FINAL_RFP_Attachment_11_T-38_Structural_Components_Re-Engineering_PWSv23_05Sep19.pdf

T-38 Structural Component Re-Engineering PWS – 05 Sep 19

DISCLAIMER

This document is for information only. No U.S. Government commitment to sell, loan, lease, co-develop or co-produce defense articles or provide defense services is implied or intended.

Disclosure Notice - This information is furnished on the condition that it will not be released to another nation without specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating U.S. agency.

UNITED STATES AIR FORCE

PERFORMANCE WORK STATEMENT (PWS)

For

T-38 STRUCTURAL COMPONENT RE-

ENGINEERING (RE)

05 Sep 19

Solicitation # FA8220-19-R-0002

Managed by:

AFLCMC/WLD

T-38 Program Office (PO) Mature and Proven Aircraft (MAPA) Branch

Hill AFB, Ogden UT

T he pic t ure c an't be di s pl ayed.

TABLE OF CONTENTS

1.0 INTRODUCTION

1.1 PURPOSE

1.2 BACKGROUND

1.3 SCOPE

1.4 TASKS

1.5 CONTRACTOR PERFORMANCE RESPONSIBILITIES

1.6 U.S. GOVERNMENT RESPONSIBILITIES

2.0 PROGRAM REQUIREMENTS

2.1 DELIVERY SCHEDULE

2.2 GENERAL REQUIREMENTS

2.3 ADMINISTRATIVE FUNCTIONS

2.4 PROGRAM MANAGEMENT

2.5 DATA MANAGEMENT

2.6 GOVERNMENT FURNISHED PROPERTY MANAGEMENT

2.7 GOVERNMENT PROGRAM AND CONTRACT MANAGEMENT

2.8 TRAVEL REQUIREMENTS

2.9 SUPPORT MEETING ENTITLEMENTS

2.10 MEETING TRAVEL ENTITLEMENTS

2.11 PROGRAM QUALITY ASSURANCE

3.0 DEFINITIONS

3.1 GENERAL DEFINITIONS

4.0 CONTRACT DELIVERABLES

5.0 POINTS OF CONTACT

APPENDIX A: COMPONENT LIST

APPENDIX B: AFMC IMT 260, First Article Requirements

APPENDIX C: LIST OF PROVIDED SUB-COMPONENT DRAWINGS

REVISION RECORD

Revision Date Description Page(s),Para(s)

ACRONYM LIST

AMARG Aerospace Maintenance and Regeneration Group AFB Air Force Base AFMC Air Force Materiel Command ATP Authorization to Proceed CAGE Commercial and Government Entity CDR Critical Design Review CDRL Contract Data Requirements List CONUS Contiguous United States COR Contracting Officer Representative DAC Days After Contract DCMA Defense Contract Management Agency DFMA Design for Manufacturing and Assembly DLA Defense Logistics Agency DoD Department of Defense DoDAAC Department of Defense Address Activity Code FA First Article FAL First Article Laboratory FAR Federal Acquisition Regulation FAT First Article Testing FEM Finite Element Model FS Factor of Safety GFP Government Furnished Property IAW In Accordance With IMS Integrated Master Schedule IPT Integrated Product Team JTR Joint Travel Regulations LH Left Hand MAPA Mature and Proven Aircraft MPR Monthly Program Reviews NDI Non-Destructive Inspection OEM Original Equipment Manufacturer PCA Physical Configuration Audit PCO Procuring Contracting Officer PDR Preliminary Design Review PO Program Office POC Point of Contact PoP Period of Performance PWS Performance Work Statement QA Quality Assurance QC Quality Control RE Re-Engineering RH Right Hand RMP Risk Management Plan

RPPOB Replenish Parts Purchase or Borrow SCD System Change Description SRR System Requirements Review TDP Technical Data Package TEMP Test and Evaluation Master Plan TIM Technical Interchange Meetings TO Technical Order WAWF Wide Area Work Flow

1.0 INTRODUCTION

1.1 PURPOSE

The purpose of this Performance Work Statement (PWS) is to provide the Contractor the requirements for the T-38 Structural Component Re-Engineering (RE) effort to re-engineer select T-38 structural components to reduce component costs using state of the art materials and processes.

1.2 BACKGROUND

Many T-38 bonded honeycomb structural components are proprietary to the Original Equipment Manufacturer (OEM). Recent cost increases have led the T-38 Program Office (PO) to investigate methods to reduce those costs through industry.

1.3 SCOPE

1.3.1 This effort shall consist of a basic year of requirements with two (2), one year options of additional or similar workload asfollows:

1.3.2 Basic Year: Develop draft Technical Data Package(s) (TDPs) for batch #1 of components (Items 1 through 4 in Table 1 (includes teardown, engineering analysis, System Requirements Review (SRR), Preliminary Design Review (PDR), Critical Design Review (CDR), and draft TDP delivery)).

1.3.3 Option Year 1: Produce First Article (FA) units from batch #1 items for

First Article Test (FAT) and Physical Configuration Audit (PCA). Upon successful completion of FAT & PCA, the Contractor will deliver final TDPs for batch #1 items. In addition, develop draft TDPs for batch #2 of components (Items 5 through 11 in Table 1) performing the same processes per paragraph 1.3.2.

1.3.4 Option Year 2: Produce FA units for batch #2 items for FAT and PCA.

Upon successful completion of FAT & PCA, the Contractor will deliver final TDPs for batch #2 items.

1.3.5 The technical data with respect to the subject components falls into two categories;

1.3.5.1 Proprietary: The top level assemblies are proprietary (see Table 1). Drawings/data for these assemblies is not available, and cannot be used for this RE effort under any circumstances. Examples of this proprietary data includes:

OEM drawings, OEM process specifications, OEM reports, etc.

