SOW_Rev_4.docx

FA8212-19-R-0020

Attachment 1 – SOW 16 May 2019

STATEMENT OF WORK

A-10 Speed Brake Five Year Indefinite-Delivery, Indefinite-Quantity (IDIQ)

Revision A Prepared by:

AFMC 416 SCMS/GUMBA

6021 Gum LN, Bldg. 1228 Hill Air Force Base, Utah 84056

Revision Record

Table of Contents

1. PURPOSE AND SCOPE

1.1 Purpose

This Statement of Work describes the requirements to produce A-10 Legacy Wing Assembly Speed Brakes P/Ns 160D712170-1, 160D712150-3, 160D712170-2 and 160D712150-4. The Speed Brakes as components of the Deceleron function by providing roll control as well as stabilizing dive speeds and reducing airplane speed in flight and on landing. The Speed Brakes are classified as a Critical Safety Items (CSI).

1.2 Scope

1.2.1 Baseline Technical Data Package (TDP)

The Speed Brake TDP shall serve as the engineering baseline. The prime contractor shall produce the Speed Brake utilizing the existing TDP and Engineering Data Requirements (EDR).

1.2.2 Manufacturing Tooling and Process Development

Government furnished tooling is not available for this acquisition. All contractor generated tooling and processes must meet technical data requirements. Quality control processes are critical to meeting required delivery schedules while ensuring structural integrity is maintained throughout the manufacturing process. Legacy tooling main assembly drawings are included in the TDP.

1.2.3 Production Planning, Qualification, and Inspection

The prime contractor shall use the Speed Brake assembly TDP and EDR as the basis for all manufactured and assembled parts. Additionally, the prime contractor shall outline their manufacturing and fabrication system prior to starting any fabrication/assembly work.

1.2.3.1 Critical Safety Items

The prime contractor shall comply with policy, procedures and responsibilities outlined by AFI 20-106 Management of Aviation CSIs. CSIs for the Speed Brake are listed in document number A3G-2016-185485 contained in the TDP.

2. REQUIREMENTS

The prime contractor shall produce Speed Brakes that are complete and ready for installation on the A-10 aircraft. The prime contractor shall be responsible for verifying the TDP is complete prior to start of First Article production. A Physical Configuration Audit (PCA) shall be performed by the contractor and verified by the Government throughout the production of the First Article.

2.1 Program Management

The prime contractor shall provide documentation and communication required to efficiently and effectively manage the contract. All communications pertinent for the execution of this contract shall be flowed to both the Procuring Contracting Officer (PCO) and Program Manager.

2.1.1 Integrated Master Plan/Integrated Master Schedule

The Contractor shall implement and maintain an integrated master plan (IMP) for this program. The IMP is an event driven plan that defines a program’s major tasks and activities and lays out the necessary conditions to complete them. This plan shall include the manufacturing/production approach, methodologies, tools, tasks, activities and procedures to be used during the production of the Speed Brakes. The IMP shall be a single plan for the entire effort, including associate and/or major subcontractor activities. [CDRL A001]

The Contractor shall implement and maintain an integrated master schedule (IMS) for this program. A baseline IMS shall be developed at the start of the program. An IMS shall be developed and maintained throughout the program (applicable delivery orders), using the original baseline schedule as an unchanging reference. [CDRL A002].

The IMS shall include a detailed timeline of the following (list is not all-inclusive):

• Tooling design and tooling production

• Critical subcomponent production and inspections (i.e. CSI components)

• First Article manufacture and inspection

• Material purchases to include long lead items

• Low rate and full rate Production

• Scheduled audits and acceptance checks

2.1.3 Monthly Status Report

The prime contractor shall provide a Monthly Status Report that covers all program activities for the period of the delivery order. It shall provide a forecast of work to be accomplished during the upcoming month. This report shall include status and progress towards open tasks 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 prime contractor shall report any situation requiring immediate action by the Government using the most expedient means (teleconference or e-mail) and document the situation in the Monthly Status Report. [CDRL A003]

The following categories are examples to be included in the monthly report (list is not all-inclusive):

• Pre-Production tool design, tool manufacture, and supply chain identification

• Manufacturing status

• Delivery schedule

• Non-conformance summary and trend analyses

• Corrective action plans

• Risk assessment of production issues (to include mitigation)

2.1.4 Meetings

The Government encourages meetings with the prime contractor to review contract status and address outstanding issues. Whenever feasible, meetings shall be held in conjunction to minimize costs. The Government anticipates a minimum of three meetings at the contractor facility (Pre-production and two Program Management Reviews (PMR)). Additional program management review meetings may be required. If additional program management reviews are required, the Government and contractor will mutually agree to the location and agenda. Additionally, to ensure effective communication throughout each delivery order, teleconferences or video teleconferences may be used frequently. All appropriate stakeholders should attend including Government personnel, prime contractor, subcontractors, etc.

