Float_Repair_PWS_2018_Final_HI_Dated_6_1_2017.docx

AI R FORCE NUCLEAR WEAPONS CENTER

HILL AI R FORCE BASE, UTAH

PERFORMANCE -BASED WORK STATEMENT (PWS) FOR

FY 18 -FY 21

Pendulous Integrating Gyroscopic Accelerometer (PIGA) Float Assembly Repair AFNWC/NIBA ICBM Systems

PR# FD202017-51638

Not On Contract Yet

Prepared by:

Jon Hall Program Manager AFN WC/NIBA H ill AFB, UT 84056 (801) 777-4242 6/1/2017

PERFORMANCE-BASED WORK STATEMENT

TABLE OF CONTENTS

SECTION I

SECTION II

2. SERVICE SUMMARY 10

SECTION III

3. GOVERNMENT FURNISHED PROPERTY, SERVICES, AND PIGA FLOAT REPAIR/PRODUCTION EQUIPMENT 14

SECTION IV

4. SECURITY OBJECTIVES 15

SECTION V

5. CONTRACTOR MANAGEMENT REPORTING 15

6.

ACROYNMS

AF

CORL

CUN

CPR

CFSR

DCM A

DI D

FAR

GD

GFE

GFM

GFP

JAW

MSY/DRA

PIGA

PMR

POC

POP

PWS

QA

RG

SAE

Air Force Contract Data Requirements List Contract Line Item Number Contracting Performance Report Contract Funds Status Report Defense Contract Management Agency Data Item Description Federal Acquisition Regulation General Dynamics Government Furnished Equipment Government Furnished Material Government Furnished Property In Accordance With Minimum Start Voltage/Demagnetized Rundown Analysis Pendulous Integrating Gyro Accelerometer Program Management Review Point of Contact Period of Performance Performance Work Statement Quality Assurance Returned Goods Society of American Engineer s

SECTION I

1. DESCRIPTION OF SERVICES: The Air Force will issue a new contract to Honeywell Aerospace located at 13350 U.S. Highway 1 9 N, Clearwater, Florida 33764-7290 to remanufacture/rebuild/repair the Pendulous Integrating Gyroscopic Accelerometer (PIGA) Float Assemblies. These assemblies are used on the Minuteman Ill Intercontinental Ballistic Missile weapon system. The CAGE code for Honeywell is 09128.

1.1 BASIC SERVICES: All services are for the Basic, Option 1, 2, 3 and a six month extension (if needed).

1.1.1 The contractor shall remanufacture/rebuild/repair PIGA Float Assemblies to the most current configuration, Part N umber 9043520-010.

1.1.2 The contractor shall have the experience, skilled workforce, tooling, facilities, knowledge, and data available to remanufacture/rebuild/repair PIGA Floats to a serviceable condition but not like new condition.

1.1.3 Contractor will be cognizant of the material quantities and provide updates to usage rates, consumed quantities, and residual quantities to include locations of the material. Based upon the unique character of critical parts and materials used within the Float Assembly and limited qualified supplier base, the contract shall maintain a sufficient quantity of critical parts and materials in stores to provide a reasonable schedule risk mitigation against unexpected supply stream interruptions. Parts and material quantities shall be based on past issue time to resolution.

1.1.4 The contractor will be cognizant of the new float bodies if it is determined a requirement.

1.1.5 The contractor shall perform acceptance testing IAW the float print, Part N umber 9043520-010, prior to presentation to the Government.

1.1.6 All replaced components found to be unusable shall be disposed I A W procedures FAR Part 45.

1.1.7 Develop plans necessary to maintain and effectively mitigate technical risks to the PIGA Float supportability, and reduce risks to the program.

1.1.8 Maintain configuration records/build documentation as necessary to be able to provide the government a record to the teardown, evaluation, and disposition (repairable, repairable with segment replacement, or scrap) of each Returned Good (RG) Float Assembly input to the contract for repair. The contractor shall also maintain configuration records/build documentation as necessary to document the repair of each RG Float Assembly delivered to the government under the contract. The contractor shall provide access to the configuration, teardown, and repair records to the Government upon request.

