ATTACK_SOW.pdf

STATEMENT OF WORK

FOR

A-10 THUNDERBOLT ADVANCED-WING

CONTINUATION KITTING

(ATTACK)

8 Feb 2018

Prepared by:

AFLCMC/WWAE

Fighter/Bomber Directorate

Hill AFB, Utah 84056

1386553897C Draft ii

REVISION CONTROL

Note: The portion of the text affected by the current revision is indicated by vertical black lines in the outer left hand margin.

Rev Date Description Sections

Initial 22 DEC 2017 Initial Release

Rev A 8 FEB 2018 Added need for kits

Additional PM language

Clarified presentation media

Confirmed incentive fee

Approval on all revisions

Small clarification

Disposition prep responsibility

IRRL maintained for contract life

FA FCA Clarification

FA PCA Clarification

OCONUS shipping reqs

Independent kit clarification

Email update

1.1

3.2.

3.2.5.1 – 3.2.5.3

3.2.7

3.3.2.1

3.4.2.1

3.4.3.2.2.1

3.3.3.1.3

3.4.1.4.1

3.4.1.5.1

3.4.2.3

3.4.2.4

5.4.1

5.4.2

5.4.3

Rev B 26 APR 2018 PLM meeting changed to optional

Added Paragraph 3.1.2.1

Added Small Business Participation

Added Gov’t Part Procurement Para

Added [A043 CDRL] Reference

Added [A043 CDRL] Reference

Section 3.4.2.2 change to 3.4.2.1.1

Section 3.4.2.2.1 change to 3.4.2.1.2

Added a draft delivery for Serial # Cntl Plan

Shipping Plan Clarification

Part Number Update

3.1.2

3.1.2.1

3.2.2.1

3.2.9

3.4.1.5.1.1

3.4.1.5.2

3.4.2.1.1

3.4.2.2.1

3.4.3.8

5.4.1

5.4.2 iii

Table of Contents

1. PURPOSE

1.1. Purpose

2. REFERENCES AND APPLICABLE DOCUMENTS

2.1. Referenced Documents

2.2. Applicable Documents

3. REQUIREMENTS

3.1. Data, 2-D Drawing, and 3-D Computer Aided Drafting (CAD) Modeling Delivery

3.1.1. Contract Data Requirements List (CDRLs)

3.1.2. Technical Data

3.2. Program Management

3.2.1. Single Manager

3.2.2. Subcontractor Management

3.2.3. Program Management Plan

3.2.4. Monthly Status Report

3.2.5. Meetings

3.2.6. System Engineering Management Plan

3.2.7. Incentive

3.2.8. Engineering Services

3.2.9. Government Part Procurement

3.3. Engineering and Quality Requirements

3.3.1. General CAD/PLM Requirements

3.3.2. Quality Assurance

3.3.3. Design Changes

3.4. General Productions Tasks

3.4.1. Manufacturing Process Development and Special Tooling

3.4.2. Production Preparation and Planning

3.4.3. ATTACK Wing Assembly Production

4. PERSONNEL QUALIFICATIONS

5. SPECIAL CONSIDERATIONS

5.1. Security

5.1.1. Safeguarding Information

iv

5.1.2. Release/Removal of Documentation

5.2. Supply/Support Requirements

5.2.1. Governmental Rights

5.3. Travel Requirements

5.4. Preservation, Packaging & Marking Requirements

5.4.1. Packaging Requirements

5.4.2. Kitting Requirements

5.4.3. Hazardous Materials (When Applicable)

5.4.4. Unique Identification (UID) Requirements

6. ACRONYMS

The following attachments will be delivered with the Technical Data Package (TDP) upon contractor’s request.

ATTACHMENT A Engineering Data Requirements

ATTACHMENT B Critical Safety Item (CSI) List

ATTACHMENT C Contract Data Requirements List (CDRL) and Distribution

ATTACHMENT D Operational and Flight Check Requirements

ATTACHMENT E Delivery Kitting List

ATTACHMENT F Government Furnished Information List

ATTACHMENT G Government Furnished Property List

1. PURPOSE

1.1. Purpose

This Statement of Work (SOW) describes requirements (exclusive of those contained in the technical data package) to produce A-10 Thunderbolt Advanced Continuation Kit (ATTACK)

Wing Assemblies. This effort will also produce individual kits if needed.

The ATTACK technical data package (162D610010-1001) supplied at contract award shall serve as the engineering baseline for this acquisition. The geometry of the baseline TDP is defined by

Three Dimensional (3-D) Models in Model Based Definition (MBD). This includes 3-D models and other data mastered in a Product Lifecycle Management (PLM) system. The PLM data fields needed for manufacturing are also output in a Human Readable Format that the Government will provide as a “Part Report.” The TDP is an input to the ATTACK, and it shall be provided by the

Government.

For bidding purposes the 162D610010-1001 Enhanced Wing Assembly (EWA) TDP will be provided with Engineering Data Requirements (Attachment A) detailing the changes that will constitute the final 162D610010-1001 ATTACK TDP supplied at contract award.

2. REFERENCES AND APPLICABLE DOCUMENTS

The following list of Government and industry specifications, standards, and other documents below are for reference. Although reference documents are specifically stated in the sections where they apply, relationships with the applicable documents are implied throughout the requirements specified below. Versions are not defined and are expected to be the most current release.