2.1.4.1 Agenda and Presentation Material

The Contractor shall publish an agenda and presentation material for all meetings and conferences excluding teleconferences or video teleconferences. The Contractor shall request from the Government, at least fifteen business days prior to any meeting, any items or issues to be discussed or presented at the meetings, and shall include such items in the agenda and presentation material. Agendas and presentation materials shall be submitted not less than ten business days prior to any meeting. [CDRL A004 and CDRL A005]

2.1.4.2 Meeting Minutes

The Contractor shall provide a written record of the discussions, decisions and action items identified at each meeting. (CDRL A006)

2.1.4.3 Physical Configuration Audit (PCA)

The Contractor shall host PCA events as required by the Government all four Speed Brake Assemblies. (Reference MIL-HDBK-61A). The PCA shall examine the actual configuration of the Speed Brakes in order to verify that the related design documentation matches the design of the deliverable items, to include validation of the supporting processes that the contractor uses in the production of the Speed Brake. The contractor shall provide a report on each PCA result which shall be submitted not later than 15 calendar days after completion of the event. (CDRL A007)

2.1.4.3.1 Configuration Audit Plan

The Contractor shall deliver a configuration audit plan (reference MIL-HDBK-61A) within 90 calendar days from deliver order award containing the provisions for performing a PCA for the Speed Brake. [CDRL A008]

2.2 First Articles

2.2.1 First Article Qualification Test Plan

The prime contractor shall provide a First Article Qualification Test Plan within 90 calendar days from delivery order award detailing how the Speed Brakes will be certified for compliance with technical data requirements and Vendor/Sub-Vendor qualification and verification process. All vendors manufacturing CSI components must be approved by ESA prior to manufacture. [CDRL A009]

2.2.2 First Article Inspection

The prime contractor shall perform a First Article Inspection (FAI) on the Speed Brake(s), to include all individual parts and subcomponents. The FAI requirements for the parts shall be AS 9102 compliant. The FAI will be used to validate the manufacturing tooling and processes used to produce the Speed Brake(s). In addition to end-item inspection of the FA Speed Brake(s), the Government with Defense Contract Management Agency’s (DCMA) assistance will inspect all individual parts, subcomponents, CSI items listed in A3G-2016-185485, Interchangeable & Replaceable (I&R) locations and conformance of processes throughout production of the First Article. DCMA will provide oversight of contractor-run FAI at both the prime contractor facility and at any subcontractor facilities. The prime contractor shall ensure that these critical components are made available for inspection before final assembly. The prime contractor shall submit a FAI report containing all supporting documentation and results of all individual parts and the final assembly in the First Article Inspection report. The PCA results may be incorporated into the FAI report. [CDRL A010] The contractor shall also include the following items in their FAI report:

· Verification of the CSI Critical Characteristics and defined in A3G-2016-185485

· All Coupon Test Results from Composite Bondings and Forgings

· Verification of Outer Mold Line for all Speed Brake Components

· Configuration Management Verification (Physical Configuration Audit).

Following the contractors FAIs, the prime contractor shall deliver the Speed Brake(s) to the United States Air Force base identified on the order. After delivery of the Speed Brake(s) to the Government facility, the Government is responsible for the following actions at the Government facility:

1) Dimensional checks

2) Installation of Speed Brake(s) on an A-10 aircraft

3) Mating of the I&R items Prime contractor personnel may be present throughout installation of the Speed Brake. If damage occurs to the FA Speed Brake(s) as a result of failed FAI, the contractor shall refurbish the asset(s) to a like new condition as part of correcting the deficiencies identified during Government FAI. For all deficiencies found, the prime contractor shall record the source of the discrepancy, and the actions necessary to correct the discrepancy. [CDRL A003] Final acceptance of the FA Speed Brake(s) will be based on successful Government FAI. Upon successful FAI, the FA Speed Brake(s) will be accepted into Government supply.

