PWS.docx

PERFORMANCE WORK STATEMENT (PWS)

For Level II Repair of J85 Bearings

PURCHASE REQUEST NUMBER: FD2030-18-01095

REV. 00

PREPARATION DATE: 31 July 2018

PREPARING ORGANIZATIONS:

421 SCMS/GUMDA

AFLCMC/LPSDB

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App.2401, et seq. Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

PREFACE SHEET

REVISION SHEET

When a revision is received, it should be inserted into this Performance Work Statement (PWS). The superseded pages should be retained as a record.

Note: The portion of the text of this specification affected by the current revision is indicated by a black underscore for figures, words, or phrases within a given paragraph, and by a black vertical line in the outer margin where the change constitutes a whole paragraph.

After the revised pages have been inserted into the PWS, the revised title page should be inserted in front of the existing title page. This revision page is placed under the basic title page.

DATES OF ISSUE FOR ORIGINAL AND CHANGED PAGES ARE:

Table of Contents

List of Tables Table 2-1… 15

List of Attachments

Description of Services

Background The United States Air Force (USAF) requires J85 engine and accessory gearbox Bearings to be inspected and repaired to maintain the J85 engine used in the T-38 aircraft. The objective is for the parts to be inspected and repaired, to provide the most advantageous cost to the government. All offerors must be qualified as a USAF repair source before contract award.

Scope This Performance Work Statement (PWS) defines the disassembly, cleaning, inspection, repair, and Level II repair requirements to return J85 Bearings to serviceable condition. The instructions use Technical Order (T.O.) 44B-1-102, MAINTENANCE INSTRUCTIONS, ANTIFRICTION BEARINGS, and the depot manuals applicable to the end item engines. All inspections and repairs shall be accomplished at the contractor’s facility utilizing contractor furnished labor, material and equipment. The PWS also includes requirements for failure analysis, testing, and reporting.

Mission Essential Services N/A

General Requirements 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.

Foreign Disclosure Restrictions do apply to this effort.

Contractor shall limit the use of outside vendors to sources approved The Air Force Cognizant Engineering Authority to perform the process being outsourced.

Contractor shall be responsible for providing all support equipment and maintaining the support equipment needed to accomplish inspection, repair of the J85 Bearings.

The contractor shall notify the Administrative Contracting Officer (ACO) electronically via email when an end item is received without a condition code tag or when the condition code is inconsistent with the “Reason for Reparable Condition” or “Remarks” on the tag or historical records. The contractor shall not proceed with work on the end item until instructions are provided by the ACO or Procurement Contracting Officer (PCO).

J85 Bearing Requirements Mixing and matching of races from two different bearings of the same part number is permissible. When accomplished on life limited bearings, the refurbished bearing shall acquire the serial number and operating codes of the highest operating time bearing.

Scrapped races may be replaced with new races if economically feasible. New replacement races must be acquired from the original bearing manufacturer.

If both inner and outer races require scrapping, the bearing shall not be refurbished. Serviceable separators and rolling elements shall be saved for replacement components in other refurbishable bearings of the same part number.

The rolling elements from two different bearings shall not be intermixed. However, the whole set of rolling elements may be transferred from one bearing to another bearing of the same part number provided they are serviceable and satisfy the clearance requirement of the bearing in which they will be installed.

Oversize bores may be made serviceable by nickel plate buildup per AMS 2404 or plating lAW MIL-STD-865 Nickel Brush Plating unless otherwise specified in the applicable bearing drawing. Finished nickel plating thickness shall not be less than 0.00005 inch and shall not exceed a thickness of 0.005 inch.

Condemnation: End items shall not be condemned by the contractor without written approval of the ACO and PCO or their representatives.

Nondestructive Inspection: Parts which have been condemned as a result of Nondestructive Inspection Methods, other inspection methods or for other reasons shall be mutilated to the extent necessary to ensure that purchasers of scrap are unable to repair the item for possible resale or reuse. All documents and tags pertinent to such condemned parts authorized for transfer to disposal shall bear a certificate to the effect that all required mutilation has been accomplished.

1.5.8 IUID will be accomplished according to the IUID Checklist. IUID requirements have not been established for this legacy engine, IUID is accomplished through normally accepted “bag and tag” procedures.

Management and Logistics Requirements 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 deliver all correspondence and documents required by this PWS, including forms, Contract Data Requirements Listings (CDRLs), and required notifications in electronic format via e-mail, unless otherwise authorized by the PCO.

