Attachment_1_PWS.pdf

PERFORMANCE WORK STATEMENT

(PWS)

For:

T-38C Fuselage Structural Modification Kit Integration – Pacer Classic III (PC III)

Structural Modification Program

14 July 2014

AFLCMC/WLDMA

staci.draney.1@us.af.mil

(801) 586-9871 sean.reiter.1@us.af.mil

(801) 586-8059

AIR FORCE LIFE CYCLE MANAGEMENT CENTER

Mature and Proven Aircraft Branch

T-38 System Program Office Hill Air Force Base, Utah 84056 i mailto:staci.draney.1@us.af.mil mailto:sean.reiter.1@us.af.mil

TABLE OF CONTENTS

RECORD OF REVISIONS ........................................................................................................ IV LIST OF TABLES ........................................................................................................................ V ACRONYMS AND ABBREVIATIONS ................................................................................... VI

1.0 DESCRIPTION

1.1 Scope

2.0 GENERAL INFORMATION

2.1 General Requirements

2.2 Programmatic Objectives and Goals

2.3 Period of Performance

2.4 Specific Requirements

2.4.1 Modification Kits

2.4.2 Supplemental Kits

2.4.3 Item Unique Identification Requirements

2.4.4 First Article Test (FAT)

2.4.5 Packaging/Labeling

2.4.6 Deficiency Resolution

2.4.7 Monthly Status Reports

2.4.8 Meetings

2.4.8.1 Weekly Technical Interchange Meetings (TIM)

2.4.8.2 Program Management Reviews (PMR)

2.4.8.3 Post Award Conference

2.4.8.4 Final Review

2.4.9 Integrated Master Schedule

2.4.10 Risk Mitigation

2.4.11 Schedule

2.4.12 Operational Safety, Suitability, and Effectiveness

2.4.13 Travel

2.4.14 Data Compatibility

3.0 GOVERNMENT FURNISHED PROPERTY (GFP) AND SERVICES

3.1 T-38C Configuration Drawings Technical Data and Material/Equipment Provided

3.1.1 Configuration Drawings

ii

3.1.2 Technical Data

3.1.3 Material/Equipment

3.2 Security and Access to Government Facilities and Equipment

3.2.1 Security Clearance

4.0 QUALITY CONTROL

4.1 Quality Assurance

4.2 Contracting Officer’s Representative

5.0 SERVICE SUMMARY

ATTACHMENT ONE: CDRLS

ATTACHMENT TWO: APPLICABLE DOCUMENTS

ATTACHMENT THREE: PC III GOVERNMENT POINTS OF CONTACT (POC)

ATTACHMENT FOUR: BILL OF MATERIALS (BOM)

iii

RECORD OF REVISIONS

REV DATE PAGE(S)

AFFECTED

PARA.

AFFECTED REASON FOR REVISION

05/29/2014 N/A N/A Original iv

LIST OF TABLES

Page

Table 1 – Critical Safety Items Requiring Source Qualification ...............................................…..2 Table 2 – Service Summary (SS) for PC III – Phase II .............................................................…..6 Table 3 – Applicable Contract Data Requirements List (CDRLs) Table 4 – Government Points of Contact ................................................................................…..10 v

ACRONYMS AND ABBREVIATIONS

AETC - Air Education and Training Command BOM - Bill of Materials CDRL - Contract Date Requirements List CLIN - Contract Line Item Number CO - Contracting Officer COR - Contracting Officer’s Representative CSI - Critical Safety Item DCMA - Defense Contracting Management Agency DO - Delivery Order FAT - First Article Test GFE - Government Furnished Equipment IPT - Integrated Product Team IMS - Integrated Master Schedule IUID - Item Unique Identification NGTS - Northrop Grumman Technical Services OSS&E - Operational Safety, Suitability, and Effectiveness PC III - Pacer Classic III POC - Point of Contact PQDR - Product Quality Deficiency Report PN - Part Number PM - Program Manager PMR - Program Management Review PoP - Period of Performance PWS - Performance Work Statement RFP - Request for Proposal SPO - System Program Office TCTO - Time Compliance Technical Order TO - Technical Order TDP - Technical Data Package TIM - Technical Interchange Meeting vi

1.0 DESCRIPTION

This Performance Work Statement (PWS) outlines the general requirements to support the T- 38C structural modification program, Pacer Classic III (PC III). This effort will provide the necessary structural modification kits for T-38C aircraft. The PC III modification will maintain Operational Safety, Suitability, and Effectiveness (OSS&E) throughout the lifetime of the aircraft. This requirement is the outcome of a T-38 structural sustainment evaluation. Air Education and Training Command (AETC) and the T-38 System Program Office (SPO) are now focused on removing and replacing key fuselage structural components on identified T-38C aircraft historically exposed to the greatest fatigue damage. PC III is the third major structural overhaul on the T-38C fuselage.