2.3 Production Assets

The prime contractor shall not begin assembly of any production units until final inspection and acceptance of the FA Speed Brake(s). The production assets shall follow the same processes and steps utilized while producing the FA.

2.3.1 Interchangeability and Replaceability

The Speed Brake contains I&R interfaces as defined in MIL-I-8500. All I&R interfaces/parts are identified in the drawings within the TDP. Interchangeability for all interfaces/parts shall be maintained throughout the manufacturing process.

2.4 Quality Assurance

Quality control processes are critical to meeting delivery schedule requirements. The prime contractor shall be AS 9100 compliant or equivalent. Subcontractors supporting production of the Speed Brake shall also be AS 9100 compliant or equivalent.

2.4.1 Non-Conforming Product

The prime contractor shall develop a Material Review Board (MRB) process for handling non-conforming products found during manufacture and production. At a minimum, the MRB process shall address the following:

· Process to identify, analyze, disposition, and repair non-conforming conditions

· Cause and corrective action process

· Process to manage, track, and document non-conformances

· Interface with DCMA and the USAF Engineering Source Authority (ESA

· Stress Analysis (analysis report or rational for not performing analysis) utilizing critical design loads and conditions provided in Engineering reports. Engineering reports will be furnished upon request from the contractor.

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 when applicable. The Government has final approval authority for the engineering methods and material data used in the stress analysis. The Government has authority to reject the contractors provided rational for not performing a stress analysis.

The 416th SCMS is the ESA for disposition of all non-conforming products under this effort. The 416th SCMS may delegate limited DCMA oversight and authority for disposition of non-conforming product. DCMA may delegate limited contractor authority, with 416th SCMS concurrence, based on a demonstrated level of expertise during the program.

MRB dispositions submitted for Government approval will have an initial response within 5 business days of receipt. These reports shall describe each non-conforming product, the repair disposition taken by the contractor, and the substantiating analysis and rationale. The 416th may delegate engineering authority to the prime contractor based on demonstrated level of expertise during the program. The Government may suspend the prime contractor’s engineering authority if monthly reports fail to demonstrate continued engineering discipline and adequate repair methodology. [CDRL A011] Request for Variance (RFV) shall be submitted via Form DD1694 for authorization to depart from a particular requirement(s) of an item’s current approved configuration documentation for a specific number of units or a specified period of time, and to accept an item which is found to depart from specified requirements, but nevertheless is considered suitable for use “as is” or after repair by an approved method. The 416th ESA will review, comment, and concur or non-concur as to the determination of the variance. The Contractor shall present all deviation information to the 416th ESA and PCO, or if delegated, to DCMA. All costs relating to rejected or approved RFV shall be the responsibility of the Contractor, and shall not be billed to the Government. [CDRL A012] The prime contractor shall record all non-conforming products on AFTO Form 95. Each AFTO 95 form shall be specific to a single Speed Brake. The AFTO 95 shall be electronically provided to the PCO and enclosed with each Speed Brake shipment. [CDRL A013].

2.4.2 Product Quality Deficiency Reporting

The prime contractor shall develop and maintain a Product Quality Deficiency Report (PQDR) review process to address any deficiencies found in delivered and accepted Speed Brake(s). The PQDR review process shall be conducted using T.O. 00-35D-54 (USAF DEFICIENCY REPORTING, INVESTIGATION, AND RESOLUTION. REV. 1, 15 MAY 2015) as a guideline and include, as a minimum, prime contractor root cause analyses of the deficiencies. T.O. 00-35D-54 will be available when requested by prime contractor. The prime contractor shall be responsible to perform the corrective action(s) on delivered and undelivered hardware to resolve the deficiencies. PQDR information shall be updated in the Monthly Status Report [CDRL A003].

2.4.3 Serial Number Control

The prime contractor shall use serial numbers to control and provide traceability for the Speed Brake. To prevent overlap with previously assigned serial numbers, the prime contractor shall assign serial numbers as identified by the Government. The contractor shall contact the PCO for the assigned serial numbers.

2.4.4 Item Unique Identification (IUID) Requirements

Per DFAR 252.211-7003, IUID shall be applied to the Speed Brake and all applicable parts in accordance with MIL-STD-130. IUID markings must meet requirements of the TDP. The IUID of the Speed Brake shall be accompanied by a Human-Readable Information (HRI) marking of 16 alphanumeric characters which includes the vendor CAGE (FSCM) of the prime contractor and a unique 4-digit number starting with a Government assigned serial number. IUID markings shall be accomplished in a manner that will not adversely affect the items required function.