The contractor shall notify the PCO, Program Manager (PM) and Production Management Specialist (PMS) via email within two (2) 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.

Delivery dates will be determined on each delivery order. Contractor shall deliver all parts on time In Accordance With (IAW) the delivery order schedule. Early delivery is acceptable.

Contractor shall provide notice to the PCO if an item exceeds the allowed schedule. The notice shall include the reason for delinquency, corrective action(s) taken, and status of any parts on order to restore repair production.

1.6.6 Contractor shall obtain and maintain accounts necessary to access programs, databases & websites. Access should be obtained in a timely manner to ensure timely and accurate reporting. A Public Key Infrastructure (PKI) certificate is required for some sites. This site will provide guidance for obtaining the PKI Certificate: https://upw.jtdi.mil/http:/webservers.internal.com:8181/registration/dodcert/pkicert.html

Commercial Asset Visibility AF (CAVAF) Once the CAT 2 PKI certificate is acquired. The contractor shall submit a DD2875 for User ID and Password to access the system.

Comprehensive Engine Management System (CEMS)-Requires a PKI certificate and AF Portal Access. AF Portal Link is: Https://www.my.af.mil The CEMS link is: https://cews.tinker.af.mil/_vti_bin/shtml.dll/Enter.htm

WebSDR- Requires a PKI certificate and AF Portal Access. The Web SDR Link is: https://www.transactionservices.dla.mil/daashome/websdr.asp

1.6.7 Contractor shall participate in supportability telecoms as requested and upon notification from PCO.

Identification, Marking, and Parts Tracking

In order to maintain identification, configuration and previous operating time, life limited bearings shall be marked in areas and by methods specified on the applicable bearing drawing or applicable bearing repair manual.

The inner and outer races and the separator of refurbished bearings shall have the same serial number.

When matching, intermixing or replacing components from different bearings of the same part number, the refurbished bearing shall acquire the serial number and operating time code of the highest operating time component.

New replacement components matched with used components in a refurbished bearing shall acquire the serial number and operating time code of the highest operating time component.

The contractor shall identify all refurbished bearings in the following manner. For the first refurbishment, add a slash after the serial number if it does not already exist, the number one, a dash, the contractor's name or symbol in less than six letters, a dash, the last two digits of the year and a slash. EXAMPLE: "SN 11132/1-ACME-86/”

For second and subsequent refurbishments continue markings from previous refurbishment identification ending slash with the subsequent refurbishment number, a dash, the contractor's name or symbol in less than six letters, a dash, the last two digits of the year and a slash. EXAMPLE: "S/N 11 132/1-ACME-86/2-ACME-87/"

On bearings whose inner and outer races were match marked at manufacture, inspect the bearing for match marks and add match marks to any new component that replaces a previously match marked component.

Material Management Contractor shall review all incoming shipping documents to ensure shipments and documents are accurate. Contractor shall submit a SF-364 (Standard Form) Supply Discrepancy Report (SDR) IAW AFJMAN 23-215 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 IAW CDRL A003

Contractor shall ensure USAF components are segregated from other non-USAF components being repaired at the contractor’s facility.

Contractor shall provide all consumable materials used for inspection and repair. The contractor shall be responsible for the disposal of consumables in accordance with local, state and federal regulations. The contractor shall procure all parts required to complete the USAF requirements. Contractor shall ensure all replacement parts used for repair are procured from the OEM or OEM approved sources. All Contractor Furnished Material (CFM) parts shall be of new condition and may be procured from the Defense Logistics Agency (DLA). To enhance CFM supportability the contractor may employ the DLA supplier collaboration program to share supply plans, forecast orders and improve demand planning efforts.

Contractor shall procure all parts required to complete repair from the OEM or OEM approved sources. Replacement parts shall be of new condition with traceability of origin. The contractor shall forecast and maintain ample inventory to promote minimal production disruption to meet delivery requirements.

Contractor shall establish and maintain a Consolidated Reparable Inventory (CRI) at the contractor’s facility upper limit of 500 each and a lower limit of zero. In the event the CRI maximum level is exceeded, the contractor shall notify, via email, the PCO, PM and PMS within five (5) working days of occurrence. The contractor shall store reparable items shipped from designated field units and Air force Sustainment Center (AFSC). The contractor shall report asset receipt and induction into CAVAF in accordance with CAVAF SOW and CDRL A001.

