ATTACH_E_F118_FRT_FRM_SOW.pdf

Attachment E

File Number: FD2030-17-00680 Page 0

STATEMENT OF WORK (SOW)

for the Remanufacture

F118-GE-100 FRONT FRAME

PURCHASE REQUEST NUMBER: FD2030-17-00680

REV: 0

PREPARATION DATE: 13 May 2019

PREPARING ORGANIZATION:

421st Supply Chain Management Squadron (SCMS)/GUMBA

Air Force Sustainment Center (AFSC) in conjunction with

Air Force Life Cycle Management Center (AFLCMC)/LPSBAB

TINKER AFB, OK 73145-3031

File Number: FD2030-17-00680 Page 1

TABLE OF CONTENT Page 1

SECTION I: SCOPE

1.0 Introduction 2

1.1 General Services and Material 2

1.2 Receiving 2

1.3 Remanufacture 3

1.3.1 Disassembly 3

1.3.2 Cleaning 3

1.3.3 Remanufacture Procedures 3

1.3.4 Assembly 3

1.3.5 Testing 4

1.3.6 Deviations 4

1.4 Reference and Technical Manuals 4

1.5 Deliverables Quality 4

1.6 Deficiency Report (DR) 4

1.7 Condemned Assets 5

1.8 Quality System and Quality Assurance Plan 5

1.9 Reporting 5

1.10 Contract Data Requirement List (CDRL) 5

1.11 Contractor Manpower Reporting 7

1.12 Document Storage 7

1.13 Shipping 7

1.14 Packaging and Handling 7

1.15 Preservation 8

1.16 Safety 8

1.17 Contractor Identification to Government Employees 9

1.18 Mission Essential Services 9

SECTION II: GOVERNMENT PROPERTY

2.0 Government Furnished Material (GMF) 9

2.1 Government Furnished Property (GFP) 9

APPENDIX “A”

ACRONYMS 10

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SECTION I: SCOPE

1.0 Introduction

The purpose of this Statement of Work (SOW) is to define the requirements necessary to ensure that the replacement of the Low Observable (LO) Coating for the F118-GE-100 Front Frames are remanufactured as nearly as possible to the original life expectancy consistent with the Air Force (AF) requirements. This SOW applies to the following National Stock Number (NSN) and Part Numbers (P/N):

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

2840-01-531-1394LR

9545M13G42 9545M13G44 9545M13G45 9545M13G46

9545M13G42 9545M13G44 9545M13G45 9545M13G46

2840-01-528-4199LR 9545M13G47 9545M13G47

The following instructions stipulated herein provide brief, concise statements providing general requirements for the remanufacture of the F118 Front Frame. The contractor shall maintain a Federal Aviation Administration (FAA) Part 145 rated repair facility rated to remanufacture the replacement of the Low Observable (LO) Coating for the F118 Front Frame; and the contractor must have the remanufacture capabilities to include appropriate technical data, remanufacture documents, and license agreements, required to accomplish the remanufacture of the Front Frame. The contractor is responsible for the production, remanufacture, and scheduled delivery of a quality product.

1.1 General Services and Material

The contractor shall provide all materials for the remanufacturing processes required to execute this contract. In exchange, in part, for each remanufactured Front Frame ordered, the Government will provide, on a one-to-one basis, a degraded or inoperable Front Frame consistent with aircraft engine usage.

1.2 Receiving

The contractor shall perform a receiving visual inspection upon receipt of each Front Frame and determine the serviceability of the Front Frame, the housing and applicable parts for reuse/remanufacturing.

NOTE: Technical Compliance Technical Order (TCTO) 2J-F118-567 will be accomplished at the OC-ALC. Ensure each assembled Front Frame is re-assembled after remanufacture with TCTO assets received with the Front Frame.

In addition, the contractor shall report in accordance with the Supply Discrepancy Report (SDR), CDRL (A005) and obtain disposition instructions for any received assets which are misidentified, misdirected, have a variation in quantity, non-requisitioned items, lost or damaged parcel post or incorrect shipments. The Contractor shall not destroy reusable shipping containers, and will reuse them for return shipment. The contractor shall initiate

File Number: FD2030-17-00680 Page 3 a SDR for such shipments or any assets as described above or received in packaging other than the contracted packaging requirements through WEB SDR.

The WEB SDR is located at: https://www.daas.dla.mil/websdr/home.asp.