2.1. Referenced Documents

*The contractor should anticipate updates to documents and specifications as marked:

1A-10C-520 Replacement of Thin and Thick-Skinned Wing Assembly P/N 160D610001 with Enhanced Wing Assembly P/N 162D610001-1001 on A-10C Aircraft

*08-A10DOC-001 A-10 Drawing Practice

*08-A10DOC-010 A10 Aircraft Integrated Configuration Management and Data Management

Plan

*11-A10DOC-004 A-10 3-D Modeling Specification

*11-A10DOC-005 A-10 NX Drafting Specification

*12-A10DOC-002 A-10 Product Lifecycle Management (PLM) Data Exchange Specification

*12-A10DOC-009 A-10 3-D Model Validation Specification

*13-A10DOC-001 A-10 2D Drawing to 3D Model Migration Specification

49 CFR Department of Transportation Final Rule, HM – 181 of The Federal

Register, 21 December 1990

AFI 20-106 Management of Aviation Critical Safety Items

AFMCI 24-201 HQ AFMC Packaging and Materials, Handling Policies and Procedures

ANSI/EIA-632 Process for Engineering a System

AS9100 Quality Management Systems – Aerospace – Requirements

AS9102 Aerospace, First Article Inspection Requirements

AS9132 Data Matrix Quality Requirements for Parts Marking

DOD 5220.22-M National Industrial Security Program Operating Manual (NISPOM)

ICAO International Civil Aviation Organization (IMDG), Annex 1International

Maritime Dangerous Goods Code

EIA-649-1 Configuration Management Requirements for Defense Contracts

EIA-649-B National Consensus Standard for Configuration Management

FED-STD-313 Material Safety Data, Transportation Data, and Disposal Data for Hazardous

Materials Furnished to Government Activities

JSSG-2006 Joint Service Specification Guide, Aircraft Structures

MIL-HDBK-505 Handbook for Definitions of Item Levels, Item Exchangeability, Models, and Terms

MIL-STD-129 Military Marking for Shipment and Storage

MIL-STD-130 Identification Marking of Military Property

MIL-STD-1530 Aircraft Structural Integrity Program (ASIP)

MIL-STD-1916 Department of Defense (DoD) Test Method Standard

(DoD Preferred Methods for Acceptance of Product)

MIL-STD-2073-1 Standard Practice for Military Packaging

MIL-I-8500 Interchangeability and Replaceability of Component Parts for Aerospace

Vehicles

MIL-STD-961 Defense and Program-Unique Specifications Format and Content

*SA220R0207 A-10 Aircraft Structural Integrity Program (ASIP Legacy V) Damage

Tolerance Re-Assessment: Reconfigured Post Desert Storm Severe

Spectrum

TO 00-35D-54 USAF Deficiency Reporting, Investigation, and Resolution

TM-86-01 Air Force Technical Manual Contract Requirements (TMCR)

2.2. Applicable Documents

00-5-1 Air Force Technical Order System

00-5-3 AF Technical Manual Acquisition Procedures

1-1-3 Preparation, Inspection, and Repair of Aircraft Fuel, Oil and Water, Alcohol

Cells and Integral Tanks

1-1-8 Application of Organic Coatings, Aerospace Equipment

1-1-689 Prevention and Control of Corrosion and Fungus in Communications, Electronic, Meteorological and Avionic Equipment

1-1-691 Aircraft Weapons Systems-Cleaning and Corrosion Control

1A-10C-2-1-1 General Aircraft/Equipment

1A-10C-2-27 Flight Controls, JG Series

1A-10C-2-28 Fuel System, JG Series

1A-10C-2-32 Landing Gear System, JG Series

1A-10C-2-94 Armament, JG Series

1A-10C-3-1 Structural Repair Manual

1A-10C-36 Nondestructive Inspection Manual

1A-10C-6 Inspection and Maintenance Requirements

16-A10DOC-004 CSI List for A-10 Non-Propulsion

29 CFR Occupational Safety And Health Administration, Labor

33B-1-1 Nondestructive Inspection Methods

42A-1-1 Safety, Fire Precaution and Health Promotion Aspects of Painting, Doping, and Paint Removal

42A1-1-3 Solvents Approved for Air Force Use

AS 9132 Data Matrix Quality Requirements for Parts Marking

H4-1 (and H4-2) Federal Supply Code for Manufacturers Cataloging Handbook

MIL-HDBK-61A Configuration Management Guidance

MIL-HDBK-512 Parts Management

MIL-HDBK-516 Airworthiness Certification Criteria

MIL-HDBK-729 Corrosion and Corrosion Prevention, Metals

MIL-HDBK-1568 Material and Processes for Corrosion Prevention and Control in Aerospace

Weapon Systems

MIL-STD-1686 Electrostatic Discharge Control Program for Protection of Electrical and

Electronic Parts, Assemblies, and Equipment (Excluding Electrically

Initiated Explosive Devices

3. REQUIREMENTS

The TDP will be delivered to the contractor as documented in the Government Furnished

Information (GFI) List (Attachment F). The prime contractor shall be responsible for verifying the TDP is complete prior to start of first article production. The prime contractor shall produce

ATTACK Wing Assemblies, complete and ready, for installation on the A-10 aircraft. The prime contractor shall have a working knowledge and demonstrated capability in the application of the government Technical Order (TO) system as well as applicable MIL HDBKs and MIL

STDs specified in SOW Section “2. REFERENCES AND APPLICABLE DOCUMENTS.”

3.1. Data, 2-D Drawing, and 3-D Computer Aided Drafting (CAD) Modeling Delivery

The contractor shall meet the minimum requirements specified below in regards to digital data, Two Dimensional (2-D) drawings, and 3-D CAD modeling delivery.

