PWS Eaton starter Redesign.pdf

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Performance Work Statement (PWS)

United States Air Force

KC-135 Eaton Starter Redesign

Component Improvement Program (CIP)

December, 2019

Contract Number TBD

Eaton Aerospace LLC

Revision 1

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1.0 INTRODUCTION:

With aging aircraft hardware, new mission requirements, and a desire to keep weapon systems operational beyond original projections, the Government has an increasing desire to improve safety, reliability and maintainability while driving down the cost of ownership of aircraft systems and subsystems. The Government answers this requirement by funding improvement projects under the Component Improvement Program (CIP).

Secondary Power Systems (SPS) is comprised of those parts which are used to start main engines with start carts, Auxiliary Power Units (APU), or Jet Fuel Starters (JFS) as well as those parts which are integral for continual aircraft power generation via Accessory Drive Gearboxes (ADG) or Aircraft Mounted Accessory Drive (AMAD) gearboxes and Power Take-Off (PTO) shafts.

This performance work statement is specifically tailored for the KC-135 Hydraulic Starter Motor for which Eaton is the Original Equipment Manufacturer (OEM). The use of sound engineering is required to research and develop the necessary solution.

The government will be the funding source for this activity. The funding used is research, development, test and evaluation (RDT&E) or what the Air Force identifies as 3600 funds. This type of funding is incremental and used in one year additive cycles. Funding is provided by the CIP program office in fiscal year increments but the projects are managed by calendar year. This requires the contractor to be flexible and agile to support government needs.

2.0 SCOPE OF WORK:

This Performance Work Statement (PWS) outlines the basic services the government expects the selected contractor to render in support of the Component Improvement Program as requested and approved by the appropriate government personnel. These basic services include continuing sustainment engineering efforts, technical data, drawings, change proposals, manpower support, research, design activities, prototype hardware manufacture, testing, product and procedure improvements, reports, conferences, analytical investigations, hardware evaluation, and to include any other expertise and support deemed appropriate.

Primary CIP program objectives are to improve the safety, reliability, durability, operability, supportability, affordability and maintainability.

3.0 APPLICABLE DOCUMENTS:

• MIL-HDBK-516 “Airworthiness Certification Criteria”

• AFI 62-601 “USAF Airworthiness”

• AFPD 62-6 “USAF Airworthiness”

• MIL-STD-882 “System Safety”

• MIL-STD-130 “IUID”

• MIL-HDBK-61A “Configuration Management”

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4.0 DESCRIPTION OF TASKS TO BE PERFORMED:

Project objectives require the selected contractor to provide the government system managers with continuing expert operational, technical, and engineering support. Systems need to be kept mission ready and maintained to perform their intended function at all times. Program execution is managed by the government and EPD tasks are accomplished by the responsible qualified and approved contractor.

The approved tasks should improve the system’s safety, reliability, and maintainability while trying to optimize ownership costs to the government. Projects should be planned and completed in one year increments; or, the shortest time practical. Specific project task objectives should accomplish engineering and management actions as required per EPD as necessary to; but, not limited to:

1. Immediately resolve or mitigate safety of flight problems.

2. Improve system maintainability and reliability.

3. Increase mission operational readiness.

4. Investigate and incorporate industry advancements.

5. Extend hardware service life.

6. Monitor trends in performance.

7. Investigate, analyze, and resolve in-service related deficiencies.

8. Reduce cost of weapon system ownership and upkeep.

9. Respond rapidly to field reported problems.

10. Provide sustaining engineering support.

11. Design new support and test equipment.

12. Develop new inspection and repair methods.

13. Provide project support documentation.

14. Design, create, and test prototype hardware.

15. Improve engineering support data.

16. Create and deliver progress and final reports.

17. Solve obsolescence issues.

18. Perform Analytical Condition Inspection (ACI) tear downs and evaluations.

19. Accomplish Accelerated Mission Tests (AMT).

20. Perform Engineering Investigations (EI) and/or Product Quality Deficiency Reviews (PQDR).

21. Support Operational Safety, Suitability, and Effectiveness (OSS&E) functions.

22. Perform Program Management (PM) for day to day support.

23. Update interface control documentation.

24. Perform Failure Modes and Effects Criticality Analysis (FMECA).

25. Support system safety program.

26. Environmental risk management.

27. Support airworthiness certification.

28. Provide project management.

5.0 CIP REQUIREMENTS

The Component Improvement Program (CIP) shall be performed in accordance with requirements defined in this document and implemented through the approved Engineering Project Description (EPD).