1.3.5.2 Non-Proprietary: The majority of sub-components of the top assemblies are not proprietary in accordance with the 2005 revision of the Northrop Grumman Licensing Agreement (NGLA) that was agreed upon between NG and The T-38 Program Office. The NGLA allows the government “Unlimited Rights” to drawings identified on “Appendix A” of that agreement. The contractor will be provided with all drawings applicable to the Re-Engineering sub-components that are found on Appendix C of this PWS as a part of a TDP with the RFP. Non-proprietary sub-components will not require the development of Technical Data Packages by the contractor unless changes are made to the sub-component.

1.3.6 The following documents shall be used as a guide for this effort; Mil-

Hdbk-115A and the Defense Logistics Agency (DLA) Technical and Quality Policy and Procedures Deskbook, Appendix 37.

1.4 TASKS

1.4.1 Reverse and/or Re-engineer components:

1.4.1.1 The Contractor shall obtain a minimum of four (4) components for each item set identified in Table 1 and Figure 1 to reverse engineer the part. Based on the availability of the four (4) components, three (3) shall be of one side, either the left hand (LH) or right hand (RH). One (1) component of the opposing/bilateral side may be used to comparatively and non-destructively confirm the components are mirror images. If one component is not sufficient to confirm this, additional components shall be obtained. If the components are not mirror images, three (3) components of both sides must be obtained.

Table 1: Component List

Set Item FSC NIIN P/N Component Description

Batch

#1

1 1560 012873202 3-11801-503 Door, MLG Inboard Wheel (LH) 2 1560 012873201 3-11801-504 Door, MLG Inboard Wheel (RH)

3 1560 007848262 2-25100-605 Aileron (LH) 4 1560 007848263 2-25100-606 Aileron (RH)

#2

5 1560 008682156 2-26100-505 Flap (LH) 6 1560 008682157 2-26100-506 Flap (RH)

4 7 1560 008679687 3-31415-3 Leading Edge, Vertical Stabilizer

8 1560 010722707 3-24132-501 Wing Leading Edge (LH) 9 1560 010722706 3-24132-502 Wing Leading Edge (RH)

6 10 1560 010718300 3-23801-501 Trailing Section, Wing

7 11 1560 010665974 3-31429-13 Trailing Edge, Vertical Stabilizer

NOTE: As part of this effort for the top level components noted in Table 1 above, separate TDPs shall be developed for each sub-component and specifically the Flap and Aileron honeycomb trailing edge panels shall be interchangeable with the current configuration trailing edge panels:

• Aileron Trailing Edge Panel P/N: 3-25101-1 NSN: 1560-00-

907-9290

• LH Flap Trailing Edge Panel P/N: 3-26101-501 NSN: 1560-

01-077-4134

• RH Flap Trailing Edge Panel P/N: 3-26101-502 NSN:

1560-01-068-3846

1.4.1.2 Manufacturing and Material Limitations: Re-engineered first article and production components shall not require additive manufacuturing processes.

Figure 1: Structural Components Considered for Effort

1.4.2 Analysis Requirements:

1.4.2.1 Component Procurement: There are several avenues to

procure the components required for this effort. The availability of components for each component listed in Table 1 limits the options available to procure the components required.

1.4.2.1.1 Step 1: If components are available through DLA, the components shall be procured as Contractor owned property via DLA utilizing FedMall. The Contractor must obtain or have a current CAGE code and Department of Defense Address Activity Code (DoDAAC) for access.

1.4.2.1.2 Step 2: If components are unavailable for

procurement through DLA, the Contractor will determine if components are available from surplus vendors. If surplus components are available, the contractor will coordinate with the PO to determine if surplus components are acceptable for purchase. If the PO deems the parts acceptable, the contractor shall procure the components as Contractor owned property.

1.4.2.1.3 Step 3: If components are unavailable for

procurement through DLA, or surplus vendors, the Contractor will request components via the Replenish Parts Purchase or Borrow (RPPOB) program from DLA for Non-Destructive Inspection (NDI) only and will return the components to DLA at the end of the contract (See DoD Instruction 4140.57).

1.4.2.1.4 Step 4: If components are unavailable for

procurement or loan through DLA, or through surplus vendors, the Contractor will coordinate with the PO to acquire components from the other government organizations (i.e. the field, the Depot, NASA, Navy, or the 309th Aerospace Maintenance and Regeneration Group (AMARG)) on loan for NDI only or without intent to return for destructive testing and analysis. The Contractor will pay for shipping and/or coordinate pick up of components from government location to contractor’s location of choice.

NOTE: If Contractor identifies parts required from other government organizations, the government will have 30 days after receipt of GFP Inventory Plan/Schedule (CDRL A001) to coordinate shipment to the Contractor or pick up of parts by the Contractor.

1.4.2.2 Scanning and Teardown Inspections: The Contractor will acquire one (1) component of each set for NDI, 3D scanning, destructive inspections, etc. Three (3) additional components of each set will be requested via one of the options listed in section 1.4.2.1 for NDI only.

All components will be used for developing outer mold line data, structural interfaces, etc. The purchased asset will be used for destructive teardown to develop component strength characteristics (i.e. bonding strength, shear strength, stiffness, etc.), internal structural interfaces, material types, etc. The Contractor will provide a Test and Evaluation Master Plan (TEMP) for government approval 2 weeks prior to tear down and destructive testing (CDRL A002).

NOTE: For components that are mirror images of each other e.g. Aileron, Flap, MLG Door, and Wing Leading Edge, three

(3) components of each set (either the LH or RH side) are required for scanning and teardown inspections. For the opposite side, one (1) component is required as an inspection article for verification purposes only.

If requested by the Contractor, on-aircraft physical component and aircraft measurements will be coordinated with the T-38 PO after contract award.