1.1.9 Maintain Government Furnished Equipment (GFE), Government Furnished Material (GFM), and Government Furnished Property (GFP). Develop plans necessary to maintain PIGA Float supportability and reduce risks to the program.

1.1.10 The contractor shall update all applicable drawings and specifications.

1.1.11 Contractor shall be cognizant of the of both internal and industry parts, materials, and techno logy availability , evolution, and trends which may positively or negatively impact the ability to manufacture or support the PIGA Float Assembly and shall develop plans to mitigate or take advantage of these changes. The contract shall ensure that the AF Program Manager is made aware of issues which impact PIGA Float production capabilities.

1.1.12 Contractor's quality management system shall comply with SAE Aerospace Industry Standard AS91000. The contractor shall be responsible for flow of quality assurance requirements to sub-contractors and suppliers as necessary to ensure that all parts, materials, services provided to the government under this contract ensure the reliability, maintainability, and serviceability of the products provided.

1.1.13 Contractor's workmanship requirements for all parts, materials, services and end items provided under this contract shall be as defined within the contractor's internal manufacturing documentation and the applicable PIGA technical baseline.

1.2 GENERAL TASKS: All tasks are for the Basic, Option 1, 2, 3 and Option 4 (six month extension - if needed).

1.2.1 Contractor will support three Program Management Reviews (annually), weekly telecoms , travel in support of this effort and support any Government visits to the Contractor 's or second tier vendor's facilities. The contractor will travel to the venders when deemed necessary.

1.2.2 During the Period of Performance Honeywell will acquire used float bodies provided by the Government as Returned Goods (RG). The contractor will remove any normal and occasionally heavy pitting from the RG float bodies through their normal machining process.

1.2.3 Data Deliverables; CDRL's A00l, A002, A003, A004, A005 shall be posted for viewing on the DAPTIV website and notification via email to those on the CDRL distribution list. Data deliverables will also be submitted to the data manager via encrypted email to TopVue at https:icbm.topvue.com/topvue-icbm/. This is for unclassified CDRL submittals only.

1.2.3.1 Contractor shall submit a Status Report IAW CDRL A001, DI-MGMT-80368A.

1.2.3.2 Contractor shall submit a Contract Funds Status Report IAW CDRL A002, DI-MGM T-81468/T.

1.2.1.1

1.2.3.3 Contractor shall submit a Status of Government Furnished Equipment (GFE) Report IAW CDRL A003, Dl-MG MT-80269 on the Health of the GFE including down time, and any issues that arise. Record the specific items of GFE, GFM and GFP that have been removed or added to the contract. All GFE test stations or equipment that encounters a hard failure, contractor will contact the Air Force within 24 hours.

1.2.3.4 Contractor shall submit Briefing Material I AW CDRL A004, D l-MGMT-81-605.

1.2.3.5 Contractor shall submit Report Record of Meeting Minutes IAW CDRL A005, Dl-ADM N-81 505.

1.2.4 Remanufacture/rebuild/repair PIGA Float Assemblies to the most current configuration, Part N umber 9043520-010 to a serviceable, but not like new condition. This is a very unique contracting arrangement. It resembles a five (5) year contract because the Period of Performance's (POP) overlap in order to keep the repair li ne flowing because of long lead times.

Basic - Repair 96 PIGA float assemblies with a POP from November 01, 2017 through October 31, 2019. Float deliveries will begin in April 2018 at a Rate of eight floats assemblies per month ending in March 2019. Replace degraded parts to sustain and ensure serviceability to the SLEW test stations (refer to paragraph 1.3.2).

· Option 1 - Repair 96 PIGA float assemblies with a POP from November 01, 2018 through October 31, 2020. Float deliveries will begin in April of 2019 at a rate of eight PIGA float assemblies per month ending in March 2020.

· Opt ion 2 - Repair 96 PIGA float assemblies with a POP from November 01, 20 19 through October 31, 2021. Float deliveries will begin in April of 2020 at a rate of eight PIGA float assemblies per month ending in March

· 2021.

· Option 3 - Repair 96 PIGA float assemblies with a POP from November 01, 2020 through October 31, 2022. Float deliveries will begin in April of 2021 at a rate of eight PIGA float assemblies per month ending in March 2022.