The contractor shall provide the necessary personnel, administration, facilities, knowledge, reports, drawings, studies, hardware, resources, and materials; other than those specified as government furnished materials (GFM), needed to successfully complete approved projects in a timely manner and

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The SOO will specify the project requirements and deliverables as outlined herein and the contractor will create an EPD based off of the SOO. It is preferred that all documentation be delivered in electronic media in a fashion that is acceptable to both the contractor and the government; and submitted through the Contracting Officer.

5.1 ENGINEERING REQUIREMENTS

5.1.1 Engineering Services Memorandum (ESM)

The contractor shall submit a proposed CIP project as an Engineering Services Memorandum (ESM) along with the Engineering Project Description (or Notification) (EPD or EPN) to the government; or, shall prepare and submit one at the request of the government. The request will come in the form of a Statement of Objectives (SOO) delivered by the government contracting officer. The proposed project should be uniquely identified and self-contained. The EPD/EPN describing this effort should contain as a minimum a tracking number, title, project description, task milestones outline, schedule, cost, implementation method/cost, Life Cycle Cost (LCC) benefit analysis (as required). (A001: DI-MISC-80748)

5.1.2 Final Reports

The contractor shall submit a final report after the completion or cancellation of the EPD/EPN or phase of the EPD/EPN. The final report should summarize and document all project efforts while providing enough detail such that the conclusions and recommendations of the report can be verified. Supporting scientific and technical data, charts, graphs, photographs, inspection results, trials, and related documents should be included. A draft copy of the report shall go to the government for review 45 days before the performance period ends. (A002: DI-MISC-80048)

5.1.3 Test Plan

The contractor shall prepare and submit test plans and procedures to the government for approval as required by an individual EPD/EPN prior to the start of any testing activities. The test plan outlines the plans and performance objectives at all levels of testing. It provides the government with the test concept, objectives and requirements. It details the test methods, elements, responsible activities, and procedures required. (A003: DI-NDTI-80566)

5.1.4 Test/Inspection Report

The contractor shall submit test and/or inspection reports to the government as required by the EPD/EPN when testing is completed. The test/inspection report is used to document test and/or inspection results, findings and analyses. These reports include a description of the test facilities & equipment used, a description of the testing completed, and a copy of all of the data collected & results from the testing. The test report should summarize all aspects of the effort and provide sufficient data such that the government can verify the test results and conclusions. As required in the EPD/EPN the test report may be submitted in electronic and/or paper copy. (A004: DI-NDTI-80809)

5.1.5 Part Failure Analysis Report

As required on the EPN/EPD the contractor shall submit a Failed Item Analysis Report that provides documented results of investigation/inspection findings of a failed end item or part. This could be a teardown findings report, or the government may require the contractor to evaluate specific failed

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5.1.6 Safety Assessment Report (SAR)

As required on the EPD/EPN, the contractor shall submit a Safety Assessment Report that details a comprehensive evaluation of the safety risks being assumed prior to test or operation of the system.

This will identify all the safety features of the system, design, and procedural hazards that may be present in the system being acquired. (A006: DI-SAFT-80102)

5.1.7 Airworthiness Specification

As required on the EPD/EPN, the contractor shall submit an Airworthiness Specification. This report will document the airworthiness certification basis: applicable airworthiness certification criteria, compliance standards/requirements, and methods compliance. The specification will be used to support the government’s airworthiness type certification of the aircraft design. It will be tailored to fulfill airworthiness requirements with results from CIP projects. (A007: DI-SESS-81766)

5.1.8 Airworthiness Certification Criteria Report

As required on the EPD/EPN, the contractor shall submit an Airworthiness Certification Report, the purpose of the Airworthiness Certification Criteria Report is to provide airworthiness certification criteria verification results. The data will be used to support program managers’ airworthiness type certification of aircraft. (A008: DI-SESS-81768)

5.1.9 Ozone Depleting Substances (ODS)

The Contractor shall not incorporate into nor use any Class I or Class II ODS in the manufacture of items provided for in this contract, unless specifically approved by the Government’s representative. If an EPD potentially requires use of an ODS for mission critical requirements for which economically and technically feasible substitutes are not available, it will be evaluated by the Government and considered for approval.