1.1 Scope

This PWS specifies the programmatic and technical activities required to accomplish the PC III modification parts procurement, kit assembly, and necessary tasks to ensure execution of the structural modification kits. These tasks are for the manufacturing and kitting of fuselage structural components for PC III T-38C aircraft. PC III has two distinct phases described as follows: Phase I – Sole-source to Northrop Grumman Technical Services to provide up to 51 kits; Phase II – Competitive (small business set-aside) will provide the remaining 74 required kits. Phase II, detailed in this PWS, will provide the necessary integration of kits, program management, logistics, discrepancy reporting/resolution, and sub-contract management. The Period of Performance (PoP) and ordering period for Phase II will span five years, with an anticipated delivery period of six years. Any additional phases would be executed as separate contractual efforts as deemed appropriate by the Government.

2.0 GENERAL INFORMATION

2.1 General Requirements

This PWS is intended to provide the structural modification kits for the PC III effort as well as the program management and reporting necessary for the completion of the PC III Structural Modification Kit Integration.

2.2 Programmatic Objectives and Goals

Recent engineering test and analysis suggest that a significant number of aircraft in the T-38 fleet are at risk for grounding prior to 2020 due to cracking in fatigue-critical structure. Without key replacement parts, such as dorsal longerons, the situation would adversely affect mission capability and fleet viability.

PC III is the solution for ensuring the structural service life of the T-38 fleet until 2020. PC III will replace vital, fatigue sensitive structural items including the following: steel dorsal longerons, cockpit longerons, and the upper/lower center longerons. In addition, associated bulkheads/formers, skins, and floors will be included in this remove and replace effort.

The Contractor shall perform the following integration functions: material procurement, manufacturing, kit assembly, delivery of kits, and deficiency reporting/remediation.

2.3 Period of Performance

The PoP for this requirement will be from contract award through the acceptance of the final modification kit. Beginning at contract award, the ordering period will span five years and the anticipated delivery period will span six years.

2.4 Specific Requirements

The Contractor shall be required to perform the tasks outlined in this PWS; subparagraphs 2.4.1 through 2.4.14.

2.4.1 Modification Kits

Provide complete parts and hardware kits as specified in the Bill of Materials (BOM), located in Attachment Four, and Technical Data Package (TDP) attachments of the Request for Proposal (RFP). Parts and hardware shall comply with the specifications identified in the TDPs attached to the RFP. Nine part numbers, listed below in Table 1, are classified as Source Directed Parts and must be manufactured by a qualified/directed source. Source Qualification Statements can be found in Attachment A of the TDPs. Defense Contracting Management Agency inspection of these characteristics will be communicated upon award and the contractor will need to facilitate these inspections.

Table 1 – Source Directed Parts *110-1101-13

Upper (Cockpit) Longeron F.S.

144-284 LH

*3-11413-3 Steel Dorsal

Longeron, F.S.

284-445, LH

2-11412-13 Upper (Center) Longeron, F.S.

284-325, LH

2-11308-13 Lower (Center) Longeron, F.S.

284-325, LH

3-11608-503 C.F.S.

487.223 Former

*110-1101-14 Upper (Cockpit) Longeron F.S.

144-284 RH

*3-11413-4 Steel Dorsal

Longeron, F.S.

284-445, RH

2-11412-14 Upper (Center) Longeron, F.S.

284-325, RH

2-11308-14 Lower (Center) Longeron, F.S.

284-325, RH

*Northrop Grumman Source Directed Parts

2.4.2 Supplemental Kits

Provide supplemental kits that may result from validation/verification activities. Supplemental kits will be an un-priced Contract Line Item Number (CLIN); however, this CLIN will have supplemental kit pricing matrix at the time of contract award. If/when supplemental kits are required; the Air Force will require a fixed price proposal to award a Delivery Order (DO) to produce any additional parts or supplemental kits. A Request for Proposal (RFP) will call for submittal as soon as possible, but no later than 30 calendar days after notification. Proposal costs may be paid for by the Air Force.

