12._J-1_PCIII_Fastener_PWS.docx

PERFORMANCE WORK STATEMENT

(PWS)

For:

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

21 May 2015

AFLCMC/WLDMA

christopher.alfaro@us.af.mil

(801) 777-9466 staci.draney.1@us.af.mil

(801) 586-9871 russell.walter.1@us.af.mil

(801) 777-6295

AIR FORCE LIFE CYCLE MANAGEMENT CENTER

Mature and Proven Aircraft (MAPA) System Program Office (SPO) T-38 Program Office Hill Air Force Base, Utah 84056

Table of Contents

Table of Tables

Table 1 - Record of Revision

ACRONYMS AND ABBREVIATIONS

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 fastener 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 Program Office 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.

PROGRAM BACKGROUND

PC III has two distinct phases described as follows: Phase I – Sole-source to Northrop Grumman Technical Services (NGTS) to provide aircraft structural modification kits and fastener kits for up to 51 aircraft; Phase II – Competitive (small business set-aside) will provide the remaining required aircraft structural modification kits and the fastener kits for 99 aircraft.

SCOPE

This PWS specifies the programmatic and technical activities and tasks required to accomplish the PC III fastener(s) procurement, such as manufacturing and kitting of fasteners for PC III T-38C aircraft. The Contractor shall perform the following integration functions: program management, material procurement, manufacturing, logistics, fastener kit assembly, delivery of kits, deficiency reporting /remediation and sub-contract management.

GENERAL INFORMATION

General Requirements This PWS is intended to provide instruction for the fastener kits for the PC III effort, as well as the program management and reporting necessary for the completion of the PC III Program.

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, the situation would adversely affect mission capability and fleet viability. The PC III Program is the solution for ensuring the structural service life of the T-38C fleet until 2029. PC III will replace vital, fatigue sensitive structural items such as 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. Due to such replacements, new fasteners are required.

Period of Performance (PoP) 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. Any additional phases would be executed as separate contractual efforts as deemed appropriate by the Government.

Specific Requirements The Contractor shall be required to perform the tasks outlined in this PWS; subparagraphs 2.4.1 through 2.4.12.

Fastener Kits Provide complete fastener kits as specified in the Bill of Materials (BOM), located in the Technical Data Package (TDP). Parts and hardware shall comply with the specifications identified in the TDPs attached to the RFP. Source Directed Parts must be manufactured by a qualified/directed source. These parts are documented 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.

Item Unique Identification Requirements Mark Item Unique Identification (IUID) relevant parts in accordance with MIL-STD-130N w/CHANGE 1, dated 16 Nov 2012.

First Article Test (FAT) Coordinate and comply with Government FAT requirements located in the Technical Data Package (TDP), specifically the FAT form and the BOM. Source Directed parts to proprietary sources (i.e. Northrop Grumman) will not require FAT. 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.

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 accordance with the most current revision of MIL-STD-2073-1E w/CHANGE 1, MIL-STD-130N w/CHANGE 1, and MIL-STD-129R.

Contract Data Requirements List (CDRL) Provide all deliverables listed in Attachment 1. Delivery requirements can be found in DD Forms 1423-1. 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.

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) Discrepancy reporting and remedial planning. (CDRL A001) Deficiency Resolution Provide direct engineering and programmatic support to the Government regarding any fastener 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 delivery orders to eliminate repeat discrepancies. (CDRL A001) Meetings Bi-weekly Technical Interchange Meetings (TIM) Conduct bi-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. (CDRL A002) Meeting minutes are to be submitted no later than two days after weekly meetings.

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 the PMR. (CDRL A002) 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 the conference. (CDRL A002) 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 the review. (CDRL A002) Integrated Master Schedule (IMS) 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 A003) 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 A004) 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. The Schedule, Section B will specify delivery dates in each DO.

CSI Requirements Ensure kits and parts meet any CSI characteristics defined in the provided TDPs.

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.

GOVERNMENT FURNISHED PROPERTY/INFORMATION (GFP/I)

T-38C Configuration Drawings Technical Data and Material/Equipment Provided Configuration Drawings The Government will provide the Contractor with Government owned drawings, specifications, and any previous T-38C contractor reports as they are identified and requested by the Contractor, and as they pertain to the PWS. Distribution statements and/or disposition instructions for all drawings and specifications can be found on each document.

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. Distribution statements and/or disposition instructions for all Government TCTOs, Air Force Form 761 packages, and Attachment A data can be found on each document.

Contractor Acquired Property (CAP) 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 Government acceptance and at contract conclusion, all CAP tooling produced and funded under this effort will become property of the Government through passage of title. Disposition instructions for all tooling produced will be given at a later date.

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.

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.

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.

Quality Assurance The Government will periodically evaluate the Contractor’s performance through Defense Contract Management Agency (DCMA) assessments of performance, products, and services performed. Following contract award, the identity of the DCMA Quality Assurance Specialist (QAS) or representative, with a letter of delegation and authority from the Contracting Officer (CO) will be promptly furnished to the successful bidder/offeror. The QAS could evaluate the Contractor’s performance through semiannual on-site inspections of the Contractor’s Quality Control Program. The QAS 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 QAS may also decrease the number of inspections if performance merits. The Contractor and all sub-vendors shall have and maintain AS9100 compliance or equivalent compliance/certification.

ATTACHMENT ONE: Contract Data Requirements List (CDRL) Table 2 – CDRL for PC III

ATTACHMENT TWO: Applicable Documents MIL-STD-129R –“Military Marking for Shipment and Storage,” 2014 MIL-STD-130N w/CHANGE 1 – “Identification Marking of U.S. Military Property,” 2012 MIL-HDBK-896 – “Manufacturing and Quality Program,” 2008 MIL-STD-2073-1E w/CHANGE 1 –“Standard Practice for Military Packaging,” 2011

ATTACHMENT THREE: PC III Government Points of Contact (POC) Table 3 – POC List for PC III

ATTACHMENT FOUR: BILL OF MATERIALS (BOM)

The most current BOM will be mailed and provided the same day of solicitation issuance on Digital Versatile Disk (DVD). Offeror’s shall request and sign a Non-Disclosure Agreement (NDA) prior to receiving the DVD by contacting Russell Walter and Melissa Hayhurst. Contact information is provided on the previous page.