T53_APPENDIX_A_-_PWS__v8 _30_Apr_15.pdf

T53 APPENDIX A - PWS

APPENDIX A

PERFORMANCE WORK STATEMENT (PWS)

For Inspection, Repair, and or Overhaul of the T53-L-703 Gas Turbine Engine Assembly

Version 8

PREPARATION DATE: 30 Apr 15

PREPARING ORGANIZATION:

AFLCMC/LPSC

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.

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ENGINE ASSEMBLY

REPAIR AND OR INSPECTION

CLIN STRUCTURE

CLIN

SUB

CLIN Noun / CLIN Title

FY16-17 1 YR

BASIC Annual

BEQ / or Yearly Hours Estimate

FY17-18 Option Yr 1 Annual

BEQ / or Yearly Hours Estimate

FY18-19 Option Yr 2 Annual

BEQ / or Yearly Hours Estimate

FY19-20 Option Yr 3 Annual

BEQ / or Yearly Hours Estimate

FY20-21 Option Yr 4 Annual

BEQ / or Yearly Hours Estimate

X001 Tear Down & Inspect 13 14 10 13 13

FY16-17 1250

Yearly Forecast =

FY17-18 1250

Yearly Forecast =

FY18-19 1250

Yearly Forecast =

FY19-20 1250

Yearly Forecast =

FY20-21 1250

Yearly Forecast =

X002 AA 1250 Hour Inspection - LEVEL 1 1 1 1 1 1 AB 1250 Hour Inspection - LEVEL 2 1 0 1 0 0 AC 1250 Hour Inspection - LEVEL 3 0 1 0 1 1

FY16-17 2500

Yearly Forecast =

FY17-19 2500

Yearly Forecast =

FY18-19 2500

Yearly Forecast =

FY19-20 2500

Yearly Forecast =

FY20-21 2500

Yearly Forecast =

X003 AA 2500 Hour Inspection - LEVEL 1 2 2 3 3 3 AB 2500 Hour Inspection - LEVEL 2 3 2 2 3 3 AC 2500 Hour Inspection - LEVEL 3 3 4 0 0 1

X004 5000 Hour Inspection - Overhaul 0 0 0 0 0

X005 Unscheduled Engine Removal (UER) 3 4 3 5 4

X006 O&A - Other 5000 (hours) 5000 (hours) 5000 (hours) 5000 (hours) 5000 (hours)

X007 MISTR Rotary Pump (Scavenge Pump) 0 (hours) 600 (hours) 120 (hours) 120 (hours) 120 (hours)

X008 Test Cell Run 5 6 5 6 5

X009 CDRLS - Data Reporting

X010 Travel

FY17-18 Option Yr 1 - CLINs

100X

FY18-19 Option Yr 2 - CLINs

200X

FY19-20 Option Yr 3- CLINs

300X

FY20-21 Option Yr 4- CLINs

400X

T53 CLINs with Best Estimated Quantities (BEQs)

CLIN ITEM DETAILS

FY16-17 1-Yr Basic Period CLINs 000X

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TABLE OF CONTENTS

1 DESCRIPTION OF SERVICES

1.1 Background

1.2 Scope

1.3 Mission Essential Services

1.4 General Requirements

1.5 Transition Phase-In……………………………………………………………

1.6 T53-L-703 Gas Turbine Engine Assembly Requirements

1.7 Repair and Inspection Requirements ………………………………………....…6

1.8 Testing and Government Acceptance ……………………………………...…..12

1.9 Material and Logistics Requirements……………………………….….…..…..12

1.10 Material Management

1.11 Quality Requirements

1.12 Reporting Requirements

1.13 Programs, Databases, and Websites

1.14 Publications

2 SERVICE SUMMARY20

2.1 Service Summary (SS) Requirements

2.2 Surveillance Methods21

2.3 Contractor Performance Evaluation

3 GOVERNMENT FURNISHED PROPERTY (Not Applicable)………………….22

ATTACHMENTS to PWS (provided as separate documents):

A: TECHNICAL DATA

B: ACROYNMS

C: CONDEMNATION LIST ITEMS

D: CDRLS & DIDS SUMMARY

D-1 CDRLs D-2 DIDs

E: COMPREHENSIVE ENGINE MANAGEMENT SYSTEM (CEMS) ACCESS AND

SECURITY CHECK PROCESS

F: SPECIAL PACKAGING INSTRUCTIONS

F-1: ENGINE CAN SPECIAL PACKAGING INSTRUCTIONS

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1 DESCRIPTION OF SERVICES

1.1 Background

The United States Air Force (USAF) requires a T53-L-703 engine used in the TH-1H Helicopter, to be disassembled, inspected, repaired and or overhauled, assembled and tested as required In Accordance With (IAW) Honeywell Original Equipment Manufacturer (OEM) Commerical T53-L-703 manuals. The objective is to provide the USAF with serviceable T53-L-703 engines, in terms of reliability, quality, and affordability. The USAF will not accept direct sale of engines or parts that have not been repaired / inspected / tested IAW Honeywell manuals. All repairs will be completed by a Honeywell authorized repair facility, that is also FAA certified and ISO9001:2000 or higher version certified. The Contractor shall provide proof of Honeywell certification as an authorized engine / component repair facility for the T53- L-703 engine and its covered components for themselves or any sub contractor who is performing the maintenance actions as part of the their Proposal to be considered for evaluation of the T53-L-703 workload.