· Extension - Repair 48 PIGA float assemblies with a POP from November 01, 2021 through December 31, 2022. Float deliveries will begin in April of 2022 at a rate of eight PIGA float assemblies per month ending in September 2022.

1.2.5 Replace up to six (6) (estimated) chipped or cracked Jewels received from the Government specifically for jewel replacement on PIGA Float assemblies per contract year. This task will not require complete float acceptance test, however will include verification that the wheel starts. If the wheel fails the verification wheel start test then it will be shipped in place, for payment, and retained as an RG input for future input to the Float Repair CLIN. These floats do not count toward s the quantities required for remanufacture/rebuild/repair and will be priced under a separate contract li ne item.

1.2.6 Remove and replace defective Ferrite Rotors or kiss-lap up to ten (10) (estimated) Ferrite Rotors on PIGA Float Assemblies received from the Government per contract year. This task will not require complete float acceptance test, however will include verification that the wheel starts. If the wheel fails the verification wheel start test then it will be shipped in place, for payment, and retained as an RG input for future input to the Float Repair CLIN. These floats do not count towards the quantities required for remanufacture /rebuild/repair and will be priced under a separate contract line item.

1.2.7 Remove and replace one Jewel and one Ferrite Rotor on one on PIGA Float Assemblies received from the Government per contract year. This task will not require complete float acceptance test, however will include verification that the wheel starts. If the wheel fails the verification wheel start test then it will be shipped in place, for payment, and retained as an RG input for future input to the Float Repair CLIN. The float will not count towards the quantities required for remanufacture /rebuild/repair and will be priced under a separate contract line item.

1.2.8 There will be one un-priced contract line item number (CLIN) in the basic and each option period. This CLIN will be for Over and Above work to include float body requirements, procure new float bodies, additional Jewel (1.2.5) and Ferrite Rotor (1.2.6) repairs from Boeing Heath and additional Segment Replacements, development of second source repair material/vendors such as, but not limited to Segment Replacement, repair/replacement of PIGA Float production GFE/tooling, fixtures and any other tasks that are not currently defined but are determined within scope of the contract.

1.2.9 Contractor shall support the PIGA Technical Integrating Meetings (TIM) and brief the status of the PIGA Float Assembly.

1.2.10 Contractor shall prepare up to 50 PIGA Float Gimbal hardware designated for segment replacement for long term storage and retain at the contractor’s facility for input to segment replacement.

1.2.11 During the Basic and each Option 1, 2, 3 Period , the contractor will perform a total of 30 Segment Replacements; perform all necessary inspections on the resulting segment/gimbal sets and stock these sets as Government Furnished

1.2.12 Material (GFM) to be utilized as required GFM in the repair line and support the delivery of 96 repair Float Assemblies. If the Option IV - six month extension is required the contractor will deliver 15 Segment Replacements and 48 repaired Float Assemblies.

1.3 SPECIFIC TASKS: The following tasks are specific in nature and apply only during the identified contract option year or years and are thus performed in addition to the tasks described in sub-section 1.2 above.

1.3.1 During the basic option year, the contractor shall work with the PIGA design agency to undertake a comprehensive review of all Piece Part Prints, Assembly Prints, and Source Control Drawing (SCD) and commercial items utilized in the manufacture and repair of the 16 PIGA Float Assembly and it various component parts and sub-assemblies. This study shall identify and generate a comprehensive list of materials under these classifications which have a critical impact on the quality and reliability of the Float Assembly or its parts and components. “Critical Impact’ shall be categorized as materials which are a part of a baselined manufacturing process, are required to be of a known or quantified quality, consistency, or composition, and which if became unobtainable in the required state to support Float manufacturing would result in a significant risk to Float manufacturing outcomes, schedules, or cost to the government. The contractor shall publish the findings of the review to the government and implement those program baseline engineering documentation changes need and as demand necessary to better define and control the SCD or commercial items critical to float manufacturing. Baseline document changes will processed through the Guidance SSC Control Board process or 16 PIGA Float Repair Manufacturing documentation change control process (design agency review and approval) process.