This system of reporting an SDR has been developed in compliance with DoD Manual 4140.01-V1, Supply Chain Material Management Procedures and 4000.25, Defense Logistics Management System (DLMS), which requires automated SDR processing and IAW Contractor Asset Visibility for the Air Force (CAV AF) Statement of Work (SOW).

The prime packaging specialist may authorize exceptions to these requirements.

1.3 Remanufacture

The contractor shall remanufacture the replacement of the Low Observable (LO) Coating for the F118 Front Frame as follows:

1.3.1 Disassembly

The contractor shall disassemble the Front Frame to the extent required for remanufacture of the LO Coating of the Front Frame.

1.3.2 Cleaning

All grease, oil, dirt, corrosion, and moisture must be removed prior to inspecting, remanufacturing, or re-assembling the Front Frame.

1.3.3 Remanufacture Procedures

To bring the F118 Front Frame to a like new condition the Contractor shall remanufactured by replacing the Low Observable Coating when required IAW the contractor’s established procedures and this SOW. Low Observable Coating is utilized for both original manufacturing, and the restoration of the F118 front frames back to the original life expectancy, or nearly so. Serialized Military parts, life limited parts, cannot be replaced by remanufactured parts. All tooling and parts required to accomplish the 100% inspection, teardown, and remanufacture of each Front Frame shall be Contractor Furnished Material (CFM). Remanufacture procedures shall include:

Low Level Remanufacture – (This level is expected to be less than 1% of the total effort) After inspection and/or teardown, any work to the Front Frame that will only require a total of minor remanufacturing processes to any or all parts of the Front Frame. Examples include but are not limited or exclusive to the following: minor re-coating and re-caulking of the Outer Flow Path, Inner Flow Path, minor re-adhesive application to Struts, Teflon Ring, minor re-sealing to the edges of Inlet Guide Vanes, Inlet Seal, and any other parts as necessary to return the asset to a “like new” condition, or nearly so.

Medium Level Remanufacture – (This level encompasses more than 97% of the total effort) After inspection and/or teardown and cleaning, any work to the Front Frame that will require major replacement and remanufacturing processes to any or all parts of the Front https://www.daas.dla.mil/websdr/home.asp

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Frame. Examples include but are not limited or exclusive to the following: major re-coating and re-caulking to many areas (7-10) of the Outer Flow Path, some flow paths may require stripping and recoating between struts; edges required re-sealing and scuff and nicks smoothed out; adhesive injection is required on de-bonded or blistered areas on the Inner Flow Path, coating removal and replacement; major re-adhesive injection application or re-sealing to edges on many or all Struts; Blending of several areas in the Teflon Ring, resealing and re-caulking of many areas and edges of any and all Inlet Guide Vanes and Shroud Assemblies along with Alodine touch-up application on areas and re-bonding or adhesive injections of blistered areas; paint touch-ups, re-sealing of edges and/or adhesive injection to Inlet Seals; Welding of dents in manifold; and reassembly of parts as necessary to return the asset to a “like new” condition, or nearly so. The Contractor shall notify the PCO of any work that is outside the scope of the Medium Level of remanufacture in this SOW, and prior to any of that work commencing.

High Level Remanufacture – (This level is expected to be less than 1% of the total effort) After inspection and/or teardown and cleaning, any work to the Front Frame to include all of the medium level remanufacturing processes to any or all parts, plus complete removal and replacement of Low Observable Coating on six or seven Struts plus reassembly as necessary to return the asset to a “like new” condition, or nearly so.

High-Plus Level of Remanufacture - (This level is expected to be less than 1% of the total effort) After inspection and/or teardown and cleaning, any work to the Front Frame to include all of the medium level remanufacturing processes to any or all parts, plus complete removal and replacement of Low Observable Coating on all 13 Struts plus reassembly as necessary to return the asset to a “like new” condition, or nearly so. The only time historically this level of remanufacture was accomplished, the work scope of the frame was 4X that of the historical average, and the damage was far worse than any damage the Contractor had ever seen on any other.

1.3.4 Testing

Each Front Frame shall be tested to ensure that all operational and performance requirements are met per the required blueprint. When the Front Frame passes all required tests, the contractor shall ensure that all assembly is complete (including safety wire) before returning to service.

1.3.5 Assembly

Assembly of the Front Frame shall be IAW the appropriate technical procedures.

NOTE: Technical Compliance Technical Order (TCTO) 2J-F118-567 will be accomplished at the OC-ALC. Ensure each assembled Front Frame is re-assembled after remanufacture with TCTO assets received with the Front Frame.