Contractor shall notify the ACO/PCO to request reparables, if adequate reparables are not in the CRI to complete an order. Once reparables are received the contractor shall notify the ACO/PCO so a firm delivery schedule can be established.

Contractor shall establish and maintain a Consolidated Serviceable Inventory (CSI) at the contractor’s facility upper limit of two each and a lower limit of zero each. In the event the CSI maximum level is exceeded, the contractor shall notify the PCO, PM and PMS within five (5) working days of occurrence. The contractor shall store completed serviceable items and ship them directly to a designated user at a Field Unit, 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.

This contract does not allow for Commercial Packaging. Contractor shall properly package the Bearings in accordance with AFMC Form 158 packaging requirements and place a serviceable tag, DD Form 1574, both inside the package along with the serviceable part and attached to the outside of the package.

Quality Requirements Contractor shall ensure all parts identified as serviceable are delivered to the Government defect free.

Contractor shall have in place and maintain a quality management system in compliance with ISO 9001:2008. 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 9001:2008 requirements and the adequacy of implementing procedures. 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. IAW AFI 63-138, effectiveness of the contractor’s quality management system will be tracked via Defect Detection—comparing the COR/QAR defect % finds to the Contractor defect % finds.

Contractor shall have in place and maintain procedures to maintain measuring and test equipment in accordance with ISO 90011:2008, ANSI/NCSL Z504.3-2006, or equivalent.

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

Contractor shall investigate all Deficiency Reports submitted by the USAF against reportedly defective items inspected, repaired, by this contract in accordance with Technical Order (TO) 00-35D-54 and prepare a report of findings per CDRL A004.

Reporting Requirements All reporting shall be accomplished in a timely manner with 100% accuracy.

Commercial Asset Visibility Air Force (CAVAF)/Government Furnished Material Report. Contractor shall provide end item reporting into Commercial Asset Visibility Air Force. 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. The Bearings shall be properly registered within CAVAF system. CDRL A001 and attached CAVAF Statement of Work.

Depot Maintenance Production Report. The contractor shall provide an updated weekly/monthly production report to the government IAW CDRL A002

Report of Shipping and Packaging Discrepancy. Contractor shall submit upon discovery of discrepancies for items of supply received for overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damaged or improperly packaged shipment. Submit Standard Form 364 per AFJMAN 23-215 IAW CDRL A003

Product Quality Deficiency Report (PQDR). Using 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 calendar 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 calendar days. Reports shall be submitted IAW CDRL A004.

Government Industry Data Exchange Program (GIDEP) Alert/Safe-Alert Report. The contractor shall participate and comply with the GIDEP reporting requirements IAW CDRL A005

Government Industry Data Exchange Program (GIDEP) Alert/Safe-Alert Response. Contractor shall provide the government with a response in relation to any failure experience report IAW CDRL A006

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 IAW CDRL A007

The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the bearings via 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.

Reporting Period: Contractors are required to input data by 31 October of each year. However, due to the delayed implementation, input of FY12 data is required by 31 Mar 13.

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.

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.

Publications Contractor shall establish and maintain a Technical Order Distribution Office (TODO) account in accordance with T.O. 00-5-1 and be placed on initial distribution of the TOs listed in attachment 1 to this PWS. Contractor must possess all Technical Data (required to accomplish J85 engine and accessory gearbox bearing inspection and repair) including manuals, repair instructions, modification instructions, service bulletins, technical orders (TOs), and service letters. Contractor must obtain appropriate Air Force Instructions (AFIs), Air Force Material Command Instructions (AFMCIs) and general technical orders (00 series) expressly required to perform the work in this contract via the internet at www.e-publishing.af.mil. In the event that a form or publication (Non OEM Technical Data) is not available online, the QAR will provide the form, instruction, or publication to the contractor upon written request (e-mail is acceptable) by the contractor. In the event that laws, regulations, TOs, AFIs, AFMCIs change during the term of this contract, the contractor is required to comply as such changes come into effect. Contractors delivering or handling official USAF records shall comply with the applicable records management regulations AFI 33-322, AFMAN 33-363, and AFI 33-364 (in their entirety).