1.2 Scope

This PWS defines the requirements to return a T53-L-703 engine to serviceable condition. Some engines require scheduled inspections or life limited parts replacements. Other engines require repair due to failed performance on test cell or Unscheduled Engine Removals (UERs), necessitating repair beyond the capabilities of the USAF Intermediate Level (I-Level) repair facility.

1.3 Mission Essential Services

There are no mission essential services for this PWS. If at any time, mission essential services should be designated, the Government Procuring Contracting Officer (PCO) will notify the Contractor and the Contractor shall provide a plan within 10 business days to the PCO for approval to meet the designated mission essential services as required / directed by the PCO.

1.4 General Requirements

1.4.1 Custody of Engines: The Contractor shall have a system of internal controls to manage (control, use, preserve, protect, repair and maintain) engines and associated subassemblies in its possession IAW Federal Acquisition Regulation (FAR) Part 45.

1.4.2 Preservation: The Contractor shall follow the preservation/re-preservation requirements IAW Technical Order (T.O.) 2J-1-18. The Contractor shall inspect all engines and power sections received no later than the third workday after receipt to determine the adequacy and proper documentation of preservation. End items with inadequate preservation shall be inducted or re-preserved IAW T.O. 2J-1-18 within ten (10) working days after inspection.

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For all other end items, the Contractor shall preserve items IAW applicable T.O.s.

1.4.3 The Contractor shall have capabilities and access to appropriate OEM commercial technical data, overhaul documents, and license agreements, required to accomplish the requirements in this PWS.

1.4.4 The Contractor shall provide and maintain the required support equipment per the T53 Commercial OEM manauals needed to accomplish all engine requirements of this PWS.

1.4.5 Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as a Contractor 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.

1.4.6 Foreign Disclosure Restrictions do apply to this effort. There are no restrictions for workload performance to be done within the United States or at a Foreign location outside the United States. The Contractor shall maintain and adhere to all OEM technical data export control restrictions and also obtain any required customs / export shipping liscenses should the Contractor intend to perform the workload outside of the United States.

1.4.7 The Contractor shall notify the Administrative Contracting Officer (ACO) or

Procurement Contracting Officer (PCO) electronically via email within one (1) business day from receipt of asset 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. If end item is received with parts missing, contractor shall notify PCO once discrepancy is identified. The Contractor shall not proceed with work on the end item until instructions are provided by the ACO or PCO.

1.4.8 The Contractor shall prepare historical records of actions performed on each end item, on AFTO Form 95, which will be included with the engine, and shall provide a written and/or electronic copy to the AFLCMC/LPSEC Cognizant Engineering Authority (CEA) (via email) within two (2) working days of shipment. See para 1.12.5 for additional information.

1.4.9 The Contractor shall provide the standard commercial warranty as provided by the OEM for equipment installed in the engine. The standard engine warranty is 1000 Engine Flight Hours (EFH) or 24 months for workmanship

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on the engine and all components. In addition, a 2000 EFH or 48 months warranty is provided on all approved OEM parts installed. This warranty applies to non-OEM and OEM workmanship. Warranties listed above shall begin after Government acceptance of the serviceable T53-L-703 engine and it’s covered components. The Source of Repair (SOR) shall ensure the AF receives full warranty consideration and compensation. Warranty tracking and reporting shall be complied IAW Honeywell Commercial Techncial Data.

1.4.10 If future warranty work is required, the Contractor shall submit a written workscope for any item that was inducted as an Engineering Investigation (EI) or Teardown Report (TDR) IAW CDRL A002. The Contractor shall include in the written workscope the work required and all costs that would be incurred to bring the item back to serviceable condition to the Government PCO prior to performance of any required work. If the item is found to not be warranty related, and still requires repair/work efforts, contractor shall treat the action as an Over & Above (O&A) tasking.

1.5 Transition Phase-In

Due to the Government requirement to have digital fingerprints and background investigations / clearances in order to get a PKI / CAC Card to be able to access Government systems, and due to the length of time required to obtain the CAC Card, the Government will allow the Contractor a transition phase-in period to reach Full Operational Capability (FOC) for system access within 180 calendar days after award.

The Contractor shall provide to the PCO a written email confirmation showing initiation of digital fingerprints sent to the FBI within 10 calendar days after contract award and will also provide a monthly status report IAW CDRL A011 showing progress / issues towards achieving issuance of CAC Cards and System Access Forms to perform Government system reporting as described in paragraphs 1.12 and 1.13. During the interim transition phase-in period, the Contractor shall still be responsible to provide the applicable maintenance data / system reporting actions to the Government via prescribed email procedures to the various Government System Offices of Responsibility for all items inducted into maintenance / repair until the Contractor has been able to obtain CAC Cards and system access to do the reporting requirements on their own as prescribed by this PWS. Government System contacts will be provided during the Post Award Conference after contract award.

Additionally, the Contractor shall provide a Transition Phase-In Plan with timeline and risks to address the following:

1.5.1 A facilities lay-out, workflow, location and methodology for where and how the workload will be performed at the beginning of contract period of performance.

1.5.2 Accomplishment of hiring/retraining skilled personnel.

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1.5.3 A plan for equipment upkeep and maintenance, calibration to preclude any work stopages that would affect on time delivery of engines.