1.3.6 Remanufacture Deviations

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Prior to the remanufacturing of any Front Frame, the contractor shall obtain written approval from the PCO for any deviations from the processes, materials, material processes, or procedures and must show that the intent of the process, materials, material process or procedures conform to processes required by the contractor’s established procedures and this Statement of Work. The F118 cognizant engineer reserves the right to approve or disapprove any processes or procedures when they fail to meet the intended requirements of the Front Frame.

1.4 Reference & Technical Manuals

In execution of this SOW, all remanufactured items must meet the inspection criteria, and the contractor shall apply manufacturing processes, tools, and products as prescribed in FAR 22.1003-6(a)(1)(iv) and the contractor’s established procedures, along with any outstanding FAA Airworthiness Directives.

1.5 Deliverables Quality

The contractor shall ensure that materials, parts, and accessories used in remanufactured components are restored to original life expectancy or nearly so, and are interchangeable without alterations.

1.6 Deficiency Report (DR) Investigation

The contractor shall investigate and submit findings to include root causes and a corrective action against all DRs submitted against reported defective items remanufactured by this contract. Each DR will be processed IAW T.O. 00-35-D-54 using SF Form 368, USAF Material Deficiency Reporting System, in a timely manner to meet suspense dates assigned by the action agency IAW Deficiency Reporting (CDRL A004).

1.7 Condemned Assets

Any Front Frame or component parts that exceed present remanufacture and inspection limits shall be condemned at the contractor’s facility and processed through Plant Clearance Automated Reutilization Screening System (PCARSS). The contractor shall not utilize serviceable parts from condemned assets. The contractor will be allowed to move components among repairable end items to expedite the remanufacture of replacing the LO Coating of the Front Frame, versus maintaining serial number integrity.

Condemned assets shall not count toward production and be reported to the Production Management Specialist (PMS) with the 421 SCMS/GUMBA/AFSC to establish usage rates and cost planning. The Contactor shall report all condemned parts via CDRLs Commercial Asset Visibility Air Force (CAV AF) System (CDRL A002) and Contract Depot Maintenance Production Report (CDRL A001).

1.8 Quality System and Quality Assurance Plan

Each Front Frame identified as serviceable shall be delivered to the Government free of defects. The contractor shall also 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

File Number: FD2030-17-00680 Page 6 and implement procedures to properly maintain measuring and test equipment IAW 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 contractor shall develop a quality program that shall be designed to promptly detect and correct conditions adverse to quality.

1.9 Reporting

The contractor shall provide completed Certificate of Conformance documentation, or a completed FAA Form 8130-3, Airworthiness Approval Tag with each Front Frame that have been remanufactured with the intent of returning the part to serviceable condition.

This documentation shall have the part number, serial number, work accomplished, and Service Bulletins complied with on a serviceable tag, DD Form 1574. Also,

1.10 Contract Data Requirement List (CDRL)

The contractor shall ensure that all reporting as specified under the following Contract Data Requirement List (CDRL) are accomplished:

A001: Contract Depot Maintenance (CDM) Production Report

The contractor shall prepare the report using Table I in DID DI-PSSS-81995 as of the last working day of the month and forward to the PMS or original mail service NLT the fifth working day of the month during which the contracts assets are received. Reports will continue to be forwarded unless contract is terminated and the last report will be annotated as “Final Report”. The contractor’s format with the same data elements as found on the CDM report may be accepted if approved by the PCO and IAW CDRL DD Form 1423-1.

A002: Commercial Asset Visibility Air Force (CAV AF) Reporting

The contractor shall report End Item transactional data through electronic submission in CAV AF using the CAV AF website IAW the referenced DID and/or IAW the CAV AF SOW and shall not be waived. The transactions and data will be submitted by the contractor daily IAW CAV AF User Guide, Version 8.0.1 or higher. For CAV AF reporting, the Contractor shall submit SDRs when required and IAW CDRL Form 1423-1.

A003: Comprehensive Engine Management System (CEMS) Reporting The Contractor shall provide the following information for each remanufactured F118 Front Frame on Air Force (AF) Form 1534:

a) Configured Item Identifier (CII) Designation

b) Serial Number (S/N)

c) Date work was accomplished

d) Stock Record Account Number (SRAN)

e) Part Number (P/N)

f) Type of Transaction

g) Time on Front Frame

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The AF Form 1534 is required to be submitted by close of business of the business day following the occurrence of the reportable event.

(An example of the AF Form 1534 may be provided to use as a guide.)