1.3.2 GFE SLEW Station Wire Wrap Circuitry Replacement:

During the Basic contract year, the contractor shall design, develop, fabricate and implement drop in replacement circuitry for the proto-type wire wrap technology circuitry contain in the two GFE SLEW Test Stations. The replacement circuitry shall consist of production type printed wiring boards and shall be designed to be direct drop in (form, fit, and function) replacements for the existing circuitry. The replacement boards not alter the functionality of the existing circuitry and the design shall be such as not to require any modification of other existing circuitry or software within the SLEW Test Stations.

1.3.3 New Float Body Assemblies:

The contractor shall procure new 9043535-010 Float Body Assemblies from General Dynamics – MS, Cullman, AL. during the Basic and Option periods as noted below. The contractor shall perform in process and final source inspection on each of the new segment, gimbal, and float body assemblies purchased. The contractor shall also arrange for validation metrology to be performed by Draper Laboratories on the first and last piece (Float Body Assembly) of each manufacturing lot purchased. The Draper Laboratories metrology data will be used for establishing an assessment of the accuracy for the manufactures acceptance metrology data.

Contract Year Quantities are as noted below.

1.3.4 Hysteresis Ring Assembly Lifetime Quantity Build:

During the Basic year, the contractor shall acquire a total of 1095 Hysteresis Ring Assemblies (Air Force Part Number 8050103-010) processed up to the final grind operations. These parts are intended, along with a quantity purchased under contract FA8204-14-C-0002 FY2017, to provide a life of type supply of nearly completed Hysteresis Ring Assemblies sufficient to support Gas Bearing Wheel fabrication through the end of Minuteman III LGM 30 Guidance deployment. These assemblies shall become GFM assets for future float repair manufacturing contracts.

Option 4, FY21 Extension - Qty 5

1.4 GOVERNMENT ACCEPTANCE INSPECTION

DCMA will provide onsite visual inspection of the end item float including the data package at the contractor's facility and accept the float on the Government's behalf for the Basic, Option 1, 2, 3 and a six month extension (if needed).

SECTION II

2. SERVICE SUMMARY: The Service Summary is for the Basic, Option 1, 2, 3 and Option 4 (six month extension - if needed).

AFB, UT 84056-581 6.

and each Option year as specified in the PW S. (DCMA on site) shall visually check each float assembly , inspect data packages and accept each float on behalf of the A F.

(l .2.6) repairs from Boeing Heath and Segment Replacements, development of second source repair material/vendors such as, but not limited to Segment Replacement, repair/replacement of PIGA Float production GFE/tooling, fixtures and any other tasks that are not currently defined but are determined within scope of the contract.

CDRLs will follow the Basic, Option 1, 2, 3 and Option 4 (six month extension - if needed).

Furnished Equipment. Record the specific item s of GFE GFM and GFP that have been removed or added to the contract

SECTION III

3. GOVERNMENT FURNISHED PROPERTY , SERVICES, AND PIGA FLOAT REPAIR/PRODUCTION EQUIPMENT

3.1 The Government will provide the following: Pyroceram Slabs, RG Gimbals, Floats, P-6 Material, Ferrite Rotor Blanks, Aluminum Oxide Powder, Float Balance Fluid, and 1-400 Beryllium Material.

3.1.1 The following end item will be shipped to the contractor for remanufacture/rebuild/repair:

ITEM DESCRIPTION

PIG A FLOAT ASSEMBLY

NSN

1420-01-386-7795AH

PIN

9043520-0I0

3.1.2 All remaining Government Property associated with FA8204- 1 O-C-0010 may be used on this Contract. Additionally, all Government Property accountable to this Contract may be utilized by Government Contract FA8204-10-C-00 10.

SECTION IV

4 SECURITY OBJECTIVES

Some elements of this contract require consideration of classified information. DD Form 254 provides classification guidance along with DOD 5220.22M.

SECTION V

5 CONTRACTOR MANAGEMENT REPORTING

The contractor shall report ALL contractor labors hours (including subcontractor labor hours) required for performance of services provided under this contract for the Air Force 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.

Contractors are required to input data by 31 October of each year. Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data. Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for government personnel and contractors are available at the Army CMRA link at http://www .ecmra.mil.