1.4.2.3 Component Structural Analysis: The Contractor shall perform adequate analysis to demonstrate the Re-engineered or Reverse Engineered components have, at a minimum, equivalent properties over the current components. For example; a reverse engineered component may require very limited analysis, a hybrid component (metal skin/composite core) may require more detailed hand calculations, and an all composite component may require extensive analysis to demonstrate equivalency. All analyses will be provided as a deliverable for review by the T-38 PO (CDRL A003). The following are some of the analyses that may be considered depending on the fabrication process being proposed:

1.4.2.3.1 Equivalent strength and stress analysis:

Qualification testing can be reduced or eliminated for Design for Manufacturing and Assembly (DFMA) components’ consolidation by maintaining the current load paths, and maintaining equivalent stiffness and strength. Static and bearing strength, durability, and damage tolerance analysis, will be required for any material changes from original components.

1.4.2.3.2 Equivalent Stiffness Analysis: For new component

configurations, the following testing should be considered: aero elastic divergence, flutter, skin waviness (due to transonic and supersonic airflow) and avoidance of buzz. These would be analyzed for various areas on each structural component while evaluating the overall component bending, in plane and torsional stiffness characteristics.

1.4.2.3.3 Mass Properties and Dynamic Analysis: For new

component configurations, mass properties will be calculated and documented. Depending on the results of the dynamic analysis, a change in dynamic response of the reverse engineered component, a dynamic analysis may be required for the adjacent/mating components.

1.4.2.3.4 Fatigue and Life Estimate Analysis: Contractor will perform fatigue analysis to estimate life expectancy of the component.

1.4.2.3.5 Loads Development and Analysis: Ideally a T-38

Finite Element Model (FEM) with all load conditions at max deflection control surface pressure distributions would be available and used to develop all of the structural component external and internal loads. However, due to the proprietary nature of the OEM data, this information is not available.

In lieu of using a FEM, the Contractor shall be required to accomplish one of two approaches to qualify new component configurations:

Approach 1: The Contractor shall prove that any changes to configuration is of equal or higher strength than the original; or

Approach 2: The Contractor shall be required to utilize simplified and bounding conservative approach to establish the external loads in support of structural sizing. As an example, for control surface, maximum aircraft performance would be used to determine the highest dynamic pressure and then use a worst case airflow surface impingement angle and/or control surface deflection to develop the maximum aero pressure limit loads.

These loads will then be applied to the structural components surface and then, using balanced reactive interface loads, analytical FEM models would determine the internal loads. Structural sizing will be based on the ultimate loads (limit loads x ultimate Factor of Safety (FS), typical Aerospace FS is 1.5).

1.4.2.3.6 Dimensional Tolerance Analysis: For all interface

points between the contract components and the aircraft, a plan for establishing dimensional tolerance requirements shall be created and approved by the government.

1.4.3 Testing Requirements:

1.4.3.1 Component Level Testing: Structural components that are reverse engineered to the original manufacturing configuration will not require component level testing. However, for re-engineered structural components where the manufacturing configurations and materials cannot be qualified and certified by similarity / analyses (with the appropriate test FS, typical Aerospace FS is 1.5), representative component manufacturing configuration and material testing is required.

Material testing shall include durability and environmental testing. An Acceptance Test Plan shall be proposed by the Contractor 2 weeks prior to testing and approved by the government for component level testing (CDRL A004).

NOTE: Testing may be waived by the government where test data exists for previously approved systems.

Examples of possible testing include: coupon level test, destructive and non-destructive testing, vibration testing, moment of inertia on control surfaces, fatigue testing, static testing, etc.

1.4.3.2 First Article Deliveries: The Contractor shall complete FA assemblies for LH components of each set identified in Table 1 in Section 1.4.1.1 of this PWS. The Contractor shall provide in the proposal, costs to produce three (3) or and five (5) FA assemblies of each component (21 or 35 FA assemblies total).

The assemblies shall be delivered to the Hill AFB First Article (FA) Lab for testing 90 days prior to the PCA. The Contractor will provide the government all requirements listed in Appendix B of this PWS, AFMC IMT 260, First Article Requirements, with the delivery of FA assemblies. After FA testing is complete, these assemblies will be delivered to a T-38 operating base for test fit on an aircraft and completion of the

PCA.

1.4.4 Technical Documentation:

1.4.4.1 TDP Development: A TDP shall be developed for each

component (including all subcomponents that the government has not been granted unlimited rights) (CDRL A005, CDRL A006).

1.4.4.1.1 A Draft TDP shall be required at the end of the

Basic Year for batch #1 components and required production tool and at the end of Option Year 1 for batch #2 components and required production tools.

The Draft TDP will include adequate detail to proceed with manufacturing of FA units during the manufacturing phases of the contract. The Draft TDPs shall include but are not limited to: 3D models, 2D drawings, detail notes, Bill of Material, etc.

(CDRL A005, CDRL A006).

1.4.4.1.2 Final TDPs (updated and approved Draft TDPs after

completion of the PCA) shall include but are not limited to: 3D models, 2D drawings, detail notes, Bill of Material, etc. All models and drawings shall be accomplished using English units. All Technical Data will be government owned at the completion of the contract and shall not include proprietary data or restrictive markings on components, processes, etc.

All drawings shall be completed using the Air Force format provided in CDRL A005 and A006 and will include Air Force part numbers and CAGE Codes.

Delivery format requirements for all 3D models and 2D drawings shall follow MIL-STD-31000A (CDRL

A005, CDRL A006).

Contractor shall deliver five (5) electronic (DVD) copies of the complete TDP (CDRL A005, CDRL A006)

• Native 3D models (Siemens NX is preferred, Solidworks is acceptable)

• Associated Native 2D drawings (these are linked and driven by the 3D models)

• .PDF viewable copy of the 2D drawings

• .STP files derived from the native 3D models

The Contractor shall deliver a final TDP for each component and production tools to the government upon successful completion of FAT and PCA. The Contractor must deliver complete data packages for every reverse/re-engineered component that is sufficient for competitive manufacture of the component and data package must be delivered without restrictive markings.