1.5.4 A risk mitigation plan for possible work stoppages due to skilled personnel shortages or loss of facility usage due to emergencies / unforeseen events

The Contractor shall report status of the transition phase-in IAW CDRL A011 as well as via scheduled telecoms with the PMO and PCO.

1.6 T53-L-703 Gas Turbine Engine Assembly Requirements

1.6.1 The Contractor shall perform all work IAW all pertinent Honeywell technical manuals, service bulletins, spare parts bulletins and temporary revisions.

These may include, but are not limited to, Overhaul Repair Instructions (ORI) and/or Overhaul Modification Instructions (OMI) issued by OEM. These forms of instructions and publications will not be furnished by Air Force and can only be obtained directly through OEM. See “Technical Data” documents provided in Attachment A to this PWS. Contractor shall perform all work at the Contractor’s facility and /or at their OEM / Government CEA approved sub-vendor facilities.

1.6.2 Life Limited Parts: All hot section components shall have a minimum of 1250 hours remaining and all cold section components will have a minimum of 2500 hours remaining. In addition, all components shall have equivalent cycles remaining to achieve these hours. Cycle ratios shall be calculated in accordance with T.O. 2J-T53-4C, the Air Force supplement to the Honeywell maintenance manuals. CEMS records shall be reviewed for all cycle and hour limited components inducted for overhaul or repair and a determination shall be made for remaining hours and cycles. This build policy shall apply regardless of component source, whether new, cannibalized, or otherwise.

1.6.3 All deviations from Honeywell technical maintenance manuals require approval from the Air Force CEA. The Contractor shall provide a deviation request in writing to the Government PCO and CEA via email describing the purpose for the deviation with all supporting details. The Contractor shall not proceed until guidance is provided by the PCO.

1.6.4 All condemnations of any item listed within ATTACHMENT C shall require approval from the Air Force CEA. The Contractor shall notify in writing via email to the Government CEA and PCO a description of deficiencies necessitating condemnation. The Contractor shall not proceed until disposition instructions are provided by the PCO.

1.7 Repair and Inspection Requirements – Contractor shall perform work and charge for material usage as applicable and within defined CLIN parameters as follows:

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1.7.1 CLIN X001: Teardown and Inspection (TD&I). The Contractor shall provide reports to the Government T53 Program Office to identify root cause analysis, primary failed item, failure mode, corrective actions required to restore serviceability of reparable engines, and recommendations to preclude recurrence IAW CDRL A002.

1.7.2 CLIN X002: 1250 Hour Inspection. Work required for the 1250 hour inspection is defined by pertinent Honeywell technical maintenance manuals.

In the case of these inspections contractor shall provide a teardown report IAW CDRL A002 to the government detailing the results of the inspection and all work and material required to return the engine to serviceable condition.

Contractor shall conduct Turbine Nozzle flow checks as a part of this effort.

Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN. This CLIN is further divided into three sub-CLINs, LEVEL 1, LEVEL 2, and LEVEL 3, which will differenciate the amount of work required to return an engine to serviceable condition as follows:

1.7.2.1 CLIN X002AA: 1250 Hour Inspection LEVEL 1 Repair: 1250

Hour Inspection Level 1 areas of repair scope is defined as follows:

• No cracks or dust on forward side of Power Turbine Bearing Housing

• Gap between Rear Bearing Cover and Exhaust Diffuser is within limits

• No evidence of leaks from the Rear Second Power Turbine Housing Seal

• No Oil Leaks from the No. 2 Seals

• All wear on the Power Shaft splines is acceptable

• Combustion Liner and Housing, Exhaust Diffuser and Power Turbine

Bearing Housing do NOT need to be removed from Turbine Assembly for further inspection

• No Life Limited components require replacement

1.7.2.2 CLIN 0002AB: 1250 Hour Inspection LEVEL 2 Repair: 1250 Hour Inspection Level 2 areas of repair scope is defined as follows:

• Gap between Rear Bearing Cover and Exhaust Diffuser exceeds limits requiring replacement of the Exhaust Diffuser or the Rear Bearing Cover

• Any additional disassembly is required to repair oil leaks

• Combustion Liner and Housing, Exhaust Diffuser or Power Turbine

Bearing Housing need to be removed from Turbine Assembly for further inspection

• No more than three life limited parts require replacement

1.7.2.3 CLIN 0002AC: 1250 Hour Inspection LEVEL 3: 1250 Hour

Inspection Level 3 areas of repair scope is defined as follows:

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• Additional disassembly is required for a more stringent inspection and/or repair of the Combustion Chamber or Second Power Turbine Rotor per applicable Technical Data

• Removal of the First Gas Producer Nozzle is required for addition inspection

• Four or more life limited parts require replacement

1.7.3 CLIN 0003 2500 Hour Inspection. Work required for the 2500 hour inspection is defined by pertinent Honeywell technical maintenance manuals.