The point of contact for verification of part numbers and serial numbers for NSN:

2840-01-531-1394LR and 2840-01528-4199LR (CII: HF11820) is:

Henry Warden

AFLCMC/LPSBA

Email: Henry.Warden@us.af.mil Phone: (405) 736-3459

A004: Deficiency Report (DR) 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 or equivalent and IAW CDRL DD Form 1423-1.

A005: Shipping and Packaging Discrepancy Report (Supply Discrepancy Report)

The contractor shall notify the government within five (5) working days of discovery or discrepancy when freight contents do not agree with the shipping documents and IAW CDRL Form 1423-1.

The contractor shall use WEBSDR to submit an electronic SF-364 (Standard Form) IAW T.O. 00-35D-54 or a paper SF 364s until access to WEBSDR is attained, upon discovery of discrepancies for items of supply received for: overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damage, and/or improperly packaged shipment.

1.11 Contractor Manpower Reporting

The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the USAF via electronic Contractor Manpower Reporting Application (eCMRA) which is 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 01 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported NLT 31 October of each calendar year. Contractors may direct questions to the CMRA helpdesk.

Uses and Safeguarding of Information:

Information from the secure website is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.

http://www.ecmra.mil/

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User Manuals:

Data for Air Force service requirements must be input at the Air Force CMRA link.

However, user manuals for the government personnel and contractors are available at the CMRA link at http://www.ecmra.mil.

1.12 Document Storage

All records and reports outlined in this SOW shall be prepared for each part and a copy kept on file by the contractor for five (5) years. The Government’s technical representative reserves the right to request and view any records at any time.

1.13 Shipping

The Contractor shall meet the delivery schedule. 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 in accordance with the contract’s delivery schedule. The contractor shall not destroy reusable shipping containers, and will reuse them for return shipment.

1.14 Packaging and Handling

The contractor shall be responsible for the preservation and packaging of the Front Frame IAW the Special Packaging Instructions (SPI) specified on AFMC Form 158. The contractor shall place a serviceable tag, DD Form 1574, inside the package along with the assembly as well as outside the package.

In addition, all markings and labeling of units and shipping containers shall be packed IAW T.O. 00-85B-3, using Special Packaging Instruction (SPI) F000003X46 or MIL-STD-129, Rev R, Department of Defense Standard Practice, Military Marking for Shipment and Storage. The contractor shall use additional guidance for preparation and shipment IAW T.O. 00-20-1, T.O. 00-20-3, MIL-STD-2073-1, MIL-STD-129, AFPAM24-237, and AFMAN 24-206. This contract does not allow for commercial packaging.

The contractor shall meet the delivery schedule IAW 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. This contract does not allow for Commercial Packaging.

1.15 Preservation

The contractor shall be responsible for the preservation and packaging of the Front Frame 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.

http://www.ecmra.mil/

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The contractor shall not destroy reusable shipping containers, and will reuse them for return shipment. Units shall be packed IAW with T.O. 00-85B-3 using Special Packaging Instruction (SPI).

1.16 Safety

The Contractor shall maintain and execute a safety program using MIL-STD-882D, AFI 91-301 and AFI 91-204 as guides. The Contractor shall comply with all safety provisions and technical specifications listed in the contractor’s established procedures, along with any outstanding FAA Airworthiness Directives. 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 remanufacture/replace)

f. Nomenclature of equipment and personnel involved in accident/incident

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.

1.17 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.

1.18 Mission Essential Services

Not applicable.

SECTION II: GOVERNMENT PROPERTY

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2.0 Government Furnished Material (GFM)

NONE. All parts and components required to accomplish the intent of the T.O., SOW, or SBs shall be contractor furnished material. Contractor furnished material and parts used for replacement shall be parts specified in T.O. 6J3-4-113-4, SBs or as written approval from the AFLCMC/LPSEB and/or AFLCMC/LPSBA in writing through the PCO.

2.2 Government Furnished Property (GFP)

All items to be remanufactured will be shipped to the contractor. This is only GFP that will be applicable to this contract.

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APPENDIX “A”

ACRONYMS

ACSS Air Combat Sustainment Squadron AF Air Force AFMC Air Force Materiel Command CAVAF Commercial Asset Visibility Air Force CDRL Contract Data Requirements List CMM Commercial Maintenance Manual DD Department of Defense DER Designated Engineering Representative DR Deficiency Report ESM Engine Shop Manual IAW In Accordance With ISO International Standards Organization LO Low Observable 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 SB Service Bulletin SDR Supply Discrepancy Report S/N Serial Number SOW Statement of Work SS Service Summary SOW Statement of Work USAF United States Air Force