1.4.4.2 Technical Publications and Retrofit Instructions: New part numbers for the eleven (11) RE’ed and all sub-components shall be required. The T-38 PO will update applicable Technical Orders (TO) with the updated part number information.

If special retrofit instructions are required, they shall be provided (CDRL A007). For example: A scenario when an area would require a new retrofit instruction to be authored would be with the introduction of a new material and/or process which requires step by step instructions to install or repair the new structural component

1.4.5 Tooling:

1.4.5.1. A TDP shall be developed for each production tool. All assembly/drilling jigs that have a tooling drawing should also be provided. Follow the same instruction in 1.4.4.1.1 through

1.4.4.1.2 for Tooling TDP development.

1.4.5.2. The Contactor will provide a cost estimate for completing the contract with and without delivering government owned Production Tools.

1.5 CONTRACTOR PERFORMANCE RESPONSIBILITIES

1.5.1 The Contractor shall meet or exceed the minimum performance metrics per the Service Summary listed in Section 2.11.5, Table 3.

1.5.2 The Contractor shall perform the tasks listed above and achieve the performance standards for each task. For specified tasks, the Contractor shall submit performance-based plans, which shall provide assurance that the Contractor will meet all performance standards outlined herein and comply with contract requirements.

The Contractor shall abide by all applicable laws, regulations, and guidelines, including future changes thereto.

1.5.3 The Contractor shall be responsible for all costs associated with meeting metrics as described in this PWS, with the exception of Government-requested changes. The only person that can request a change or obligate the government is the Procuring Contracting Officer (PCO). All changes require a fully signed modification before work shall begin.

1.6 U.S. GOVERNMENT RESPONSIBILITIES

The government will monitor the Contractor’s performance in accordance with (IAW) procedures set forth in the Services Summary, Table 3 of this document, and the procedures set forth in the Inspection of Services Clause, 52.246-4 for fixed price and 52.246-5 for cost reimbursement.

2.0 PROGRAM REQUIREMENTS

2.1 DELIVERY SCHEDULE

2.1.1 The Contractor shall adhere to the delivery schedule listed in Table 2.

Table 2: Delivery Schedule

Paragraph Description CDRL Due Date

1.4.2.1.4 2 6 1 1

Initial GFP Inventory Plan/Schedule A001 30 DAC

2.6.1.1

Annual GFP Inventory

A001

Annually; NLT end of PoP for Basic Year, Option Year 1, Option Year 2

1.4.2.2 Test and Evaluation

Master Plan A002 2 Wks. Prior to Testing

1.4.2.3 Analysis Reports A003 1 Week after completion of

Analysis

1.4.3.1 Acceptance Test Plan A004 2 Wks. Prior to Testing

1.4.4.1.1, 1.4.5

Batch 1 Draft Technical Data Packages

A005 A006

301 DAC Basic Year

1.4.4.1.1, 1.4.5

Batch 2 Draft Technical Data Packages

301 DAC Option Year 1

1.4.4.1.2, Batch 1 Final A005 511 DAC Option Year 1, 30

1.4.5 Technical Data

Packages A006 days after FAT/PCA – batch #1

1.4.4.1.2, 1.4.5

Batch 2 Final Technical Data Packages

A005 A006

511 DAC Option Year 2, 30 days after FAT/PCA - batch #2

1.4.4.2 Retrofit Instructions A007 With Final TDP Delivery

2.4.1

Integrated Program Management Report – IMS only

A008

First Submission - within 12 working days after the end of the second full accounting period following ATP Subsequent Submissions- Monthly within 12 working days after the close of the contractor’s monthly accounting period

2.4.2 Management Plan A009 30 DAC Basic Year

2.4.5 Small Business

Subcontractor Report A010 Semi-annually

2.4.6 Contractor’s Risk

Management Plan A011 30 DAC Basic Year

2.9.1.1

Technical Review Presentation Package

– SRR Basic Year

A012

1 Wk. Prior to Review

– SRR Option 1

A013

– SRR Option 2

A014

2.9.1.2

– PDR Batch 1

A015

2.9.1.2

– PDR Batch 2

A016

2.9.1.3

– CDR Batch 1

A017

2.9.1.3

– CDR Batch 2

A018

2.9.1.4 Monthly Program

Review A019 Monthly

2.9.2 Support Meeting

Minutes A020 1 Wk. After Meeting

2.2 GENERAL REQUIREMENTS

2.2.1 The Contractor shall manage the total work effort as specified and shall assume total responsibility for all requirements.

2.2.2 The Contractor shall provide all services, materials, supplies, supervision, labor, management services, planning, programming, transportation, administration, and general and specialized equipment necessary to provide the specified services IAW the terms, conditions, and specifications of this contract.

2.2.3 The Contractor shall perform all related Contractor administrative services required to perform work required for material requisitioning, financial control, and correspondence.

2.2.4 The Contractor shall maintain accurate and complete records, files, and libraries of documents IAW this PWS.

2.2.5 The Contractor shall maintain schedules of key meetings, reviews, projects, and processes described in this document.

2.2.6 The Contractor shall provide Contract Data Requirements List

(CDRLs) as referenced in Table 4 as applicable.

2.3 ADMINISTRATIVE FUNCTIONS

2.3.1 The Contractor shall perform administrative functions, to include scheduling meetings, arranging facilities, providing status reports, documenting official decisions and actions assigned, and maintaining charter documents, records, and databases referenced within this document.

2.3.2 The Contractor shall appoint a primary Point of Contact (POC) for this contract. This individual shall be the primary representative and have the Contractor’s full authority to act on matters pertaining to the performance of the services under this contract.

