporting Application (eCMRA), a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

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."

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.

mailto:steven.gastineau@us.af.mil http://www.ecmra.mil/

File Number: FD2030-15-02637 6

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.

1.9 Document Storage: All records and reports outlined in this PWS shall be prepared for each part and a copy kept on file by the Contractor for five (5) years. The Government Technical Representative reserves the right to request and view any records at any time.

1.10 Packaging and Handling: The contractor shall be responsible for the preservation and packaging of the F108 Module 14 (Navy) IAW the Special Packaging Instructions specified on AFMC Form 158. The contractor shall place a serviceable tag, Department of Defense (DD) Form 1574, inside the package along with the assembly as well as outside the package.

In addition, all marking and labeling of unit and shipping containers shall be in accordance with Mil- Std-129P, Department of Defense Standard Practice, Military Marking for Shipment and Storage. Use additional guidance for preparation and shipment IAW T.O. 00-20-1, 00-20-3, MIL-STD-2073-1, MIL-STD-129, AFPAM24-237, and AFMAN 24-206. This contract does not allow for Commercial Packaging.

1.11 Shipping and Transportation: The contractor shall meet the delivery schedule as outlined in Schedule B of the contract. The Contractor shall ship or transport applicable assets as appropriate in order to have the assets available to support the customer’s operational requirements and IAW the contract. The Contractor shall not destroy reusable shipping containers, and will reuse them for return shipment.

1.12 Contractor Identification to Government Employees: 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.

1.13 Safety: The Contractor shall maintain and execute a safety program using MIL-STD-882E, Air Force Instruction AFI 91-204 as guides. The Contractor shall comply with all safety provisions and technical specifications listed in CFM56 Engine Shop Commercial Maintenance Manual (CMM).

All Contractor personnel and technicians shall comply with system safety engineering principles during all levels of remanufacturing.

While performing work under this contract the contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. The contractor shall notify the PCO within eight (8) hours of any damage to Government Furnished Property (GFP) where the dollar value exceeds $500,000.00 and within two workdays, for any damage to GFP less than $500,000.00 during the execution of the contract.

Mishap notifications shall contain, as a minimum, the following information:

a. Contract, Contract Number, Name and Title of Person(s) Reporting

b. Date, Time and exact location of accident/incident

c. Brief Narrative of accident/incident (Events leading to accident/incident)

d. Cause of accident/incident, if known

e. Estimated cost of accident/incident (material and labor to repair/replace)

f. Nomenclature of equipment and personnel involved in accident/incident http://www.ecmra.mil/

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g. Corrective actions (taken or proposed)

h. Other pertinent information

If requested by the designated PCO, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office.

1.14 Mission Essential Services: N/A

SECTION II

SERVICE SUMMARY (SS)

2.0 Service Summary: Contractor performance shall be measured and assessed, using the Performance Objectives listed in the Module 14 (LPT Shaft Assembly) SS, Table 2-1.

2.1 Service Summary Requirements: The Contractor shall ensure the performance objectives and thresholds are achieved as follows:

2.1.1 Performance Objectives and Thresholds: The Contractor shall achieve performance thresholds identified in Table 2-1 of this PWS. The contractor service requirements are summarized into performance objectives that relate directly to the mission essential items.

The performance threshold describes the minimum acceptable levels of service for each requirement. The government will use the surveillance methods contained in the surveillance plan to evaluate the contractor’s performance for the performance objectives listed below.

In the event the performance objective is not met, the contractor will be given a reasonable 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.

NOTE: The Quality Assurance Representative (QAR)/Defense Contract Management Agency (DCMA) will exercise surveillance over the performance thresholds. 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.

2.1.2 Surveillance Methods: The Contractor shall support the QAR/DCMA 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

NOTE 1: The method of surveillance may include one or more of the methods specified above.

NOTE 2: The Government will use the methods contained in the Surveillance Plan (SP) to evaluate the Contractor’s performance for the listed performance objectives. The Module 14 (LPT Shaft Assembly) QAR/DCMA will monitor contractor performance to determine if it meets the contract thresholds as set forth in the performance measures and this PWS.

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2.2 F108 Module 14 (LPT Shaft Assembly) Service Summary:

Table 2-1

2.3 Contractor Performance Evaluation: Evaluation will occur when the F108 Module 14 QAR or DCMA evaluates the service of the Contractor to determine whether or not it meets the SS objectives of the contract. In the event the performance measure is not met, the QAR or DCMA will issue written notification to the Contractor. In cases where the Contractor fails to implement corrective action, the QAR or DCMA will take appropriate measures.

SS -1: The contractor's failure to meet this requirement shall result in a negative Contractor Performance Assessment Reporting (CPAR) rating and remedies as allowed under FAR 52.212-4 Inspection/Acceptance.

SS - 2: The contractor's failure to meet this requirement shall result in a negative CPAR rating and remedies as allowed under FAR 52.212-4 Inspection/Acceptance.

SECTION III

3.0 GOVERNMENT PROPERTY

3.1 Government Furnished Material (GFM): None. Contractor shall furnish all material, support equipment, tools, test equipment and services. Government Furnished Material will not be provided. Contractor furnished material used for replacement shall be parts specified in ESM CFM56-2A Engine Shop Manual or have written approval from Navy Propulsion Engineering, E6B ISS Propulsion Engineering Team Technical Element (Navy Code 4.4.3.3) in writing through the PCO. No commercially used or overhauled material can be used in the repair of these modules.

3.2 Government Furnished Property (GFP): All parts to be overhauled will be shipped to the contractor.

Performance Objective

Reference / Paragraph

(Para)

Performance Threshold

SS - 1

Quality Product:

Each of the F108 Module

Identified as serviceable shall be delivered to the

Government defect free.

PWS Para 1.3

100% of Module 14 Delivered shall be defect free.

SS - 2 Delivery Performance:

The contractor shall meet the delivery schedule.

PWS Para

1.6 & IAW

Contractual

Delivery Schedule.

100% of Module 14 shall be delivered IAW the contractual delivery schedule.

File Number: FD2030-15-02637 9

APPENDIX “A”

ACRONYMS

ACSS Air Combat Sustainment Squadron AF Air Force AFMC Air Force Materiel Command CAVAF Commercial Asset Visibility Air Force CEMS Comprehensive Engine Management System CDRL Contract Data Requirements List CFMI CFM International CII Configured Item Identifier CMM Commercial Maintenance Manual DD Department of Defense DER Designated Engineering Representative DCMA Defense Contract Management Agency DR Deficiency Report FAA Federal Aviation Administration FAR Federal Acquisition Regulation IAW In Accordance With ISO International Standards Organization LPT Low Pressure Turbine NSN National Stock Number OC-ALC Oklahoma City Air Logistics Center PCO Procurement Contracting Officer PCARSS Plant Clearance Automated Reutilization Screening System P/N Part Number PMS Production Management Specialist PWS Performance Work Statement SB Service Bulletin SDR Supply Discrepancy Report S/N Serial Number SP Surveillance Plan SRAN Stock Record Account Number SS Service Summary TAFB Tinker Air Force Base USAF United States Air Force