5.1.10 Study/Analysis

The Contractor shall develop, manage and document analysis and methodology necessary to complete the requirements of an approved EPD. The Contractor shall report methods used and results of study/analysis in a technical report. (A009: DI-MISC-80508)

5.2 CIP PROGRAM MANAGEMENT

5.2.1 Program Progress Report

The contractor shall provide a Quarterly Status Report (QSR) in June, September, December and March.

Status reporting shall include progress to date, problems, open issues, current status, schedule update, spend update and expected completion date. The contractor program manager should meet with government personnel monthly, or as needed, to insure the program communication is clear, concise, and timely. (A010: DI-MGMT-80555)

5.2.2 Technical Reviews and Audits

Technical reviews such as Preliminary Design Reviews, Critical Design Reviews, Test Readiness Reviews, etc., may be required for this project. These reviews are conducted to evaluate the completeness, risk, effectiveness, analysis, etc. of the requirement. They are also to reduce risk, cost and ensure that the project is progressing as required.

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Prior to any technical review, the contractor shall provide entry criteria checklist and show that each item is accomplished or will be accomplished by the time of the review. After the review, the report shall provide documentation showing the exit criteria and how/why it was accomplished. (A011: Only applicable sections of IEEE 15288.2, as identified in each individual EPD/SOO)

5.2.3 Conferences /Review Agenda

The contractor shall provide a conference/review agenda 2 weeks prior to the scheduled program review. (A012: DI-ADMN-81249)

5.2.4 Meeting Minutes

The contractor shall provide formal published meeting minutes for formal design reviews and major program reviews as required in individual EPD/EPN. The contractor shall provide a conference report within 2 weeks after each conference/review is held. (A013: DI-ADMIN-81250)

For informal telecoms, monthly project status meetings, etc. the contractor is not required to submit formal published meeting minutes, but shall submit informal minutes/action items via email directly to the government project manager within 2 working days after the meeting.

5.2.5 Contractor Manpower Reporting

The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the USAF via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil. Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar year. Contractors may direct questions to the CMRA help desk.

5.2.6 Integrated Master Schedule

The IMS is a time-based schedule containing the networked, detailed tasks necessary to ensure successful program/contract execution. The IMS shall be used to verify attainability of contract objectives, to evaluate progress toward meeting program objectives, and to integrate the program schedule activities with all related components. The work breakdown structure should be tied to the projected schedule and updated periodically throughout the project. The contractor shall establish an IMS to help manage and track progress. It shall be delivered within 2 weeks after the contract is signed and updated regularly. It will be delivered as a part of the QSR (if required), and at each technical review. Specific tailoring will be outlined in the applicable CDRL. (A014: DI-MGMT-81861)

5.2.7 Government Furnished Property, Material and Equipment (GFP/GFM/GFE) The Contractor shall manage U.S. Government furnished property, material and equipment according to FAR 52.245-1 in Section I of the basic contract. The Contractor shall provide an inventory report at the end of the contract. (A015: DI-MGMT-80441)

5.3 CONFIGURATION MANAGEMENT

5.3.1 Technical Publication Manual Requirements

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The contractor shall develop and submit technical publication source data for engineering, hardware, and procedural methods developed under this contract as required by the EPD/EPN project description.

Source data format shall be identified by the EPD/EPN. Technical publication source data includes, but is not limited to the following:

1. Illustrated Part Breakdown (IPB)

2. Required Parts Supply Technical List (RPSTL)

3. Operating Procedures

4. Inspection Procedures

5. Repair/Overhaul Procedures

6. Assembly/Disassembly Procedures

7. Test Procedures

8. Support Equipment Operation

9. Time Compliance Technical Orders (TCTO)

10. Commercial Service Bulletins

(A016: DI-TMSS-81354)

5.3.2 Engineering Change Proposals (ECP)

The ECP shall be prepared and submitted by the contractor per Mil-STD-973. The ECP shall be submitted to the government as required by the EPD/EPN. The ECP shall be in a format that is mutually agreed upon by the government and contractor. It shall be submitted to the government for review and approval 60 days prior to period of performance closure. It shall also be submitted to the government prior to incorporating any changes. (A017: DI-SESS-80639)