2.3.3 The Contractor employees shall be trained, qualified, certified, or licensed as required to perform this contract.

2.4 PROGRAM MANAGEMENT

2.4.1 Integrated master Schedule (IMS): The Contractor shall provide an IMS within 12 working days after the end of the second full accounting period following Authorization to Proceed (ATP) (CDRL A008).

2.4.1.1 The IMS shall be to the level of detail required to develop work packages and define activities to which durations can be assigned. The Contractor shall use best commercial practices in the development and maintenance of the schedule. The format utilized must be compatible with Microsoft Project and Microsoft PowerPoint for government review and use.

2.4.2 Management Plan: The Contractor shall provide a Management

Plan (CDRL A009).

2.4.3 Meetings and Reviews: The Contractor shall plan, arrange and coordinate meetings, reviews, and working groups as required in Section 2.9 of this PWS.

2.4.4 Small Business Participation: The government has set a minimum overall small business subcontracting goal (first-tier) or 15% of the total subcontracted amount that the contractor agrees to put forth a good faith effort to achieve.

2.4.5 Small Business Utilization Reporting: The Contractor shall manage their subcontracting plan per the appropriate contract clause IAW Federal Acquisition Regulations (FAR) 52.244-2 and 52.219-9, and provide a Small Business Subcontractor Report semi-annually

(CDRL A010).

2.4.6 Risk Management: The Contractor shall develop the criteria, methods, and procedures used for identifying critical risks associated with the implementation of this Contract. Using the latest Department of Defense (DoD) Risk Management Guide as reference, the Contractor shall implement a risk management process and provide a Risk Management Plan (RMP) that efficiently identifies, analyzes, mitigates, and tracks potential impacts to mission success (CDRL A011).

2.5 DATA MANAGEMENT

2.5.1 Documentation deliverables shall be delivered in accordance with this

PWS and the Form DD1423s attached to the task order, unless otherwise specified by the Government Program Manager (PM) and Contracting Officer (CO) through a contract modification or CO letter.

If there is a discrepancy in due dates between the PWS and the DD1423s, this PWS shall take precedence. Due dates falling on non-working days (Saturdays, Sundays, and recognized national (legal) holidays) shall be construed to mean the next regular working day. All due dates (i.e. 30 DAC) are calendar counted unless designated otherwise.

2.5.2 The government will have unlimited rights to items, systems, processes, software, and technical data developed under this contract.

2.5.3 Prior Government Approval: The Contractor shall obtain prior written approval from the PCO before committing to the use of any private and mixed funds developed items, components, processes, and technical data which they:

• Intend to deliver with Limited Rights

• Intend to deliver with Government Purpose License Rights

• Intend to deliver with Restricted Rights

• May have less than Unlimited Rights

• Will use in the performance of this contract

• Cannot meet the requirements outlined in Section 1.4.

2.6 GOVERNMENT FURNISHED PROPERTY MANAGEMENT

2.6.1 Government Furnished Property (GFP)

2.6.1.1 The Contractor shall provide a GFP Inventory Plan/Schedule and Report IAW FAR 45.202 and DI-MGMT-80441A for Batch #1 within 30 days of basic year contract award and for Batch #2 within 30 days of option year 1 contract award (CDRL A001). This plan will outline the procurement strategy for each component required to be acquired by the Contractor via one of the methods outlined in section 1.4.2.1 of this PWS. The Contractor shall provide an updated version of this report annually NLT the end of the period of performance (PoP) for the base year, option year 1, and option year 2.

2.6.1.2 The Contractor shall be responsible for all repairs to the GFP for the duration of the PoP or while the GFP is in the Contractor’s possession. IAW FAR 52.245-1 Government Property, the Contractor shall return to the government all GFP at the conclusion of the loaned period in an “as is” condition.

2.7 GOVERNMENT PROGRAM AND CONTRACT MANAGEMENT

2.7.1 The government Program Manager will provide the Contractor access to all technical data required to perform approved tasking’s. Only the government Program Office Contracting Officers’ Representative (COR) has authority to approve contractdeliverables.

2.7.2 Responsibility for contracting activities rests solely with the PCO. No conversation, recommendations, or direction, whether given directly by, or implied by government personnel, that will affect thescope, schedule, or price of the contract covered by this PWS, shall be acted upon by the Contractor unless specifically approved by the PCO and issued through a formal contract modification.

2.8 TRAVEL REQUIREMENTS

The Contractor shall obtain approval from the government Program Manager a minimum of five business days in advance before traveling.

Airfare for travel and per Diem shall be billed IAW FAR 31.205-46. The Contractor shall be responsible for making all necessary travel arrangements. If emergencies or contingencies require immediate travel authorization or approval, the Contractor shall contact the PCO.

2.9 SUPPORT MEETING ENTITLEMENTS

2.9.1 The Contractor shall support and host the following meetings:

2.9.1.1 Post-Award Kick-Off Conference and Systems

Requirements Review (SRR): The Contractor shall conduct, at their facility, a contract kickoff meeting and SRR within 30 days after contract award for basic year (CDRL A012) and option year contracts (CDRL A013, CDRL A014). The estimated duration for this task is 1-2 days. A SRR is a formal review conducted to ensure that system requirements have been completely and properly identified and that a mutual understanding between the government and Contractor exists.

2.9.1.2 Preliminary Design Review (PDR): The PDR is a technical assessment that establishes the Allocated Baseline (functional and interface characteristics) of a system to ensure a system is operationally effective and has a reasonable expectation of satisfying the requirements within the currently allocated budget and schedule. The Contractor shall provide documentation to support the following objectives of the PDR for batch #1 (CDRL A015) and batch #2 (CDRL A016) one (1) week prior to the review:

• An established system allocated baseline

• An updated risk assessment for the Engineering, Manufacturing and Development (EMD) Phase

• An updated program schedule including critical path drivers

2.9.1.3 Critical Design Review (CDR): A CDR is a multi-disciplined technical review to ensure that a system can proceed into fabrication, demonstration, and test and can meet stated performance requirements within cost, schedule, and risk.