In the case of these inspections, Contractor shall provide a teardown report IAW CDRL A002 to the government detailing the results of the inspection and all work and material required to return the engine to serviceable condition. Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN. Contractor shall apply a single Item Unique Identification (IUID) label to the engine data plate IAW DODI 8320.04 and MIL-STD-130 and in conjunction with the Honeywell manual 2500 hour inspection. This CLIN will be further divided into three sub-CLINs, LEVEL 1, LEVEL 2, and LEVEL 3, which will differenciate the amount of work required to return an engine to serviceable condition as follows:

1.7.3.1 CLIN X003AA: 2500 Hour Inspection LEVEL 1 Repair: 2500

Hour Inspection Level 1 areas of repair scope is defined as follows:

• No reported Compressor Surge (stall)

• No reported Overspeeds

• No reported Overtorque conditions

• No cracks or dust on forward side of Power Turbine Bearing Housing

• Gap between Rear Bearing Cover and Exhaust Diffuser is within limits

• All wear on the Power Shaft splines is acceptable

• Combustion Liner and Housing, Exhaust Diffuser and Power Turbine

Bearing Housing do NOT need to be removed from Turbine Assembly for further inspection

• Centrifugal Compressor Impeller is not damaged beyond limits

• No mutilated Diffuser Vanes

• No Life Limited components require replacement

1.7.3.2 CLIN X003AB: 2500 Hour Inspection LEVEL 2 Repair: 2500

Hour Inspection Level 2 areas of repair scope is defined as follows:

• Gap between Rear Bearing Cover and Exhaust Diffuser exceeds limits

• requiring replacement of the Exhaust Diffuser or the Rear Bearing Cover

• Any additional disassembly is required to repair oil leaks

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• Combustion Liner and Housing, Exhaust Diffuser or Power Turbine Bearing Housing need to be removed from Turbine Assembly for further inspection

• No more than five life limited parts require replacement

1.7.3.3 CLIN X003AC: 2500 Hour Inspection LEVEL 3 Repair: 2500 Hour Inspection Level 3 areas of repair scope is defined as follows:

• Additional disassembly is required for a more stringent inspection and/or repair of the Combustion Chamber or Second Power Turbine Rotor per applicable Technical Data

• Removal of the First Gas Producer Nozzle is required for addition inspection

• Any cause to disassemble the Reduction Gearbox

• Any cause to disassemble the Accessory Gearbox

• Six or more life limited parts require replacement

1.7.4 CLIN X004 5000 Hour Inspection Overhaul / Repair. This CLIN covers any and all overhaul / repair actions to complete a 5000 Hour Inspection of the T53 engine and return to serviceability. 5000 Hour Inspections are a complete overhaul. Work required for the 5000 hour inspection is defined by pertinent Honeywell technical maintenance manuals. In the case of these inspections, Contractor shall provide a teardown report IAW CDRL A002 to the government detailing the results of the inspection and all work and material required to return the engine to serviceable condition. The Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN.

1.7.5 CLIN X005 Over and Above (O&A) – Unsheduled Engine Removals

(UERs). This CLIN includes necessary repair efforts for unscheduled and unpredictable engine events that require repair / overhaul to restore the engine and /or its’ embedded components to serviceability. These are UER events that generate for repair for reasons other than those noted in CLINs X001-X004 above and for those O&A efforts within the general scope of the contract, not covered by the line item(s) for the basic work under the contract, and necessary in order to satisfactorily complete the contract requirements. Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN. O&A efforts shall be covered by an O&A CLIN IAW DFARS 252.217-7028. Unknown repairs or other supporting actions for production may be added to the contract under the O&A CLIN.

These actions will be requested by the ACO / PCO and must be incorporated via task order. It is the Government’s intent to have a Firm-Fixed-Price Labor Wrap Rate set for the O&A CLIN up front for proposal price evaluation that may be applied to negotiated labor hours for each specific task as required along with added material costs per event. This rate shall include all

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contractor assumed risks for repair and other supporting functions required.

Estimated hours of total O&A UER actions is estimated at 200 hours on average per UER event. For fixed hourly rate items, the price negotiated by the ACO shall be based on “hands-on” labor hours multiplied by the contract fixed hourly labor wrap rate. The number of “hands-on” labor hours required shall be negotiated by the Contractor and the ACO. The fixed hourly labor wrap rate includes charges for “hands-on” labor, any labor cost which is not considered “hands-on” for which the Contractor accounts as direct labor, burdens, general and administrative expenses, and other allowable costs and profit. At any time during the contract performance, when sufficient data becomes available on a repetitive task being performed in the fixed hourly rate category, either the Contractor or the PCO may request a negotiation to establish a firm-fixed-price for that item for the the remaining life of the contract. The ACO shall advise the PCO of all such agreements in order that changes can be incorporated in periodic contract modifications.

1.7.6 CLIN X006 Over and Above (O&A) – Other Actions. This CLIN includes engines that generate for repair for reasons other than those noted in CLINs X001-X005 above and for those O&A efforts within the general scope of the contract, not covered by the line item(s) for the basic work under the contract, and necessary in order to satisfactorily complete the contract requirements.

O&A efforts shall be covered by an O&A CLIN IAW DFARS 252.217-7028.

Unknown repairs or other supporting actions for production may be added to the contract under the O&A CLIN. These actions will be requested by the ACO / PCO and must be incorporated via task order. It is the Government’s intent to have a Firm-Fixed-Price Labor Wrap Rate set for the O&A CLIN up front for proposal price evaluation that may be applied to negotiated labor hours for each specific task as required along with added material costs per event. This rate shall include all contractor assumed risks for repair and other supporting functions required. Estimated hours of total O&A actions for this contract shall not exceed 5000 hours. For fixed hourly rate items, the price negotiated by the Administrative Contracting Officer (ACO) shall be based on “hands-on” labor hours multiplied by the contract fixed hourly labor wrap rate.