5.3.3 Item Unique Identification (IUID)

All items designed, developed, or delivered to the Government as part of the CIP that are subject to DFARS mandated IUID shall specify or contain (for delivered items) a machine readable data matrix symbol. Markings shall be legible with human and machine-readable information per MIL-STD-130N, “Identification Marking of U.S. Military Property”. The identification markings shall be visible during normal handling, shall be readable, shall withstand the specified environment and cleaning processes, and shall be as permanent as the service life of the unit or at least to the unit’s point of rebuild. The barcode shall contain, at a minimum: (1) Applicable Enterprise Identifier (2) Serial Number (3) Part Identification Number. Information will be provided to verify that IUID markings have been incorporated. This can be shown with the ECP or through updated end item drawings. There may be items where no current acceptable marking method exists and will be excepted when customer and contractor agree that marking method is cost prohibitive or otherwise not feasible or desirable to mark.

5.4 DATA MANAGEMENT

5.4.1 Product Drawings and Associated Lists

The contractor shall provide the government with product drawings and associated lists to document and to incorporate detailed design changes developed under this contract into the specified model engineering parts list. The drawings and associated lists should be provided at a manufacturing level of detail and technical content. When using this CDRL, the TDP Option Selection Worksheet (Figure 2 of MIL-STD-31000) must be filled out and provided with the EPD and provided to the government. (A018:

MIL-STD-31000)

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5.4.2 Maintenance Test and Support Equipment List

The Contractor shall develop and submit Support Equipment Recommendation Data (SERD) or Maintenance Test and Support Equipment List for all SE/Standard/Modified/Handtool Lists and Test Measurement and Diagnostic Equipment (TMDE), including Peculiar Support Equipment (PSE) and Common Support Equipment (CSE), that are required for Government operation and sustainment (to include organic supply and repair). The Contractor shall consider life cycle cost when selecting SE.

SERD/Standard/Modified/Handtool Lists will be submitted in a format and schedule as required in accordance with the CDRL under the direction of the government technical representative. (A019: DI-

SESS-80294)

5.4.3 Data Rights

Data rights shall be determined in accordance with DFARS clause 252.227-7013 and DFARS clause 252.227-7015. In the event any Contractor proprietary data approved to be incorporated by the Government in any such technical data, the Government retains no rights in such Contractor Proprietary information except for such rights as may be specifically negotiated between the Government and Contractor.

5.4.4 Data Management Planning/Execution

The Contractor shall prepare, maintain, and track the contract data status and schedule.

The Contractor shall submit all CDRL documentation through electronic media. The Contractor shall ensure that contractual electronic data are delivered using the AMRDEC SAFE site or a method approved by the Government Contracting Officer.

6.0 SCHEDULE

Engineering Project Descriptions (EPDs) are generally prepared by the contractor in response to a government furnished Statement of Objectives (SOO) before October to be ready for obligation in January. Funding is received at the start of the government fiscal year (October) and projects are managed according to the calendar year. Proposals should be prepared in one year blocks to be incrementally funded at the start of the calendar year and then incremented again at the start of the fiscal year. After funds are obligated, planning must begin to prepare for the next year. Each spring, the CIP program office holds an Engine CIP Working Group (ECWG) where continuing projects and new projects are presented for approval. After project continuation approval, the contractor will work with the Air Force Program Manager to prepare and update the EPD for the next year’s obligation period.

Throughout the year, the contractor will be required to support the Air Force by holding regularly scheduled teleconferences as a form of program management to keep the project on task.

7.0 ADMINISTRATIVE ADDITIVES

7.1 PROPOSAL/ORDERING PROCEDURES

(a) Cost/price proposals for the EPD shall utilize the most current approved Forward Pricing Rate Agreement (FPRA) when available and when a current agreement is not in place utilize the most current Forward Pricing Rate Recommendation (FPRR). A firm fixed pricing arrangement will be used to satisfy the Contractor requirements. As a result, schedules and deliveries will be monitored closely. The following contract line items will be used:

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Engineering Service CLINs

0001- Phase 1

1001- Phase 2

2001- Phase 3

(b) Proposals shall include proposed total cost broken out for labor hours and expected material.