3.1.1. Contract Data Requirements List (CDRLs)

All data deliverables in this SOW shall be formatted for import into the A-10 Teamcenter environment using the “A-10 Product Lifecycle Management (PLM) Data Exchange

Specification” 12-A10DOC-002. In addition, drawing deliverables shall also be formatted for import into Joint Engineering Data Management Information and Control System (JEDMICS) using the Ogden Air Logistics Complex, Engineering, “Digital Delivery Requirements and

Metadata Instructions.” Data delivery schedule/frequency requirements are found in the CDRL for each specific task while specific delivery instructions and SOW references are found in the

Contract Data Requirements List (CDRL) and Distribution (Attachment C).

3.1.2. Technical Data

Specifications (as denoted in SOW Section “2. REFERENCES AND APPLICABLE

DOCUMENTS”) may need to be updated in support of either A-10 SPO PLM requirements or supplier enhancement requests. In these cases, the prime contractor may participate in the development, review, and implementation of these changes. To facilitate this process, the prime contractor may participate, in the weekly A-10 PLM Architecture Deconfliction Meeting to ensure potentially conflicting schema changes are reviewed and resolved among all A-10 SPO contracts/deliverables.

All tasks requiring the updating or creating of 2-D drawings, 3D models, or Part Reports shall be accomplished using one of the methodologies listed in “A-10 2-D Drawing to 3-D Model

Migration Specification” 13-A10DOC-001. Each task shall identify the specific methodology to be used along with any other requirements pertinent to the task. For updating, creating, and/or migrating 2-D drawings into MBDs, one or more of the specifications listed below will be required by each methodology to ensure a complete and accurate engineering TDP:

A-10 3-D Modeling Specification 11-A10DOC-004

A-10 3-D Model Validation Specification 12-A10DOC-009

A-10 NX Drafting Specification 11-A10DOC-005 (for CAD generated drawings/sheets)

A-10 Drawing Practice 08-A10DOC-001

3.1.2.1. Government Requested Specification or Teamcenter/NX Version Update

Specifications, Software (Teamcenter/NX) may need to be updated to ensure Government and

Contractor are in sync for data transfer.

3.2. Program Management

The prime contractor shall provide materials and services required to efficiently and effectively manage the contract. All communications pertinent for the execution of this contract shall be flowed to both the Contracting Officer and Program Manager.

3.2.1. Single Manager

The prime contractor shall establish a single point of contact for the overall management effort.

3.2.2. Subcontractor Management

The prime contractor may subcontract with other companies to establish a strong technical capability to meet diverse contract requirements. The prime contractor shall be responsible for all aspects of contract performance, oversight, and the flowing of requirements to all subcontractors.

3.2.2.1. Small Business Participation

The prime contractor shall meet a 13% small business participation under this effort.

3.2.3. Program Management Plan

The prime contractor shall produce a comprehensive Integrated Master Plan (IMP) [CDRL

A002] and Integrated Master Schedule (IMS) [CDRL A001].

3.2.4. Monthly Status Report

The prime contractor shall provide a Monthly Status Report [CDRL A003] that covers all program activities for the period. It shall provide a forecast of work to be accomplished during the upcoming month. This report shall include status and progress towards open milestones that are active, or scheduled to become active, according to the delivery schedule. The prime contractor shall identify actions being taken to correct schedule deficiencies. Changes from previous reports shall be highlighted and explained. Approved IMP and/or IMS updates shall be reflected in this report. The contractor shall report any situation requiring immediate action by the Government using the most expedient means (teleconference, e-mail, or letter) and document the situation in the Monthly Status Report. In addition, the following shall be addressed:

Manufacturing Status

Deliveries

Non-conformance Summary by Serial Number

Non-conformance Trend Analyses

Corrective Action Plans

Personnel changes and/or staffing levels

Risk assessment of production issues (to include mitigation)

3.2.5. Meetings

The Government encourages meetings with the prime contractor, and their significant subcontractors if existent, to exchange information and ideas. Whenever feasible, meetings shall be held in conjunction with other events to minimize costs (e.g. Kick-Off Meetings, Reviews, Technical Interchange Meetings, Audits, etc.). Additionally, online meetings, teleconferences or video teleconferences may be used on a more frequent basis to ensure effective communication.

When used, the contractor shall use government approved online meeting, teleconference and video teleconference services, i.e., Defense Collaboration Services (DCS). All appropriate stakeholders should be in attendance: Government personnel, prime contractor, subcontractors, etc.

3.2.5.1. Program Management Reviews (PMR)

PMRs shall alternate between Government and contractor facilities unless otherwise approved by the Contracting Officer. PMRs shall be reflected in the IMS [CDRL A001], detailed in the IMP

[CDRL A002], and updated in the Monthly Status Reports [CDRL A003]. PMRs shall be scheduled quarterly. The prime contractor, with concurrence from the Government, may schedule PMRs more or less frequently as tasks warrant. The prime contractor shall prepare an agenda for each PMR [CDRL A005]. The prime contractor shall consult the Program Manager during development of the PMR agenda to ensure Government concerns are addressed. The prime contractor shall provide electronic copies of presentation materials no later than 48 hours prior to the PMR. The prime contractor shall provide the minutes after each PMR [CDRL

A004].

3.2.5.2. Technical Interchange Meetings

The prime contractor shall conduct and support Technical Interchange Meetings (TIM) at their request or at the request of the Contracting Officer. The intent of the TIM is to foster the exchange of technical information impacting the ATTACK program. The TIM shall not replace the PMR process. The prime contractor shall prepare an agenda for each TIM [CDRL A005].

The Program Manager shall be consulted during development of the TIM agenda to ensure

Government items are addressed. The prime contractor shall provide electronic copies of presentation materials no later than 48 hours prior to the TIM. The prime contractor shall provide minutes after each TIM [CDRL A004]. TIMs shall be held alternately at Hill AFB and a contractor facility unless otherwise approved by the Contracting Officer.