The number of “hands-on” labor hours required shall be negotiated by the Contractor and the ACO. The fixed hourly labor wrap rate includes charges for “hands-on” labor, any labor cost which is not considered “hands-on” for which the Contractor accounts as direct labor, burdens, general and administrative expenses, and other allowable costs and profit. At any time during the contract performance, when sufficient data becomes available on a repetitive task being performed in the fixed hourly rate category, either the Contractor or the PCO may request a negotiation to establish a firm-fixed-price for that item for the the remaining life of the contract. The ACO shall advise the PCO of all such agreements in order that changes can be incorporated in periodic contract modifications. Items to be classified as O&A may include the following but are not limited to:

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1.7.6.1 Deficiency Report Investigation - The Contractor shall perform investigations of deficiency report items as directed by the Government (See para 1.11.3 and 1.11.4 and IAW CDRLs A003 and A004).

1.7.6.2 Deficiency Report Repair - The Contractor shall repair deficiency report items as directed by the Government (paras 1.11.3 and 1.11.4). The Contractor shall repair deficiencies within 90 calendar days of disposition from the Government.

1.7.6.3 Technical Assistance and Engineering Analysis - The Contractor shall provide technical assistance/engineering production analysis and support services as directed by the ACO/PCO. Services may include, but are not limited to, support of and facility access for Government CEA or an agent on their behalf, in regards to technical assistance for modifications and upgrades to components or engines, to correct deficiencies, performance improvement, technical analysis to determine and accomplish necessary rework, replacement, or modification, and engineering assistance for workarounds and other production related activities.

1.7.6.4 Item Unique Identification (IUID) - IUID part-marking compliance is a Department of Defense (DoD) mandate for items contained within Government inventory systems and as identified by DoD criterion requirements. IUID requirements beyond the 2500 hour inspection CLIN 0002 for the T53 engine 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.

1.7.6.5 Safety Investigation Board (SIB) - The Contractor shall support SIB or Single Investigating Officer (SIO) mishap investigations in coordination with the CEA. Contractor tasks shall include reprioritizing engine induction schedules, impounding hardware (to include quarantine of whole engine and its parts or quarantine of parts of engine as directed by SIO or CEA), coordinating work flow (disassembly, inspections, test, subcontracted O&A analyses, etc.), photographic support, damage assessment and cost determination.

1.7.6.6 Teardown Reporting – The Contractor shall provide reports to the Government T53 Program Office to identify root cause analysis, primary failed item, failure mode, corrective action, and a recommendation to preclude recurrence IAW CDRL A002. The

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Government will request these reports on a case by case basis through the PCO or ACO office as required for events not covered in CLINs X001-X006 above.

1.7.6.7 PACER / Analystical Condition Inspection (ACI) – The

Contractor shall perform ACIs as follows:

I. General:

a. Contractor shall ensure that all ACI assets are processed expeditiously. This includes priority processing of the disassembly, cleaning, inspection, machining, specialized repair, assembly and testing if required.

b. ACIs must be performed in a secured and dedicated work area that has controlled access. ACI hardware must be segregated and identified separately from production assets. ACI workload will take priority over all production workloads. The maintenance facility will assign a monitor(s) who will be responsible for expediting the ACI workload through to completion. Monitor(s) must have authority over all aspects of the ACI

c. ACI results shall be documented in a report. Report is due 120 days after completion of the clean layout inspection.

d. Perform ACI as follows:

i. Provide AFLCMC/LPSE CEA Pacer/ACI point of contact three weeks advance notice of date scheduled for the dirty layout inspection via email.

ii. AFLCMC/LPSE CEA ACI point of contact will provide notification of dirty layout inspection attendees within 7 working days.

iii. Dirty layout inspection consists of visual examination of the as is removed parts to identify any anomalies.

This will include externals, accessories, as well as module parts. Record any anomalies.

iv. After completion of the dirty layout inspection, all parts will be cleaned per applicable technical order and collected for the clean layout inspection.

v. Provide AFLCMC/LPSE Pacer/ACI point of contact three weeks advance notice of date scheduled for the clean layout inspection via email.

vi. AFLCMC/LPSE Pacer/ACI point of contact will provide notification of clean layout inspection attendees within 7 working days.

vii. Detailed clean layout inspection requirements will be provided via a Statement of Work (SOW) with attached parts listings at time of O&A generated ACI event tasking. Additionally, SOW will also provide the part

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features that require Fluorescent Penetrant Inspection and Eddy Current Inspection.

e. After completion of ACI, overhaul/repair modules per applicable technical orders.

f. Overhaul/repair externals and accessories per applicable technical orders. Externals and accessories must have 1000 hours minimum for reinstallation.

g. Rebuild engine per applicable technical orders.

h. Perform engine acceptance testing

i. Engine shipping address will be provided by AFLCMC/LPSE

Pacer/ACI point of contact after engine acceptance test is successfully completed.