7.2 ENGINEERING PROGRAM ADMINISTRATION

(a) The CIP Manager and Technical Representative for the government is AFMC 419 SCMS/GUEA, all directions, instructions and/or suggestion will be coordinated with AFMC 419 SCMS/GUEA and issued in writing, as appropriate by the PCO.

(b) The basic document for initiating an engineering project within the CIP is the Engineering Project Description (EPD) pursuant to CDRL A001.

(i) When directed by the PCO, the contractor shall immediately stop work on an existing EPD. Any further costs incurred following the stop work order on that EPD will not be allowed except for the administrative costs to summarize the work accomplished and submit the Final Report. Any remaining funds may be redirected to other EPD’s already on order.

7.3 ENGINEERING PROJECT DESCRIPTION (EPD) APPROVAL

(a) It is recognized by the parties here that it may be necessary to reprioritize Contractor efforts from time to time as a result of experience in the field or change in Government missions.

(b) Only the Contracting Office, (PCO), has the right of approval, except as defined in (d) of the Engineering Program Administration instructions above, which would impact the addition/deletion/revision of tasks on this project. It is recognized that any such additions/deletions/revisions shall be in accordance with the Performance Based Work Specification and shall not be of such nature as to constitute changes as defined in the “Changes” clause of this contract.

(c) In the event the addition of a change pursuant to the “Changes” clause increases or decreases the total contract price by the most recent Certificate of Current Cost or Pricing Data threshold or more (currently $750,000), the contractor shall comply with FAR 15.406-2 by submitting Certificate of Current Cost or Pricing Data.

7.4 INCORPORATION OF REFERENCED DOCUMENTS

All specifications, exhibits, drawings or other documents which are referenced in this contract, but are not attached hereto, are hereby incorporated by reference.

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7.5 REDIRECTION OF EFFORT

The Contracting Officer shall be the only individual authorized to redirect the effort or in any way amend any terms of this contract.

8.0 Period of Performance

Funding is requested for a calendar year and may only be available in incremental amounts throughout the year; and subject to change. Therefore, the government can only obligate funding that is actually on hand. The planned period of performance for projects will be cited on the order. If not completed, the period of performance, if remaining funding exists, may be extended at the request of the contractor or government; only with the approval of the government Contracting Officer via modification. The government Contracting Officer may require considerations depending on the circumstances for the extension. As reasonable, expensive or longer term projects should be broken down into one-year increments. The government reserves the right to terminate at any time without cause.

9.0 Performance Standards

Performance Objective

Performance Standard

Acceptable Quality Level

(AQL)

Monitoring Method eCMRA -Input data before Oct 31

-100% COR Surveillance

Deliverables (Per SOO and EPD)

Per EPD requirements

-Per Period of Performance (95% on time) -Government Quality Rejects (pass 95%)

-COR Surveillance

-Government Technical Representative

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Exhibit A CDRL Summary

CDRL PWS Para. CDRL Description DID A001 5.1.1 Engineering Service Memorandum (ESM) DI-MISC-80748 A002 5.1.2 Final Reports DI-MISC-80048 A003 5.1.3 Test Plan DI-NDTI-80566 A004 5.1.4 Test/Inspection Report DI-NDTI-80809 A005 5.1.5 Part Failure Analysis Report DI-RELI-80255 A006 5.1.6 Safety Assessment Report (SAR) DI-SAFT-80102 A007 5.1.7 Airworthiness Specification DI-SESS-81766 A008 5.1.8 Airworthiness Certification Criteria Report DI-SESS-81768 A009 5.1.10 Study/Analysis DI-MISC-80508 A0010 5.2.1 Program Progress Report DI-MGMT-80555

A011 5.2.2 Technical Reviews and Audits IEEE 15288.2

(Applicable sections) A012 5.2.3 Conferences/Review Agenda DI-ADMIN-81249 A013 5.2.5 Meeting Minutes DI-ADMIN-81250 A014 5.2.6 Integrated Master Schedule DI-MGMT-81861 A015 5.2.7 Government Furnished Property, Material and

Equipment (GFP/GFM/GFE)

DI-MGMT-80441

A016 5.3.1 Technical Publication Manual Requirements DI-TMSS-81354 A017 5.3.2 Engineering Change Proposals (ECP) DI-CMAN-80639 A018 5.4.1 Product Drawings and Associated Lists MIL-STD-31000 A019 5.4.2 Maintenance Test and Support Equipment List DI-SESS-80294