3.2.5.3. Kick-Off Meeting

The prime contractor shall hold a Kick-Off Meeting at agreed upon location within 30 calendar days of contract award. The purpose of the meeting shall be to review and gather available technical information applicable to the ATTACK program and discuss the expected course of the program. The prime contractor shall submit an agenda for the Kick-Off Meeting [CDRL A005].

The prime contractor shall consult the Contracting Officer and PM during development of the

Kick-Off Meeting agenda to ensure Government concerns are addressed. The prime contractor shall provide electronic copies of presentation materials no later than 48 hours prior to the Kick-

Off Meeting. The prime contractor shall provide the minutes of the Kick-Off Meeting [CDRL

A004].

3.2.5.4. Technical Order Guidance Conference (TOGC)

The contractor shall conduct a TOGC with in 60 calendar days after contract award at Hill AFB.

The contractor shall host two technical order in-process reviews (IPR) to be held at a time and place mutually agreed upon by the contractor and the Government within this conference.

3.2.6. System Engineering Management Plan

The prime contractor shall develop a comprehensive System Engineering Management Plan

(SEMP) [CDRL A022]. The SEMP shall include specific entrance and exit criteria for all critical events listed on the IMS. The SEMP shall be reflected in the IMP [CDRL A002]. The prime contractor shall employ a disciplined and rigorous system engineering process conforming to ANSI/EIA-632 during development and throughout production of the ATTACK Wing

Assembly.

3.2.6.1. Technical Reviews and Audits

The following technical reviews and audits shall be conducted as specified by the SEMP and

IMP:

Technical Interchange Meeting (TIM)

Functional Configuration Audit (FCA)

Physical Configuration Audit (PCA)

Production Readiness Reviews (PRR)

The prime contractor shall incorporate technical reviews and audits into the IMP [CDRL A002] and IMS [CDRL A001]. Non-conformances identified by the Government during technical reviews and audits shall be corrected by the prime contractor before proceeding. The

Contracting Officer may direct the contractor to schedule technical reviews and audits more or less frequently as conditions warrant. The prime contractor shall develop agendas [CDRL A005] and report the meeting minutes [CDRL A004] for each technical review and audit.

3.2.6.2. Configuration Management Plan

The prime contractor shall develop and maintain a Configuration Management Plan (CMP)

[CDRL A027] to control the configuration of the wing, including the existence and disposition of non-conformances, throughout this effort. The prime contractor shall demonstrate consistent supplier oversight with this requirement. The plan shall follow the requirements EIA-649-1. The plan shall also meet the requirements of 08-A10DOC-010 A10 Aircraft Integrated Configuration

Management and Data Management Plan. The CMP shall demonstrate how compatibility will be achieved with the 12-A10DOC-002 A-10 Product Lifecycle Management (PLM) Data Exchange

Specification (ADES). The Government shall approve the CMP, including all revisions, prior to use.

3.2.7. Incentive

An incentive fee CLIN is included in the contract to incentivize early delivery and approval of a

First Article and Low Rate Initial Production articles.

3.2.8. Engineering Services

The contractor shall provide engineering support services if requested.

3.2.9. Government Part Procurement

The government may have contracts in place, or in the process of being in place, with subcontractor(s) that may overlap with the ATTACK WRP contract. The prime or subcontractor(s) shall not have agreements in place that do not allow the government to procure the same parts from the same or alternate suppliers.

3.3. Engineering and Quality Requirements

3.3.1. General CAD/PLM Requirements

3.3.1.1. Model Based Definition (MBD)

All 3-D models, modified or created, for this contract (excluding tooling models) shall be accomplished and delivered in Siemens NX format with complete history and parametric data

[CDRL A023, CDRL A024]. All tooling models, modified or created for this contract, shall be delivered in Siemens NX format with complete history and parametric data unless otherwise approved by the Government. All CAD models shall be modeled according to the A10 3-D

Modeling Specification #11-A10DOC-004, existing 2-D drawings, loft data (AF released loft surfaces), and other controlling documentation. Models shall be required for all temporary and permanent fasteners; models shall be developed in coordination with the A-10 SPO. The version of Siemens NX used by the contractor shall be the same as the version used by the A-10 SPO and shall be concurrently updated to match the version used by the A-10 SPO when the A-10

SPO moves to a new version.

The prime contractor may use a translator to convert between NX and IGES/STEP in support of their subcontractors, however, the prime contractor shall demonstrate the translation process to the Government and obtain Government authorization to proceed before manufacturing to the converted 3-D Model. For a translator to be authorized, the contractor must show that the delivered 3-D Model contains all of the necessary information required to accurately produce parts as defined in the original NX model. The translator will be demonstrated, but it is not required to be delivered to the Government. The 3-D models shall define product configuration per ASME Y14.41 Model only (aka “Model Based Definition”) in lieu of drawings.

3-D Model Validation Plan

The prime contractor shall validate 3-D models, modified or created, for this contract (excluding tooling models) per the A-10 3-D Model Validation Specification # 12-A10DOC-009. All validation check lists, work flow audit logs, and Check-Mate logs/reports shall be delivered as part of the TDP with the Government having unlimited rights to use, duplicate, modify, and distribute the validation check lists, work flow audit logs, Check-Mate logs/reports IAW SOW

Section “5.2.1. Governmental Rights.”

3.3.1.2. PLM Data Linking and Submittal

The prime contractor shall acquire, maintain, and administer a PLM server with necessary hardware and software to load and manage the GFI provided TDP. Original TDP supplied using

Siemens Teamcenter/NX.