2.4.3 Item Unique Identification Requirements

Mark Item Unique Identification (IUID) relevant parts in accordance with MIL-STD-130.

2.4.4 First Article Test (FAT)

Coordinate and comply with Government FAT requirements. All kit contents, except the Northrop Grumman directed parts (RH/LH Upper Cockpit Longerons (Part Number (PN) 110-

1101-13, 110-1101-14) and the RH/LH Steel Dorsal Longerons (PN 3-11413-3, 3-11413-4)), will require FAT or a waiver approved by the AF. The Contractor shall account for Government FATs in detail within the provided Integrated Master Schedule (IMS). First Article partial waivers can be granted for existing parts suppliers for the specific item(s) being produced under existing contracts. These shall be submitted specifically stating the sub-kit, part number, nomenclature, the existing supplier (name and cage code) and existing prime supplier (name and cage code). Upon waiver approval, these items will not require shipment to First Article Lab.

2.4.5 Packaging/Labeling

Clearly mark packages in accordance with contract requirements and include a kit contents list with each kit. All kits will be packaged and marked for domestic shipments in accordance with delivery order requirements or as identified in Section D of the contract, and in the most current revision of MIL-STD-2073-1D, MIL-STD-130, and MIL-STD-129.

2.4.6 Deficiency Resolution

Provide direct engineering and programmatic support to the Government regarding any modification kit deficiency issues, technical or otherwise. Responses to deficiency reports shall be provided within five calendar days of discovery. If more than five calendar days will be required to respond then the Contractor will propose an approach and expected schedule to resolution. Discrepancies/deficiencies will be reported and tracked through the Product Quality Deficiency Report (PQDR) system. The plan for correction of deficiencies shall be provided within 10 calendar days of disposition. Corrective and preventive action shall be implemented on future DOs to eliminate repeat discrepancies. (CDRL A001)

2.4.7 Monthly Status Reports

Submit status reports by the 15th of the month following the period being reported to the Government. Monthly status reports will contain the following information: 1) Manufacturing status and schedule, 2) Kitting status and schedule, 3) Subtotal travel, and 4) Deficiency reporting and remedial planning. (CDRL A002)

2.4.8 Meetings

2.4.8.1 Weekly Technical Interchange Meetings (TIM)

Conduct weekly information exchanges between the Government and the Contractor. This is a minimum requirement and the frequency may be increased or decreased by the Government as deemed necessary. Information exchanges via teleconferencing are acceptable. Support for this meeting will include preparation of briefing materials as appropriate and meeting minutes.

Meeting minutes are to be submitted no later than two days after weekly meetings. (CDRL A003)

2.4.8.2 Program Management Reviews (PMR)

Conduct quarterly PMRs. Support for these meetings will include preparation of briefing materials as appropriate to be submitted no later than 7 calendar days prior to the scheduled conference date and preparation/distribution of meeting minutes no later than 10 calendar days following. (CDRL A003)

2.4.8.3 Post Award Conference

Conduct a post award conference to review the Government requirements and the Contractor activities that must be accomplished within 30 calendar days after contract-award, and before a comprehensive IMS has been fully developed. Support for this meeting will include preparation of briefing materials as appropriate to be submitted no later than 7 calendar days prior to the scheduled conference date and preparation/distribution of meeting minutes no later than 10 calendar days following. (CDRL A003)

2.4.8.4 Final Review

Plan and prepare a final review conference to present the results and discuss the outcomes of this effort. This review shall be held at the conclusion of each fiscal year. Support for this meeting will include preparation of briefing materials as appropriate and a final report to be submitted no later than 7 calendar days prior to the scheduled conference date and preparation/distribution of meeting minutes no later than 10 calendar days following. (CDRL A003)

2.4.9 Integrated Master Schedule

Provide a comprehensive IMS for the processes and milestones involved in kit development, FAT, procurement, production, assembly, and delivery. The schedule will also address necessary subcontractor actions and milestones. The file must be unlocked and format must be Microsoft Project 2010 or compatible earlier version. The IMS will be reviewed monthly at the corresponding TIM. (CDRL A004)

2.4.10 Risk Mitigation

Provide a thorough risk analysis and mitigation plan from the date of contract award through the end of the PoP. The risk mitigation plan shall be reviewed semiannually at the corresponding

PMR. (CDRL A005)

2.4.11 Schedule

Perform according to the Contractor developed IMS and maintain on-schedule delivery dates for all kits in accordance with the issued DO. The Government will issue DOs lead-time away.