The Contractor shall provide documentation to support the following objectives of the CDR for batch #1 (CDRL A017) and batch #2 (CDRL A018) one (1) week prior to the review:

• An system initial Product Baseline (e.g. TDPs)

• An updated risk assessment for the Engineering, Manufacturing and Development (EMD) Phase

• An updated program development schedule including fabrication, test and evaluation, and critical path drivers

2.9.1.4 Monthly Program Reviews (MPR): The Contractor shall

conduct MPRs (this can be held in conjunction with SRR, PDR, CDR, etc.). The purpose of these reviews will focus on the IMS, current status of the program, major accomplishments, questions/concerns, etc. (CDRL A019).

2.9.1.5 Face-to-Face Quarterly Meetings: The Contractor and

government will meet face-to-face at least quarterly. The MPR, SSR, PDR, and CDR can function as the Face-to- Face Quarterly Meeting.

2.9.2 Unless otherwise stated, the Contractor shall record and distribute meeting minutes and maintain an account of action items for all Government-Contractor meetings (CDRL A020) listed in Section 2.9.1.

2.9.3 The Contractor shall provide all supporting documentation for the PDR, CDR and Draft TDP, 1 weeks prior to the scheduled meeting to allow for government review.

2.10 MEETING TRAVEL ENTITLEMENTS

All per diem and travel in support of government-initiated meetings will be reimbursed at cost IAW Federal Travel Regulations for Contiguous United States (CONUS); Joint Travel Regulations (JTR) for Alaska, Hawaii and outlying U.S.; and Standardized Regulations (Sec 925) for foreign areas.

2.11 PROGRAM QUALITY ASSURANCE

2.11.1 The Contractor shall implement and maintain a Quality Assurance

(QA) program IAW either AS9100 or AS9110 standards. As part of this QA program, the Contractor shall maintain a responsive surveillance system that continually monitors, documents, and corrects deficiencies in processes and procedures. When requested, the Contractor shall allow the government access to their QA program.

2.11.2 The Contractor Quality Organization shall provide support of requirement peer reviews, monitoring of activities to ensure processes are being followed, review of products generated (e.g., System Change Description (SCD)) and support of meetings to ensure compliance with established Contractor quality standards.

2.11.3 The Program Office COR(s) will review and approve Contractor submitted metrics for purposes of billing. Program Office COR(s) must receive and concur with Contractor submitted metrics prior to Defense Contract Management Agency (DCMA) acceptance of invoices in Wide Area Work Flow (WAWF).

2.11.4 The Contractor will be notified by letter upon contract award of the

Primary and Alternate CORs assigned to this contract.

2.11.5 Services Summary: The Contractor shall be aware that in the absence of any contract requirement from the Service Summary does not detract from its enforceability nor limit the rights or remedies of the government under any other provision of the contract. The Contractor shall ensure the following service summary requirements are accomplished

Table 3: Services Summary (SS) Requirements

Item Performance Objective

PWS

Paragraph

Performance Threshold Method of Surveillance

1 First Article (FA) Assembly

1.3.3 1.3.4 1.4.3.2

Delivered NLT 90 days prior to scheduled PCA.

FA Form 206 requirements completed with 98% accuracy, corrections within 5 working days.

100% inspection

2 Initial GFP Inventory Plan/Schedule

CDRL A001

2.6.1.1

Delivered 98% of the time with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

3 Annual GFP Inventory

CDRL A001

2.6.1.1

Delivered 98% of the time with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

4 Test and Evaluation Master Plan (TEMP)

CDRL A002

1.4.2.2 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

5 Analysis Reports

CDRL A003

1.4.2.3 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

6 Acceptance Test Plan

CDRL A004

1.4.3.1 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

7 Draft Technical Data Package

(TDP)

CDRL A005

CDRL A006

1.4.4.1.1 1.4.5

Delivered 98% of the time with 95% accuracy.

Deficiencies to be corrected within 30 working days after Government review.

100% inspection

PWS

Paragraph

Performance Threshold Method of Surveillance

8 Final TDP

CDRL A005

CDRL A006

1.4.4.1.2 1.4.5

Delivered 98% of the time with 95% accuracy.

Deficiencies to be corrected within 30 working days after Government review.

100% inspection

9 Retrofit Instructions

CDRL A007

1.4.4.2 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 30 working days after Government review.

100% inspection

10 Integrated Program Management Report – IMS Only

CDRL A008

2.4.1 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

11 Management Plan

CDRL A009

2.4.2 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 30 working days after Government review.

100% inspection

12 Small Business Subcontractor Report

CDRL A010

2.4.5 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

13 Contractor’s Risk Management Plan

CDRL A011

2.4.6 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 30 working days after Government review.

100% inspection

14 Technical Review Presentation Package – SRR Basic Year

CDRL A012

2.9.1.1 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

PWS

Paragraph

Performance Threshold Method of Surveillance

15 Technical Review Presentation

Option 1

CDRL A013

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

16 Technical Review Presentation

Option 2

CDRL A014

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

17 Technical Review Presentation Package – PDR Batch 1

CDRL A015

2.9.1.2 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

18 Technical Review Presentation Package – PDR Batch 2

CDRL A016

2.9.1.2 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

19 Technical Review Presentation Package – CDR

CDRL A017

2.9.1.3 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

20 Technical Review Presentation Package – CDR

CDRL A018

2.9.1.3 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule

PWS

Paragraph

Performance Threshold Method of Surveillance

21 Monthly Program Review

CDRL A019

2.9.1.4 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule listed in Section 2.1 of the PWS

22 Support Meeting Minutes

CDRL A020

2.9.2 Delivered 98% of the time

with 95% accuracy.

Deficiencies to be corrected within 5 working days.