1.7.7 CLIN X007– MISTR Rotary Pump (Scavenge Pump). The Contractor shall receive, inspect, teardown, evaluate, repair and/or overhaul per teardown findings, assembly and test the rotory pump IAW the following OEM and USAF manuals, TCTOs, and publications provided at Attachment A to this PWS. Rotary Pumps which are determined to be unserviceable or cannot be made serviceable as discovered during teardown and evaluation shall be disassembled to the minimum extent required and authorized by Honeywell manual(s) to determine the work required to make the pump serviceable.

1.7.8 CLIN X008 Test Cell Run Support. The Contractor shall conduct Test

Cell Runs IAW with the Honeywell Overhaul Manuals to provide alternate test cell facility / capability for engines repaired at Air Force facilities, if requested by the ACO / PCO.

1.7.9 CLIN X009 CDRLs / Data. This CLIN covers the requirements to provide data in support of specified CDRLs to this PWS. This CLIN will not be separately priced and costs for data should be included as part of the end-item costs for engine, repairs, and testing CLINs.

1.8 Testing and Government Acceptance

1.8.1 The Contractor shall test engines in the operational configuration, and attach a copy of the final run sheet to the engine AFTO Form 95 IAW CDRL A009.

Any work necessary to correct a failed engine test cell run shall be the Contractor’s responsibility and will not be charged to the Air Force.

1.8.2 The Contractor shall maintain test acceptance run sheets with the record of maintenance actions accomplished. After completion of engine repair or inspection, contractor shall transfer data/engine records package to AFLCMC/LPSC Engineering within five (5) working days.

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1.8.3 The Contractor shall ensure the engine is given a complete final inspection, IAW applicable Honeywell manuals, documented with date, inspector’s name, and phone number.

1.9 Management and Logistics Requirements

1.9.1 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, and controlling production and supply actions.

1.9.2 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.

1.9.3 The Contractor shall notify the PCO, and Government Program Manager

(PM) via email within two (2) business days in the event a part or technical problem is anticipated to cause a work stoppage or production delay.

Notification will include a get-well plan to mitigate work stoppage.

1.9.4 The Contractor shall deliver engines for CLIN/SubCLINS X001-X004 as specified per CLIN/SubCLIN estimated flowdays, unless directed / negotiated by PCO / ACO to submit items sooner. For CLIN X007, test cell contingency support, the contractor shall test and return engines within seven

(7) business days from receipt of asset, unless directed / negotiated by PCO / ACO to submit items sooner. For CLINs X005-X006, Over & Above CLINS, the contractor shall deliver task orders as negotiated by the ACO for each O&A event. The Contractor shall deliver all CDRLs IAW specified CDRL delivery dates.

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

1.9.6 The Contractor shall obtain, maintain and use accounts necessary to access programs, databases and websites to perform deficiency reporting and engine management. Accounts may include, but are not limited to, Commercial Asset Visibility AF (CAV-AF), Joint Deficiency Reporting System (JDRS) and CEMS. Some databases, such as CAV-AF, will require a Public Key Infrastructure (PKI) certificate. CEMS database access requires a National Agency Check with Inquiries (NACI) and Credit Check for a security investigation via a completed AF IMT 2583 form with fingerprints provided.

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CEMS reporting by contractor will also require an established Department of Defense Activity Address Coded (DODAAC) / Stock Record Account Number (SRAN). See 1.12 Reporting Requirements for additional information and Attachment E to this PWS – CEMs Access and Security Check Process.

1.9.7 The Contractor shall participate in teleconferences, meetings, and other program reviews per Table 1.9.1 or as requested and upon notification from the PCO. Travel will be directed by the PCO and paid IAW FAR part 31 and the Joint Travel Regulations under CLIN X010 - Travel.

Table 1.9.1

Meeting Frequency Host Attendees Program Management Reviews (PMR)

Semi-annual Rotates between PMO and Contractor

PMO, Contractor, Customers, DCMA

Component Improvement Program (CIP) Conferences

Semi-annual Rotates between PMO and Original Equipment Manufacturer (OEM)

PMO, Contractor, OEM

User’s Conference Annual PMO PMO, Contractor, OEM, Customers, DCMA

Maintenance Planning Working Group

(MPWG)

Semi-annual Rotates between PMO and OEM

PMO, Contractor, Customers, OEM

Post Award Conference Once Contractor facility PMO, Contractor, DCMA

Production Meetings Bi-weekly or as required Telecom PMO, Contractor, DCMA

1.9.8 The Contractor shall complete all required data fields on the Contractor

Manpower Reporting Application (CMRA) found 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, contractor shall report all data no later than 31 October of each calendar year. Contractor may direct questions to the CMRA help desk, or consult users manuals for government and contractror personnel at the website above.

1.9.8.1 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 direct labor dollars. At no time will any data be released to the public with the Contractor name and contract number associated with the data.

1.10 Material Management

http://www.ecmra.mil/

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1.10.1 The Contractor shall review all incoming shipping documents to ensure shipments and documents are accurate. The Contractor shall submit proper documentation (see Reporting Requirements 1.12.1) 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, etc.

1.10.2 The Contractor shall perform a visual inspection upon receipt of the engine assembly for any shipping container damage using appropriate OEM technical data. The Contractor shall report to the PCO if the assembly is misidentified, misdirected, or incomplete (missing parts); the Contractor shall obtain disposition instructions from the PCO. The Contractor shall initiate a Supply Discrepancy Report (SDR), SF 364, for any assets received in other than the contracted packaging.