The prime contractor shall provide a PLM data linking plan [CDRL A008] defining how the

PLM database will maintain links from the TDP to the serialized components of the newly manufactured wing components. In addition, the plan shall define the process to transfer the applicable CDRL data to the Government during the physical delivery of each wing.

3.3.2. Quality Assurance

Quality control processes are critical to providing consistent, conforming product, to minimizing non-conforming product, and to meeting delivery schedule requirements. Full scale durability testing of the ATTACK Wing Assembly is not a requirement, because the prime contractor will be producing a derivative wing assembly that has already demonstrated fleet performance.

Therefore, it is critical that the prime contractor demonstrate their ability to practice exceptional quality control processes. The ATTACK Wing Assembly manufacturer shall be AS9100 certified. Subcontractors and vendors supporting production of the Wing Assembly shall also be

AS9100 certified (or equivalent as approved by the Government) with quality control processes compatible with the prime contractor. The prime contractor shall demonstrate consistent supplier oversight, detection of non-conformances, communication of findings from subcontractor to prime contractor engineering and program management personnel, and communication of findings (along with the scope of the finding, proposed disposition, and any other justifications) to the Government for disposition.

3.3.2.1. Quality Assurance Plan

The prime contractor shall provide the Government a Quality Assurance Plan (QAP) [CDRL

A017]. The QAP shall define the quality control processes used by the prime contractor and their suppliers to ensure the ATTACK wing assembly meets TDP requirements including dimensional accuracy, material selection, and process compliance. The QAP shall address how production escapes, non-conformances, and product quality defect reports are to be handled. The

Government shall review and approve the QAP prior to the prime contractor producing first article detail parts. The Government shall approve the QAP, including all revisions, prior to use.

Subcontractor/Partner Quality Requirements

The prime contractor is responsible for ensuring that all subcontractors, partners, and sub-tier subcontractors/partners meet the prime contractor’s quality system requirements. This includes the ability to provide transparency of non-conformances from the point of discovery to the point of delivery to the Government. The prime contractor shall demonstrate subcontractor/partners compliance with the prime contractor’s quality system requirements to the Government. The means of verification shall include audits of the quality system compliance as well as physical on-site audits of the subcontractor/partner’s processes, procedures, records, facilities, etc., as needed.

Independent Government Audit

The prime contractor, subcontractors, and partners are subject to independent Government or

Government directed audits at any time to assure procedures and processes are followed.

3.3.2.2. Critical Safety Item (CSI) Requirements

Subcontractors and prime contractor shall adhere to AFI 20-106 “Management of Aviation

Critical Safety Items.”

3.3.3. Design Changes

The prime contractor may choose to request changes to the TDP, or in certain circumstances, find that changes to the TDP are necessary. All changes to the TDP shall be approved by the

Government prior to incorporation according to the Prime contractors CM Plan [CDRL A027].

This is not applicable for production tooling TDP changes. The prime contractor shall have design authority over the production tooling with data (as required per paragraph 3.4.1.2 and its subparagraphs) and design rights transferring to the Government upon program completion.

3.3.3.1. Reasons for TDP Changes

Materials, Processes, and Manufacturing

While many updates to the Legacy configuration have already been incorporated (e.g. process specification updates, sheet metal consolidations, substituting machining for forgings where appropriate, etc.), the prime contractor may identify materials, processes, or manufacturing methods within the TDP that are not cost effective due to improvements in technology or are non-preferred. In these cases, the prime contractor may propose alternative design and/or process specification changes for approval as referenced in SOW Section “3.3.3.3. TDP Change

Process”.

Diminishing Manufacturing Sources and Material Shortages (DMSMS)

Because sources of supply for all material and parts have recently been established, it is not expected that obsolete materials will present a challenge to the contractor. If an obsolescence condition is discovered, the contractor shall document the specific case and provide an alternative solution to the Government as referenced in SOW Section “3.3.3.3. TDP Change

Process”.

Proprietary Requirements

If the prime contractor identifies any proprietary requirements (e.g. process specifications, material specifications, etc.) within the TDP where a non-proprietary alternative doesn’t exist, they shall document the specific case with the exception of MMS5039 and PS14295 noted below. They then shall provide a non-proprietary alternative solution (e.g. redesign, alternate non-proprietary process specification, etc.) with a technical justification to include analysis or test data, if applicable, to the Government as referenced in SOW Section “3.3.3.3. TDP Change

Process”.

The following specifications will not be provided with the Technical Data Package due to proprietary rights (list may not be all inclusive):

MMS5039 Nylon Powder

PS14295 Fabrication and Assembly of Selective Laser Sintered Nylon Materials

Errors, Inconsistencies, Problems within the TDP

If errors, inconsistencies, or problems within the TDP are encountered, the prime contractor shall document the specific case and provide a solution to the Government in the form of TDP change request as referenced in SOW Section “3.3.3.3. TDP Change Process”.

3.3.3.2. TDP Change Requirements

Any changes to the TDP proposed by the prime contractor shall meet the following requirements:

Design changes shall not adversely affect other areas of the structure or require additional structural inspections.

Design changes shall not adversely affect wing/aircraft reliability, maintainability, supportability, or increase overall life cycle cost.

The ATTACK Wing Assembly shall be capable of flying 10,000 flight hours prior to the first

Scheduled Structural Inspection based on the current usage severity (known as Reconfigured

Post-Desert Storm Severe Spectrum).

Durability of Fatigue and Fracture Critical (F&FC) and CSI parts shall not be adversely affected.

All Interchangeability and Replaceability features, as defined in the TDP, shall be maintained forwards and backwards with any proposed changes.

Stiffness variations shall be held to less than 5% incrementally across the wing span. This shall require analytical justification.