Periodic/calendar as defined in Delivery Schedule

3.0 DEFINITIONS

3.1 GENERAL DEFINITIONS

Acceptance: The signing of a DD Form 250 by the duly authorized government representative.

Contractor-acquired property: Property acquired, fabricated, or otherwise provided by the Contractor for performing a contract, and to which the Government has title.

Contractor-owned property: Property acquired, fabricated, or otherwise provided by the Contractor for performing a contract, and to which the Contractor has title.

Government-Furnished Property: Property in the possession of, or directly acquired by, the government and subsequently furnished to the Contractor for performance of a contract. GFP includes, but is not limited to, spares and property furnished for repair, maintenance, overhaul, or modification. GFP also includes Contractor-acquired property if the Contractor- acquired property is a deliverable under a cost contract when accepted by the government for continued use under the contract.

Government property: All property owned or leased by the government.

Government property includes both GFP and Contractor-acquired property.

Government property includes material, equipment, special tooling, special test equipment, and real property. Government property does not include intellectual property and software.

Production Tools: Tooling used to produce the structural component which also includes the establishment of the I&R interfaces. Sheet metal forming dies, machined surface molds / fabrication assembly tools that are used to create the component shape and or assembly in a honeycomb bonded assembly, part forging dies (if applicable), part casting molds (if applicable) would all fit into this category.

Re-Engineered: Any component redesigned to meet Fit and Function requirements but may be manufactured in a different Form than the original.

Example: a Re-Engineered honeycomb bonding adhesive functions the same or better than the original 1950’s adhesive but is made from current technologies. Thus, the Re-Engineered part meets the Fit and Function Requirements of the original, and the Form requirements are met or exceeded.

Reverse Engineer: Reverse engineering is the process of duplicating an item, functionally and dimensionally, by physically examining and measuring existing parts to develop the technical data (physical and material characteristics) required for competitive procurement (See MIL-HDBK-115A for details outlining Reverse Engineering). The reverse engineering process may be performed on specific items which are currently purchased sole-source. This may be due to limited data rights, an inadequate TDP, a diminished or non-existent source of supply, or as part of a Product Improvement Program (PIP). Normally, reverse engineering will not be cost effective unless the items under consideration are of a high dollar value or are procured in large quantities. Such items may be reverse engineered if an economical savings over their acquisition life cycle is demonstrated, and if other methods of acquiring the necessary technical data for competitive re-procurement are either more costly or not available.

4.0 CONTRACT DELIVERABLES

Table 4: CDRL List

CDRL

Number Short Name Full Name Paragraph DID

A001

GFP

Management

GFP Inventory Plan/Schedule 1.4.2.1.4

2.6.1.1

DI-MGMT-

80441A

A002 TEMP Test and Evaluation Master Plan 1.4.2.2 DI-QCIC-

80553A A003 Analysis

Report Component Structural Analysis Reports

1.4.2.3 OT-2018-

30103

A004

Component Level Test

Acceptance Test Plan

1.4.3.1 DI-QCIC-

80553A

TDP

Technical Data Package

1.4.4.1 1.4.4.1.1 1.4.4.1.2 1.4.5

DI-SESS-

80776A

Drawings

Product Drawings/Models & Associated Lists

1.4.4.1 1.4.4.1.1 1.4.4.1.2 1.4.5

DI-SESS-

81000E-T

A007 Retrofit Instructions

Technical Report- Study/Services 1.4.4.2 DI-MISC-

80508B

A008

IMS

Integrated Program Management Report – IMS only

2.4.1 DI-MGMT-

81861A

A009 Mgmt. Plan Management Plan 2.4.2 DI-MGMT- 80004A

A010 SB

Subcontractor

Small Business Subcontractor Report 2.4.5 DI-MGMT-

81642

A011 RMP Contractor’s Risk Management Plan 2.4.6 DI-MGMT-

81808

A012

SRR Basic

Technical Review Presentation Package – SRR Basic Year

2.9.1.1 DI-SESS-

82168

A013

SRR 1

Option 1

A014

SRR 2

Option 2

A015

PDR 1

Presentation Package – PDR

2.9.1.2 DI-SESS-

PDR 2

Technical Review Presentation Package – PDR

2.9.1.2 DI-SESS-

CDR 1

Presentation Package – CDR

2.9.1.3 DI-SESS-

A018

CDR 2

Presentation Package – CDR

2.9.1.3 DI-SESS-

A019

Monthly Program Review

Program Progress Report

2.9.1.4 DI-MGMT-

80555A

A020 Meeting Minutes

Report, Record of Meeting/Minutes 2.9.2 DI-ADMN-

81505

5.0 POINTS OF CONTACT

Casey Hodson Procuring Contract Officer – AFLCMC/WLDK 6072 Fir Ave Hill AFB, UT 84056 801-777-8416, casey.hodson@us.af.mil

1Lt Samuel Byers Project Manager/Primary COR – AFLCMC /WLDMB 6064 Dogwood Ave Hill AFB, UT 84056 801-586-2986, samuel.byers@us.af.mil

Eric Flygare Program Engineer – AFLCMC/WLDEB 6057 Box Elder Hill AFB, UT 84056 801-777-7346, eric.flygare@us.af.mil mailto:casey.hodson@us.af.mil mailto:skyler.means.1@us.af.mil mailto:eric.flygare@us.af.mil

APPENDIX A: COMPONENT LIST

Set Item FSC NIIN P/N Component Description

#1

1 1560 012873202 3-11801-503 Door, MLG Inboard Wheel (LH) 2 1560 012873201 3-11801-504 Door, MLG Inboard Wheel (RH)

3 1560 007848262 2-25100-605 Aileron (LH) 4 1560 007848263 2-25100-606 Aileron (RH)

#2

5 1560 008682156 2-26100-505 Flap (LH) 6 1560 008682157 2-26100-506 Flap (RH)