2.5 Environmental, Health, and Safety

The prime contractor shall determine and implement actions necessary to ensure environmental, health, safety policies, regulations, and laws are adhered. Engineering solutions submitted to the Air Force shall require consideration of the impact to the environment and to the worker’s health and safety. Compliance to appropriate Environmental Protection Agency (EPA), Occupational Safety and Health Administration (OSHA), and local Government and state regulations is required.

2.5.1 Environmental Compliance

Chemical and material products shall meet performance specifications and shall not violate the environmental requirements of any applicable local, state, or federal entity. The prime contractor may be required to design or redesign, develop, document, and verify processes and materials used to produce the Speed Brake(s) are environmentally compliant. Applicable pollution requirements may include a substance's toxicity, biodegradability, and Volatile Organic Compound (VOC) content. It shall be the prime contractor's responsibility to ensure project compliance with environmental regulations, ordinances, and statutes of any sovereign governing the prime contractor. Further, it shall be the prime contractor's responsibility to ensure waste products generated in assigned efforts are disposed of in a safe manner, complying with applicable regulations. In no event shall the Government be liable for the contractor's failure to comply with applicable environmental requirements. The contractor agrees to hold harmless the United States should the contractor violate any environmental regulation, ordinance, or statute. In the case where more than one environmental requirement is present, the contractor shall comply with the stricter requirement. Should there be a conflict between environmental regulations, ordinances, and statutes and the contract's specifications, the contractor shall, in writing, contact the PCO for a written resolution. Any adjustment in the specifications or contract terms by the contractor without such a resolution shall be at the contractor’s risk and expense.

2.5.2 Hazardous Materials

The use of hazardous or corrosive materials in the performance of any Task should be avoided. The use of hazardous or corrosive materials shall be reduced by elimination, substitution, or minimization using guidance as provided by the Government. If the use of hazardous materials cannot be avoided, the contractor shall identify such requirements to the Government before proceeding and shall justify the requirements in regular status reports.

2.5.3 Ozone Depleting Substances

Class I Ozone Depleting Substances (ODS) shall not be used in the performance of this contract, unless prior approval is granted from the Air Force. Class I ODS shall not be delivered as a result of this contract. The contractor shall make every effort to eliminate or reduce Class I ODS usage in hardware or processes relating to manufacturing and production of the Speed Brake(s) and all subcomponents.

2.5.4 Health and Safety

The contractor shall ensure Air Force Occupational Safety & Health Standards and other applicable safety and health standards (i.e., Occupational Safety and Health Administration [OSHA] standards) are included in specifications.

2.6 Travel Requirements

There is no requirement for travel under this contract. The contractor may observe the First Article installation at the Government facility, however, this is not a requirement levied by the Government. If the contractor and Government mutually agree to hold a meeting at a Government facility, travel costs shall not be separately priced from the Speed Brake(s) unit price.

2.7 Preservation, Packaging & Marking Requirements

The contractor shall be responsible for the preservation, packaging, and marking of all items delivered under the terms of this contract. Packaging procedures will be established in accordance with AFMCI 24-201 (paragraph 3.7) and MIL-STD-2073-1 (current revision). Speed Brake(s) ready for delivery shall be packaged IAW applicable Special Packaging Instructions (SPI).

2.7.1 Preparation for Delivery

Preparation for delivery is contained on AFMC Form 158.

2.7.2 Hazardous Materials

Hazardous materials that require Performance Oriented Packaging (POP) shall be packaged and appropriately marked (UN container markings and hazardous commodities markings) in accordance with the following regulations: International Civil Aviation Organization (ICAO), International Maritime Dangerous Goods (IMDG) Code, Annex 1, 29 CFR, Department of Transportation Final Rule, HM-181 of the Federal Register, 21 December 1990 of 49 CFR, and MIL-STD-129. Material Safety Data Sheets (MSDS) are required for known hazardous items and applicable items shown in FED-STD-313, Tables I and II. The symbol used to certify compliance with UN POP requirements shall be properly registered with the US Department of Transportation. A copy of the prime contractor’s Test Report and signed certification that the package configuration meets both CFR and UN requirements shall be made available to the procuring contract office, as required, prior to acceptance or shipment of any portion of the product IAW CDRL requirements (Reference AFMC Form 158). If it is found there are no hazardous materials in this acquisition, this particular paragraph is invalid.

Attachment A – Contract Data Requirements List

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