Design changes are limited in scope such that the ATTACK Wing Assembly remains a derivative wing assembly (e.g. material alloys, product forms, and production technologies consistent with original production) thereby requiring no additional full-scale durability testing.

Design changes and their analyses shall include no proprietary information, or shall include a non-proprietary alternative if proprietary information is included.

Analysis Requirements

When desired changes to the TDP require a stress analysis, the contractor shall perform a detailed stress analysis for each design change incorporated into the ATTACK Wing Assembly.

The contractor shall perform the stress analysis using critical design loads and conditions provided in engineering reports furnished by the government. The stress analysis shall demonstrate a positive margin of safety for the design. The contractor shall provide results of the stress analysis to the Government as part of the change request package. The Government has final approval authority for the engineering methods and material data used in the stress analysis.

When desired changes to the TDP require a Damage Tolerance Analysis (DTA), the contractor shall perform a DTA for any design change incorporated into the ATTACK Wing Assembly that affects F&FC or CSI parts. The DTA shall be performed using AFGROW DTA software version current within A-10 SPO (software not Government provided). This requires compliance to the requirements of MIL-STD-1530, JSSG 2006 and the use of specific material models, retardation parameters and other technical details provided by the government as referenced in

SA220R0207. If new materials are used for which the Government does not have current material models, the contractor shall develop these models consistent with AF material models and will only be used with the approval of the A-10 SPO. The contractor shall provide the DTA with all supporting AFGROW data as part of the change request package. The DTA shall include, as a minimum, all input and output data used in the analysis.

Human Factors Engineering

The prime contractor shall apply human factors engineering design criteria, principles, practices, and standards to the design process to achieve effectiveness, simplicity, efficiency, reliability, and safety of system operation, training, and maintenance when considering all changes to the

TDP.

Standard Items

The contractor shall use standard parts, materials, and processes consistent with the

162D610010-1001 design when considering TDP changes. The requirements for installation, operation, maintenance, removal, and repair shall be satisfied by the use of common hand tools.

The use of special tools shall be reviewed by A-10 SPO engineering to ensure field or depot supportability.

Corrosion Prevention and Control

The prime contractor shall comply with requirements of the aircraft TDP for any changes proposed. The prime contractor shall comply with industry or military standards for corrosion prevention and control measures in the testing, handling, storage, and transportation of chemical and material products unless otherwise specified per tech data or applicable Government TO.

Weight and Balance

The contractor shall consider weight and balance when developing TDP changes. Maximum weight growth is limited to 50 pounds, and the weight distribution shall be maintained.

Process and Material Specifications

Process or material specifications developed or revised with the approval of A-10 SPO engineering shall conform to the requirements of MIL-STD-961.

Systems Approach

The prime contractor shall use a systems approach in consideration of any changes associated with manufacture of the ATTACK Wing Assembly. A systems approach ensures mission objectives are not degraded and the weapon system requirements are met.

3.3.3.3. TDP Change Process

Before initiating the TDP Change Process, the contractor shall submit an information request to proceed with Engineering Change Proposal (ECP) process or alternate process directed by the

Government. This information request system is not defined by this SOW; it shall be proposed in the Configuration Management Plan [CDRL A027].

For all changes to the TDP, the contractor shall first propose the change to the Government via an ECP. If the ECP is approved, the contractor shall then deliver change documentation to the

Government. These change documents shall be consistent with A-10 SPO engineering’s MBD and PLM data linking requirements. The Government will review and approve any changes.

The Government will then provide TDP updates back to the contractor that incorporate the proposed changes.

Change Proposal

The prime contractor shall submit an ECP [CDRL A013], as well as any supporting information

(e.g. new or updated stress analysis, Damage Tolerance Analysis, test reports, etc.), to the

Contracting Officer if changes are desired or required to the ATTACK Wing Assembly. The

Contracting Officer will coordinate with A-10 SPO Engineering and will provide written authorization prior to the contractor initiating the changes.

Change Documentation

3.3.3.3.2.1. Draft TDP for Parts/Assemblies

The prime contractor shall deliver a draft TDP [CDRL A024] to the Government. The draft TDP shall include a draft Engineering Order (EO) as referenced in SOW Section “3.3.3.3.2.3.

Engineering Order (E.O.),” draft 3-D models (if applicable), draft 2-D drawings (if applicable), and draft Part Reports (if applicable) used to produce the ATTACK Wing Assembly. The draft

TDP shall be capable of supporting competitive procurement, sustainment, and maintenance of the ATTACK Wing Assembly; it shall be consistent with the format of the TDP provided; part reports will be provided back to the government with recommended changes. Data developed and delivered under this effort shall designate the A-10 SPO as the Cognizant Engineering

Authority. The Government shall have unlimited rights to use, duplicate, modify, and distribute the drawings, specifications, engineering analyses, MBDs, and any other supporting data IAW

SOW Section “5.2.1. Governmental Rights.”

3.3.3.3.2.2. Draft TDP for Specifications/Program Documents

The prime contractor shall deliver a draft TDP [CDRL A024] to the Government. The draft TDP shall include a draft EO as referenced in SOW Section “3.3.3.3.2.3. Engineering Order (E.O.),” and draft specification (if required by ECP approval) used to produce the ATTACK Wing

Assembly. The draft TDP shall be capable of supporting competitive procurement, sustainment, and maintenance of the ATTACK Wing Assembly. The draft TDP shall be consistent with the format of the TDP provided. Data developed and delivered under this effort shall designate the

A-10 SPO as the Cognizant Engineering Authority. The Government shall have unlimited rights to use, duplicate, modify, and distribute the drawings, specifications, engineering analyses, MBDs, and any other supporting data IAW SOW Section “5.2.1. Governmental Rights.”