Contractor TODOs. Because Enhanced Technical Information Management System (ETIMS) access is required to establish and manage TODO accounts, prospective TODO POCs must first obtain a CAC or an External Certificate Authority (ECA) with a minimum of a favorable national agency check (NAC) to establish Air Force Portal access needed for ETIMS. The AF portal ID of the prospective, primary TODO POC is entered into block 6 of the AFTO Form 43. The designated Adminstrative Contracting Officer representative must confirm an approved DD Form 2345; Militarily Critical Technical Data Agreement (AFI 61-204, Disseminating Scientific and Technical Information) is on file prior to approving the AFTO Form 43. The approved AFTO Form 43 is then submitted to AFLCMC/EZG. If government support contractors maintain a separate company-owned TO library, the company shall process a separate AFTO Form 43 to establish the contractor owned and operated TODO.

NOTE: Because installation of PureEdge software is required to use the IMT version of the AFTO Form 43, contractor personnel may use the MS Word version of the AFTO Form 43 (available at https://techdata.wpafb.af.mil/toprac/formshtm).

Once contractor TODO accounts are established, the contractor TODO uses ETIMS to directly order and receive the TOs required under the contract. The Government Approving Authority (GAA) should request TO account information of the contractor TODO whenever they wish to audit the account.

The Contractor shall consider the impact of a TO change on costs, schedules, and any other pertinent factors.

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

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

The contractor shall implement all no cost changes within 5 calendar days of review. Safety of Flight changes shall be implemented within one calendar 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.

Service Summary 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 contractor shall be aware that in the absence of any contract requirement from 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 that the service summary requirements are accomplished.

Service Summary (SS) Requirements The contractor shall achieve the performance objectives and performance thresholds identified in Table 2-1 of this PWS.

Table 2-1: Service Summary

1.10.1 Reports schedules should be met on time with errors corrected within 1 business day of identification. An error is defined as a rejected data submittal which is returned to the contractor for rework due to non-compliance with contract requirements.

NOTE: The PMS, Defense Contracting Management Agency (DCMA) Quality Assurance Representatives (QAR) and PCO 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.

Surveillance Methods The Contractor shall support the PMS, DCMA QAR, and PCO surveillance methods as identified below:

a. Periodic Inspection of Process or Output

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 to evaluate the Contractor’s performance for the listed program objectives. The PMS, DCMA QAR, and/or PCO will monitor contractor performance to determine if it meets the contract thresholds as set forth in the performance measures and this PWS.

Contractor Performance Evaluation The contractor shall be aware that the evaluation of performance will occur when the DCMA (QAR) and Contracting Office evaluate the service of the contractor to determine whether or not it meets the performance measures of the contract.

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

b. SS - 2: The Contractor's failure to meet the requirement for this item shall result in the possibility of an unsatisfactory or marginal under the Contractor Performance Assessment Review (CPAR) and remedies as allowed under Federal Acquisition Regulation (FAR) 52.246-4 Inspection of Services-Fixed Price.

c. SS - 3: The Contractor's failure to meet the requirement for this item shall result in the possibility of an unsatisfactory or marginal under the Contractor Performance Assessment Review (CPAR) and remedies as allowed under Federal Acquisition Regulation (FAR) 52.246-4 Inspection of Services-Fixed Price.

SECTION III-GOVERNMENT FURNISHED PROPERTY/SERVICES

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”.

Government Furnished Services N/A

ATTACHMENT 1

TECHNICAL DATA

Department of Defense Documents

Defense Logistics Agency Documents

DLMS4000.25

Air Force Documents

TO Number

Basic Date Chg.

Change Date Title

Investigating and Resolution

00-20-1-WA-1

00-20-2-WA-1

00-25-113

00-25-113-J85-WA-1

00-25-195-WA-1

2J-1-32-WA-1

44B-1-122-WA-1

2J-J85-113-5-WA-1

2J-J85-133-5-WA-1

GENERAL ELECTRIC DRAWINGS

J85-5 and J85-21 Engine Bearings

327B431

ATTACHMENT 2

SOW/PWS SAFETY AND HEALTY STATEMENT

Safety and Health

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 Contracting Officer (CO), within eight (8) hours of any damage to government property where the dollar value exceeds $500,000.00 and within two working days, for any damage to government property 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

g. Corrective actions (taken or proposed)

h. Other pertinent information

If requested by the designated CO, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office. Contractors will not dispose of contract data related to a mishap until notified to do so by the CO.

FD20301801095