1.10.3 The Contractor shall ensure USAF engines with their embedded components are not comingled with other non-USAF components being overhauled at the Contractor’s or sub-vendor facilities. Contractor shall ensure disassembled, usable parts are not commingled with contractor existing inventory.

1.10.4 The Contractor shall provide all consumable materials used for repair / overhaul. The Contractor shall dispose of consumables IAW local, state and federal regulations. The Contractor shall procure all parts required to complete the USAF requirements.

1.10.5 The 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 new or overhauled condition with traceability of origin and from approved OEM sources. The Contractor shall forecast and maintain ample inventory to promote minimal production disruption to meet the USAF required/requested delivery schedules. Contractor may procure CFM from the Defense Logistics Agency (DLA). Additionally, the Contractor shall comply with CDRL A012 to report maintenance data and parts history for items impacted within the repair process.

1.10.6 Prior to serviceable shipment, the Contractor shall contact Defense Contract

Management Agency (DCMA) by email to schedule inspection and acceptance. If DCMA does not reply within three (3) business days of the request, the Contractor shall notify the PCO via email for further direction.

Upon shipment of the asset(s), the Contractor shall provide tracking number information to the PCO and PM for each shipment. DCMA shall inspect and accept items IAW DCMA policies and procedures.

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1.10.6.1 The following Department of Defense Activity Address Code (DODAAC) will be used when shipping engine assembly and components: Ft Rucker FB3034.

The Contractor shall properly package the engine, and applicable documentation, in a serviceable shipping container described in 72-00-00, IAW T.O. 2J-1-18, 00- 85-20 and AFMC Form 158 packaging requirements, and shall ensure appropriate documentation and placement of serviceable tags, DD Form 1574, inside and outside the container. The Contractor is responsible for remanufacturing/returning damage engine shipping trailers to serviceable condition in accordance with TM 1-8145-695-24+P. This effort shall be priced as part of each CLIN Firm-Fixed-Price. The Contractor shall use the Government Transportation Accounting Code identified in the contract for transportation costs.

1.11 Quality Requirements

1.11.1 The Contractor shall deliver all engines in a fully tested, serviceable and Ready For Installation (RFI) condition. The Contractor shall have in place and maintain a quality management system in compliance with ISO 9001:2000, or higher versions. Contractor shall make available for review upon request by the Government the quality system procedures, planning, and other documentation and data that comprise the quality system. The Government will, at their discretion, perform any inspections, verifications, and evaluations to ascertain conformance to the ISO 9001:2000/or higher versions 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.

1.11.2 The Contractor shall have in place and maintain procedures to maintain measuring and test equipment IAW ISO 10021:2003, ANSI/NCSL Z504.3- 2006, or equivalent.

1.11.3 The Contractor shall support product audits, at the determination of the

Government on overhauled engines and components. The Government may select at random such quantities of end items as may be necessary to determine quality of workmanship and materials.

1.11.4 The Contractor shall investigate all Deficiency Reports submitted by the

USAF against reportedly defective items overhauled by this contract IAW Technical Order (T.O.) 00-35D-54 and prepare a report of findings (see Reporting Requirements 1.12.3).

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1.12 Reporting Requirements

The Contractor shall submit on-time, correct and complete reports IAW prescribed Contract Data Requirements Lists (CDRLS) and as directed by language to this PWS.

The Contractor shall refer to the applicable CDRL for timeframe and report requirements as well as the Data Item Descriptions for report formatting. See ATTACHMENT D for a listing of all CDRLS & DIDs. The Contractor shall not report more than one document late per quarter and no document shall be received later than five (5) business days. The Contractor shall not submit reports that require more than two corrections per report per quarter.

1.12.1 Report of Shipping (Item) and Packing Discrepancy

Contractor shall review all incoming shipping documents to ensure shipments and documents are accurate. The Contractor shall submit proper documentation 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 A001.

1.12.2 Teardown Report

The Contractor shall provide AFLCMC/LPSC Engineering a teardown report documenting extent of engine damage and deficiencies. Report may be written in Contractor format IAW CDRL A002.

1.12.3 Material Deficiency Report

The Contractor shall submit a report whenever a material or a quality deficiency, as defined by TO 00-35D-54, occurs. This includes CAT I and II Engineering Investigation Material Deficiency Reports (MDR). The Contractor shall provide a Statement of Work (SOW) for pricing request.

Contractor shall deliver a formal report of findings to the Government after receipt and analysis of the deficient material exhibit for all Mishap Investigations and CAT I & CAT II deficiency reports. If failed components require additional lab analysis, the Contractor may use independent agencies for analytical evaluation. The Contractor may request support from Government CEA for additional guidance and disposition via PCO. DR will be input to the Joint Deficiency Reporting System (JDRS). Reports shall be submitted IAW CDRL A003.

1.12.4 Product Quality Deficiency Report (PQDR)

The Contractor shall investigate and document PQDR findings, using JDRS, 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 following exhibit receipt.

Contractor shall provide substantiation of root cause of failure against reported field failure in close-out report. After completion of the PQDR investigation, the Contractor shall request disposition of exhibit through the

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PCO to PM for material induction into current delivery order or next delivery order submission. Contractor shall submit reports IAW CDRL A004.