3.3.3.3.2.3. Engineering Order (EO)

For each Government approved change to the TDP, the prime contractor shall submit an AF

Engineering Order [CDRL A014] to incorporate the change: IMT Form 3925.

Technical Order Updates

The contractor shall identify Technical Orders (TOs) impacted by TDP changes and provide source data documentation to the Government IAW TM-86-01 [CDRL A029] and the A-10 Data

Exchange Specification.

The contractor shall perform clean-up of TCTO 1A-10C-520. This involves incorporating all supplements and adding all TDP changes prior to first article install. After all updated information/changes have been incorporated after first article install, the contractor shall deliver a finalized version of TCTO 1A-10C-520.

If a final purchase is made to complete the A-10 fleet with new wings the contractor shall deliver clean-up TO source data to address removal of TCTO 1A-10C-520 from affected TOs. This completed TO source data shall be delivered 6 months prior to the last wings being delivered from the contractor to the government.

Weight and Balance Report

If TDP changes result in a weight change greater than five lbs., or affect balanced components

(e.g. deceleron assembly, trim tab assembly, etc.), the contractor shall generate an updated

Weight and Balance Report for the ATTACK Wing Assembly [CDRL A021]. The contractor shall deliver the Weight and Balance Report after the construction of the First Article Exhibit

Assembly of Government accepted change. The contractor shall generate an updated Weight and Balance Report if changes during production alter the weight and balance.

3.4. General Productions Tasks

3.4.1. Manufacturing Process Development and Special Tooling

The TDP provided by the Government will be adequate to support the production of ATTACK wings. The specific production processes to include raw material procurement, production process development, tooling, planning, quality assurance, etc., are the responsibility of the prime contractor. Controlled processes are critical to meeting required delivery dates and to ensure structural integrity is maintained throughout the manufacturing process. The requirements stipulated in MIL-STD-1530 shall be used in developing production capability.

3.4.1.1. Manufacturing Processes

The prime contractor shall prepare a list of proposed manufacturing methods with justification for evaluation and approval by A-10 SPO engineering prior to use [CDRL A035].

Prohibited Processes

Laser, plasma, Electrical Discharge Machining (EDM), torch, and other thermal processes (e.g.

cutting, trimming, or coating removal) are not currently approved for production/procurement of

A-10 parts. Likewise, non-thermal cutting processes involving high pressure fluids and slurries

(e.g., water jet) are also not currently approved for use in production/procurement of A-10 parts.

Additionally, plastic media blasting and similar coating removal processes are approved for use at A-10 USAF Depots only. These processes may not be used in the production/procurement of

A-10 parts unless qualified and approved by A-10 SPO Engineering. For any questions regarding qualification of any of the aforementioned processes, contact A-10 SPO engineering through the Contracting Officer.

Concentric Bushings

To preserve maintainability, all manufacturing processes and associated tooling shall ensure all bushings in the final deliverable product are concentric unless approved by A-10 SPO

Engineering or specifically approved in the TDP.

3.4.1.2. Special Tooling

Government Furnished Property (Attachment G) contains available tooling from the last wing procurement effort. While considerable effort has been placed in identifying this tooling, the list may not be final or all-inclusive. The contractor may utilize this tooling or develop their own.

The tooling is located and packaged at AMARG (Davis Monthan AFB, AZ).

The prime contractor shall design (if not using GFI special tooling TDP for production) and produce required special tooling for production pursuant to the chosen manufacturing/process methods to fabricate ATTACK Wing Assemblies at a rate consistent with contract requirements.

Special tooling which is specifically designed and produced to manufacture the ATTACK Wing

Assembly shall become Government property immediately upon production of the tool. Final disposition of the specialized tooling shall be as directed by the Contracting Officer. Any duplication and/or production of master tooling shall be approved by A-10 SPO Engineering.

The special tooling developed under the ATTACK contract shall be controlled per FAR 52.245-

1.

Special Tooling Definition

The prime contractor shall prepare a list of tooling used, and its purpose, for Government evaluation and disposition [CDRL A034].

Special Tooling Drawings and MBDs

At a minimum, and only for those tools the prime contractor or subcontractors have developed or modified beyond what was provided in the Tooling TDP, the prime contractor shall deliver a

Tooling TDP before the first Production Readiness Review, second submission 60 calendar days before the end of production, and at the Government’s request [CDRL A023]. If only a detail part is modified or created, the remaining parts in the tooling assembly do not need to be updated to the standard specified in this statement of work. The TDP shall contain all parts in that tooling assembly in order to retain the assembly structure and associated parent child relationships therein. The contractor produced tooling TDP shall be consistent with SOW Section “3.3.1.1.

Model Based Definition (MBD).” The tooling TDP shall support sustainment and maintenance of the ATTACK Wing Assembly. The Government shall have unlimited rights to use, duplicate, modify, and distribute the drawings, specifications, and MBDs developed under this effort IAW

SOW Section “5.2.1. Governmental Rights.”

GFI Special Tooling TDP

A special tooling TDP is provided as GFI to be used at prime contractor discretion and risk. The

GFI special tooling TDP may or may not be complete, may include unnecessary components, and has not been validated/verified to produce conforming product. The Government is not responsible for any errors or missing data in the GFI special tooling TDP. The contractor is fully responsible to ensure the ATTACK Wing Assembly meets all TDP requirements.

3.4.1.3. Special Tooling Report

The prime contractor shall deliver a Special Tooling Report [CDRL A042] that includes a brief description of tools in the Special Tooling list [CDRL A034], their intended use, associated part and/or assembly numbers, and pictures of the tools in use.