When applicable, Liquidated Damages of $5,740 per day will be assessed in accordance with FAR 52.211-11 in Section F if late delivery results from a contractor caused delay. The Schedule, Section B will specify delivery dates in each DO. The Government requires the Contractor to make advance notification as specified in the Services Summary.

2.4.12 Operational Safety, Suitability, and Effectiveness

Ensure kits and parts meet OSS&E requirement as defined in MIL-HDBK-514 as well as any CSI characteristics defined in the provided TDPs.

2.4.13 Travel

Propose necessary travel requirements with each DO proposal. Travel will be issued on a Cost Reimbursable No Fee CLIN. The Contractor must attain approval from the Government Program Office NLT seven calendar days prior to each trip.

2.4.14 Data Compatibility

Provide Government compatible and unlocked documents for all Contractor work. The Government uses a MS Windows 7 based operating system, 2010 MS Office, and current versions of Adobe products.

3.0 GOVERNMENT FURNISHED PROPERTY (GFP) AND SERVICES

3.1 T-38C Configuration Drawings Technical Data and Material/Equipment Provided

3.1.1 Configuration Drawings

The Government will provide the Contractor with Government owned Technical Orders (TO), Time Compliant Technical Orders (TCTO), drawings, specifications, and contractor reports as they are identified and requested by the Contractor and as they pertain to the PWS.

3.1.2 Technical Data

The Government will provide the Contractor with all necessary Government TCTOs, Air Force Form 761 packages, and Attachment A data to accomplish the tasks detailed in this PWS.

3.1.3 Material/Equipment

Applicable structural components (GFP) may be provided by the government to aid in Contractor process and procedure development and verification. Upon contract award, Contractors shall have the means to provide effective and efficient stewardship of Government property. GFP will be documented in an attachment to the contract. GFP must be returned to the Government in the state in which it was originally given for installation on PC III production aircraft. Contractors shall adhere to DFARs PGI 245.1 for GFP.

All required tooling to include but not limited to reference tools, shop aids, templates, fabrication tools, machine tools, bonding tools, assembly and installation tools, inspection tools, extrusion dies and castings shall be identified and produced by the contractor.

Upon payment through Wide Area Workflow and at contract conclusion, all tooling produced and funded under this effort will become property of the Government through passage of title.

Disposition instructions for all tooling produced and GFP will be given at a later date.

3.2 Security and Access to Government Facilities and Equipment The Contractor shall be responsible for safeguarding all Government property provided for the Contractor’s use. Contractors are prohibited from Government facilities without the presence of Government personnel. The Contractor shall coordinate the need, time, and personnel requiring access to Government facilities with the Government Program Manager (PM), at least one week prior to the requested need date. The Government PM, or designated representative, will coordinate between the Contractor and base personnel as needed.

3.2.1 Security Clearance

The efforts required for this task are UNCLASSIFIED and will not require Contractor personnel to obtain a security clearance. Contractor personnel shall abide by all Government rules, procedures, and standards of conduct. Contractors requiring access to Government Automated

Information Systems shall have background investigations and security awareness training completed prior to the start of contract performance. When the PoP is complete and/or the Contractor personnel leave work on this project, they will return all access cards and base identification badges prior to departure.

4.0 QUALITY CONTROL

The Contractor shall abide by quality control programs the Government deems necessary. All tasks outlined in this PWS will be conducted in a professional manner and in accordance with the CDRLs, Service Summary, and official Government guidance in order to provide products that are accurate, free of error, and complete.

4.1 Quality Assurance

The Government will periodically evaluate the Contractor’s performance through Contracting Officer’s Representative (COR) assessments of performance, products, and services performed.

The COR could evaluate the Contractor’s performance through semiannual on-site inspections of the Contractor’s Quality Control Program. The COR may inspect each product as completed or increase the number of quality control inspections if deemed necessary due to repeated deficiencies discovered during inspection, delivery, or installation. The COR may also decrease the number of inspections if performance merits. The Contractor and all sub-vendors shall have and maintain AS9100 or equivalent certification.

4.2 Contracting Officer’s Representative

The COR or designated alternate is the authorized Government representative who will perform assessments of the Contractor’s performance. Following contract award, the identity of the COR, with a letter of delegation and authority from the Contracting Officer (CO) will be promptly furnished to the successful bidder/offeror. The COR or alternate will inform the CO when deficiencies occur and will request corrective action. The COR will make note of the deficiency on their dated assessment checklist which will also be signed by the contract manager.