4 7 1560 008679687 3-31415-3 Leading Edge, Vertical Stabilizer

8 1560 010722707 3-24132-501 Wing Leading Edge (LH) 9 1560 010722706 3-24132-502 Wing Leading Edge (RH)

6 10 1560 010718300 3-23801-501 Trailing Section, Wing 7 11 1560 010665974 3-31429-13 Trailing Edge, Vertical Stabilizer

APPENDIX B: AFMC IMT 260, First Article Requirements

APPENDIX C: LIST OF PROVIDED SUB-COMPONENT DRAWINGS

2-11801 DOOR-WHEEL, MAIN LANDING GEAR, ASSY OF

2-11802 HINGE-DOOR, WHEEL, MAIN LANDING GEAR

2-11803 SUPPORT-UPLOCK, FORWARD, MAIN LANDING HEAR DOOR, ASSY OF

2-11807 SUPPORT-UPLOCK, AFT, MAIN LANDING GEAR DOOR

2-11847 SUPPORT-SWITCH, LINK, MLG DOOR

2-11849 RIB-DOOR, MAIN LANDING GEAR, ASSY OF

2-11887 SEAL-WHEEL DOOR, MAIL LANDING GEAR, ASSY OF

2-23801 PANEL-TRAILING SECTION, WING STA 108.25 TO 125.0, ASSY OF

2-24131 STRUCTURE-LEADING EDGE, WING ASSY OF

2-24134 DOUBLER-UPPER, LEADING EDGE,WING

2-24135 DOUBLER-LOWER, LEADING EDGE, WING

2-24138 TUBE-CONTROL CABLE, LEADING EDGE, WING

2-25101 PANEL-TRAILING SECTION, AILERON, ASSY OF

2-25103 SPAR-TRAILING SECTION, AILERON

2-25105 HINGE INSTL-INBD AILERON

2-25106 HINGE-INBD AILERON

2-25107 HINGE INSTL-OUTBOARD, AILERON

2-25108 HINGE-OUTBD, AILERON, ASSY OF

2-25109 SPAR INSTL-FRONT, AILERON

2-25110 SPAR-FRONT, AILERON

2-25111 RIB INSTL-INTERMEDIATE, AILERON

2-25112 RIB INSTL-SUPPORT, STA 76.275, AILERON

2-25113 RIB INSTL-SUPPORT, STA 83.12, AILERON

2-25114 FORMERS INSTL-LEADING EDGE, AILERON

2-25116 SEAL-AILERON, INBOARD

2-25117 PIN, HINGE, AILERON-INBD

2-25118 PIN, HINGE, AILERON-OUTBD

2-25119 SKIN-UPPER, AILERON

2-25120 SKIN-LOWER, AILERON

2-25121 RIB-SUPPORT, STA 83.12, AILERON

2-25122 RIB SUPPORT, STA 76.275, AILERON

2-25125 SEAL-AILERON, OUTBD

2-25126 PIN-RETAINING, HINGE PIN, AILERON

2-26101 PANEL-TRAILING, SECTION, FLAB ASSY OF

2-26104 SKIN-LOWER, TRAILING SECTION, FLAP

2-26105 HINGE INSTL-INBOARD, FLAP

2-26106 HINGE-INBD, FLAP, ASSY OF

2-26107 HINGE INSTALLATION-OUTBOARD, FLAP

2-26108 HINGE ASSY-OUTBD FLAP

2-26109 SPAR INSTL-FRONT, FLAP

2-26110 SPAR-FRONT, FLAP, ASSY OF

2-26111 RIBS INSTL-INTERMEDIATE, FLAP

2-26114 RIBS INSTL-NOSE, FLAP

2-26115 SKIN-LEADING EDGE, FLAP

2-26116 SKIN-INTERMEDIATE, UPPER, FLAP

2-26117 PIN-HINGE, OUTBOARD, FLAP

2-26119 CAP-UPPER, FRONT SPAR, FLAP

2-26120 CAP-LOWER, SPAR, FRONT, FLAP

2-26121 RIB-NOSE, FLAP W S 66.25

2-26122 HINGE-FLAP, STA 66.25

2-26123 SKIN-INTERMEDIATE, LOWER, FLAP

2-26124 PIN-HINGE, INBD, FLAP ASSY OF

2-26200 HINGE INSTL-FIXED, FLAP OUTBD, WG STA 66.250

2-26201 HINGE FIXED FLAP, OUTBD, WG STA 66.250

2-26202 SHIM-LAMINATED, FIXED FLAP HINGE, WG STA 66.250

2-31414 LEADING EDGE INSTL-VERT STAB

2-31415 SKIN-LEADING EDGE, VERT STAB

2-31429 TRAILING EDGE INSTL-VERT STAB

2-31430 SKIN-TRAILING EDGE, VERT STAB

3-00506 MARKING INSTL-EXTERIOR AND INTERIOR, WING

3-00507 MARKINGS EXTERIOR, FORWARD FUSELAGE

3-00511 MARKINGS-EXTERIOR AND INTERIOR, AFT FUS

3-00512 MARKINGS, WING-EXTERIOR AND INTERIOR

3-24131 STRUCTURE-LEADING EDGE, WING, ASSY OF

3-26254 HINGE ASSEMBIXED, FLAB OUTBD-WG STA 66.250

3-43112 BRACKET-HYDRAULIC TUBE SUPPORT, WING LE STA 39.40, AFT

3-43113 BRACKET-HYDRAULIC TUBE SUPPORT, WING LE STA 39.40, FORWARD

40S203 SHIM, BASKET NUT AND SPECIAL

40S240 SEE 40S240

F164 FLUSH HEAD, BLIND

F200 SHIM (LAMINATED)

P164 ALUMINUM ALLOY SHEET, PERFORATED, STAGGERED ROUND HOLES

PLT110 VISU-LOK, FASTENER, BLIND