3.4.1.4. Tooling Control

The prime contractor shall define the methods of controlling, maintaining, and tracking master and special tooling used for production. The prime contractor shall control, maintain, and track the tooling in their property management system per FAR 52.245-1. In addition, they shall provide a quarterly government property detail report to the government contracting official. If master tooling or special tooling is in use by another contractor on a different contract, a loan use agreement will need to be in place prior to use. The contractor is responsible for any damage or loss of the tooling, and they shall return or deliver it to the government in serviceable condition.

Master Tooling Control

All master tooling provided by the government shall not be modified by the contractor per FAR

52.245-1. The government shall retain ownership of all tooling provided to the contractor. The contractor is responsible for all packaging per MIL-STD-2073 and shipping costs for moving master tooling to sub-contractors after the prime contractor has accepted stewardship of master tooling. The contractor shall inspect all master tools for damage upon receipt and prior to shipping while verifying that the tool is in proper working order. Any damage or non-conformances found on master tooling shall be reported to A-10 SPO engineering with a proposed disposition for government approval or disposition. The contractor is responsible for any damage to master tooling while it is in their possession, and they shall return or deliver it to the government designated location in serviceable condition.

3.4.1.5. Interchangeability and Replaceability (I&R)

The ATTACK Wing Assembly contains I&R items as defined in MIL-HDBK-505. The prime contractor shall provide I&R between ATTACK Wing Assembly components/assemblies for all

I&R interfaces as defined in the TDP. All I&R production parts shall be managed per MIL-I-

8500. A First Article Demonstration (FAD) is required for all interchangeable items. Dates shall be provided to the Government at least 10 working days prior to event to allow Government participation/witness of the FAD. The results of the FAD shall be presented to the Government for approval prior to acceptance of the item in questions. The prime contractor shall be responsible to define the method of controlling individual I&R features, through the use of tooling and/or other means.

Interchangeable Replaceable Requirements List

The Interchangeable Replaceable Requirements List (IRRL) shall be created by the prime contractor, approved by A-10 SPO Engineering [CDRL A043], and maintained throughout the life of the contract. The IRRL shall list discrete features to be controlled, the method of compliance, and those parts/assemblies requiring cycle checks for all I&R items in the ATTACK

Wing Assembly. The IRRL shall define the method of demonstrating I&R within the assembly process and during the First Article Demonstration (FAD) according to MIL-I-8500 using

Control Media and/or other ATTACK Wing Assembly parts. Other methods of demonstrating

I&R may be approved by A-10 SPO Engineering and documented in the IRRL. Any duplication and/or production of master tooling shall be documented in the IRRL.

3.4.1.5.1.1. Interchangeable by Nature of Manufacture

With prior Government approval, and as documented in the IRRL [CDRL A043], Interchangeable by Nature of Manufacture (INM) is an acceptable method of meeting interchangeable requirements. For INM items, normal inspection procedures and manufacturing controls shall be considered satisfactory control of dimensional accuracy, manufacturing processes, and tooling. INM items do not require cycle checks.

Backward Interchangeability and Replaceability

The prime contractor shall provide backward I&R between ATTACK Wing Assembly components/assemblies and EWA components/assemblies for all interfaces defined in the

ATTACK Wing Assembly TDP. The IRRL [CDRL A043] shall define the method of demonstrating I&R between the ATTACK Wing Assembly and the EWA according to MIL-I-

8500 using Control Media and/or EWA parts. Other methods of demonstrating backwards I&R may be approved by A-10 SPO Engineering and documented in the IRRL.

Cycle Checks of Control Media

The interval between cycle checks on all control media, as defined in MIL-I-8500, shall be approved by A-10 SPO Engineering prior to production. Any changes made to cycle check intervals during production shall be approved by A-10 SPO Engineering prior to implementation.

3.4.2. Production Preparation and Planning

The prime contractor shall use the TDP as the basis for all manufactured and assembled parts.

The prime contractor shall demonstrate their partners, subcontractors, and suppliers are in place to support production.

3.4.2.1. Production Qualification

The prime contractor shall provide a Production Qualification Plan (PQP) [CDRL A030] prior to producing the ATTACK Wing Assembly first article. The Government will approve the plan

(and all revisions) prior to the contractor producing first article detail parts. The plan shall address:

Partners, subcontractors, and suppliers in place to support production

Production capacities at all levels to support the expected delivery rates

The manufacturing, production, final assembly, and inspection processes available to produce the wing and corresponding certifications of the processes and personnel

Equipment and facilities available and planned to produce the ATTACK Wing Assembly

Control and certification of materials, parts, assemblies, and services provided by outside vendors in support of this effort

Verification that all special tooling and tools are qualified to produce the wing to the TDP requirements on a repeatable basis

Tool validation and verification (to include procedures and frequency)

Master (GFE) and special tooling control

List approved sources that will provide Fatigue and Fracture Critical (F&FC) and CSI

CSI Inspection Plan

The prime contractor shall develop a CSI Inspection Plan, which will be reviewed and approved by the Government, to supplement the PQP for all parts and assemblies identified on the CSI List

(Attachment B). This plan shall have specific provisions for demonstrating conformance to CSI requirements and address how vendors will receive Government approval to be a CSI provider.

Risk Assessment

The prime contractor shall perform a risk assessment of the manufacturing/production processes of the ATTACK Wing Assembly and identify factors that could impact the production schedule or quality of the wing. The contractor shall provide this analysis, as well as risk mitigation, to the Government prior to production. The analysis shall be included in the PQP.

3.4.2.2. Functional Configuration Audit Plan

The prime contractor shall develop a Functional Configuration Audit (FCA) plan [CDRL A025] that describes how…