1.12.5 Significant Historical Data

The Contractor shall retain all pre-existing Significant Historical Data on the AFTO Form 95 or transcribe/copy pre-existing data from other forms or records onto an AFTO Form 95 IAW CDRL A005. The Contractor shall document and retain all maintenance/inspection/test work records generated during repair, overhaul, or modification of contract end items. The Contractor shall convert all records to a scanned digital format and maintain an index of each component package. Upon request of the PCO or ACO (whether at contract expiration or at any time during the contract period), the Contractor shall provide maintenance records for any end items within 24 business hours of request. Upon expiration of the contract, the Contractor shall send a records index and all records to the Government IAW CDRLs A010. IAW FAR 4.703, The Contractor shall retain any records generated for three years after final payment. Additionally, for any Critical Safety Items records generated, the Contractor shall maintain records for up to ten years after final payment. Furthermore, at the end of this period, or in the event of relocation or shutdown, all records should be offered to the procuring activity prior to disposal.

1.12.6 Comprehensive Engine Management System (CEMS) Reporting The

Contractor shall load engine and engine component assembly into CEMS IAW CDRL A006. All part number changes and TCTO accomplishment shall be documented. CEMS POC is Colleen Law (405) 734-4011. CEMS reporting requires access to the CEMS database with security check validation IAW Attachment E – CEMS Access and Security Check Process.

NOTE: Security check processes can take ~ 6 to 12 months for completion and are required before the Contractor can obtain access to the CEMS database. For CEMs transactions reporting required while the security clearance is being worked please contact the CEMS Help Desk at CEMS.pmo.helpdesk@us.af.mil

1.12.7 Commercial Asset Visibility Air Force (CAV-AF) The Contractor shall provide end item reporting into Commercial Asset Visibility Air Force.

Contractor reporting requirements into CAV-AF require each asset be identified by actual NSN. CAV-AF reporting requires corresponding CLIN submission as detailed on the basic contract. The engine assembly shall be properly registered within CAV-AF system IAW CDRL A007 and

APPENDIX B.

1.12.8 Depot Maintenance Production Report

The Contractor shall provide updated production reports to the Government

IAW CDRL A008.

mailto:CEMS.pmo.helpdesk@us.af.mil

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1.12.9 Test Cell Run Report

The Contractor shall provide copies of all test cell run sheets IAW CDRL A009. The Contractor shall make available individual test cell run reports at the request of AFLCMC/LPSC and shall include all test cell run reports with engine records upon engine delivery.

1.12.10 Depot Maintenance Action Report

The Contractor shall provide all records of maintenance actions to the Government IAW CDRL A010.

1.13. Programs, Databases & Websites: The Contractor shall obtain and maintain, at a minimum, the accounts identified below to access programs, databases & websites. The Contractor shall obtain a Public Key Infrastructure (PKI) certificate when necessary for access. The Contractor shall provide proof of process initiation to obtain all required accesses to below mentioned programs and data bases within 10 calender days of contract award.

a. Joint Deficiency Reporting System (JDRS)

b. Commercial Asset Visibility Air Force (CAVAF)

c. Web Based Commercial Asset Visibility (WebCAV or CAV)

d. D042 Comprehensive Engine Management System (CEMS)

e. Enhanced Technical Information Management System (ETIMS)

f. Web-based SDR system

g. Electronic Data Access (EDA)

h. Wide Area Work Flow (WAWF)

i. DLA Forecasting Systems

j. Contractor Performance Assessment Rating System (CPARs)

k. ECMRA http://www.ecmra.mil for Full Time Equivalent Reporting

l. Common Access Card (CAC)

1.14. Publications: The Contractor shall possess and maintain up to date copies of all OEM Technical Data required to accomplish engine assembly repair and/or inspection, including Manuals, Overhaul Repair Instructions, Overhaul Modification Instructions, Service Bulletins, Technical Orders (TOs), and Service Letters. The Contractor shall obtain appropriate Air Force Instructions (AFIs), Air Force Material Command Instructions (AFMCIs) and General Technical Orders expressly required to perform the work in this contract via the internet at https://www.my.af.mil/etims/ETIMS/index.jsp. In the event that a form or publication (Non OEM Technical Data) is not available online, the Quality Assurance Representatives (QAR)/Contracting Office Representative (COR) 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.

1.14.1 The Contractor and any sub-vendors delivering or handling official USAF records shall comply with the applicable records management regulations AFI 33-322, http://www.ecmra.mil/

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AFMAN 33-363, and AFI 33-364 (in their entirety). 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 TOs, TMs, TCTOs, and other directives within (5) calendar days of receipt.

1.14.2 The Contractor shall implement Safety of Flight changes within (1) calendar day after receipt of PCO approval and funded authorization. The Contractor shall notify the PCO within one calendar day that changes have been incorporated. The Contractor shall notify the PCO in writing of estimated cost impact within 30 calendar days for non-safety flight changes and 15 calendar days for safety of flight changes if the Contractor determines the changes will result in cost impact.

1.14.3 Contractor shall establish and maintain a Technical Order Distribution Office

(TODO) account IAW T.O. 00-5-1 and be placed on initial distribution of applicable TOs. To obtain a TODO account, the Contractor shall submit a completed AFTO Form 43 (USAF TODO Assignment or Change…