The role of the COR is strictly to monitor and assess performance; the COR does not have the authority to obligate the Government.

5.0 SERVICE SUMMARY

Table 2 describes the Service Summary for tasks outlined in this PWS. Efforts described in this PWS, will be for the following services: technical support, logistics, and program management related activities.

Table 2 – Service Summary for PC III – Phase II Item No. Performance Objectives PWS

Reference Performance Threshold Remediation

Modification Kits: The Contractor is to deliver the required modification kits to support the PC III Structural Modification Program

2.4.1, 2.4.2, 2.4.3, 2.4.4, 2.4.5, 2.4.11

No kit deliveries may be late;

the Contractor shall notify the Government as soon as possible but no later than one month prior if the scheduled contractual kit delivery is not going to be met

Contractor shall provide Government with a mutually acceptable remediation plan within two weeks of notification or two weeks prior to the scheduled delivery date

2 Deficiency Reports: The Contractor shall provide a deficiency report and get well plan upon discovery of each discrepancy, technical or contractual

2.4.6 No delivered assets are to be

deemed defective

Deficiencies shall be brought to the Government’s attention immediately upon discovery, and a discrepancy report submitted through the PQDR system within seven calendar days of discovery. Contractor shall provide an acceptable report no later than seven calendar days after notification of non-acceptance. Contractor shall provide an acceptable get-well plan within seven calendar days after notification of non-acceptance

3 Monthly Status Reports:

The Contractor shall provide a monthly report including the following: 1) Manufacturing status and schedule, 2) Kitting status and schedule, 3) Subtotal travel, 4) Discrepancy reporting and remedial planning

2.4.7 Contractor shall provide

monthly status reports to provide accurate progress updates towards delivery dates by the 15th of every month following the period being reported

Contractor shall provide an accurate report no later than seven calendar days after notification of non-acceptance

4 Integrated Master Schedule: The Contractor shall provide and maintain an IMS to include all steps necessary to complete the requirements herein

2.4.9 First submission shall be

within 30 calendar days after contract award; the schedule shall be updated, reviewed, and submitted to the Government monthly. The file format must be Microsoft Project and unlocked

Contractor shall provide an accurate schedule no later than seven calendar days after notification of non-acceptance

5 Risk Mitigation Plan: The Contractor shall identify possible risks in combination with the Government IPT and develop and maintain a Risk Mitigation Plan

2.4.10 First submission shall be

within 45 calendar days post contract award; the plan shall be updated, reviewed, and submitted to the Government semiannually at the corresponding PMR

Contractor shall provide an acceptable plan no later than seven calendar days after notification of non-acceptance

ATTACHMENT ONE: CDRLs

Table 3 – CDRL List for PC III PWS Paragraph CDRL CDRL Description DID

2.4.6 A001 Discrepancy Reports/Get-well Plans FAA-ILS-014

2.4.7 A002 Monthly Status Reports DI-MGMT-80227

2.4.8 A003 Briefing Material DI-MGMT-81605

2.4.9 A004 Integrated Master Schedule DI–MGMT-81861

2.4.10 A005 Risk Mitigation Plan DI-MGMT-81808

ATTACHMENT TWO: Applicable Documents

MIL-STD-129 –“Military Marking for Shipment and Storage,” 2007

MIL-STD-130 – “Identification Marking of U.S. Military Property,” 2007

MIL-HDBK-514 – “Operational Safety, Suitability, & Effectiveness for the Aeronautical Enterprise,” 2003

MIL-STD-2073-1D –“Standard Practice for Military Packaging,” 2005

ATTACHMENT THREE: PC III Government Points of Contact (POC)

Table 4 – POC List for PC III Position Name Email Phone Number

Contracting Officer Russell Walter russell.walter.1@us.af.mil (801)777-6295 Contract Specialist Aaron Parr Aaron.parr.1@us.af.mil (801)586-7781 Program Manager Staci Draney staci.draney.1@us.af.mil (801)586-9871 Aerospace Engineer Matthew Morgan Matthew.morgan.22@us.af.mil (801)777-5281 Logistics Manager David Aguillard david.aguillard.1@us.af.mil (801)586-3091 Program Manager Sean Reiter sean.reiter.1@us.af.mil (801)586-8059

ATTACHMENT FOUR: BILL OF MATERIALS (BOM)

The final kit BOM will be provided at contract award