Purchase Spec A-10 Fuselage Fixture 14 May 12.pdf

HILL AIR FORCE BASE

Ogden Air Logistics Center

PURCHASE SPECIFICATION

A-10 Fuselage Fixture and Associated Components

14 May 2012

Hill Air Force Base

Ogden Air Logistics Center

Purchase Specification

A-10 Fuselage Fixture and Associated Components

1.0 Scope

1.1 This Purchase Specification (PS) is for the manufacture and purchase of two (2) A-10 fuselage fixtures and associated components as defined in the provided drawings. These fixtures are designed to support the A-10 fuselage during structural repair. They are primarily self-contained with associated equipment stored on-board except for several items (Crown

Skin Brace tools, and the Nose and Tail Support). The A-10 Fuselage fixture and associated equipment will be manufactured using the Air

Force provided drawings, technical data and specification. Full rights of ownership for all technical data, intellectual property and reproduction will be retained by the United States Air Force. This specification lists minimum requirements

2.0 Basic Requirements

2.1 The contractor shall use the Air force provided drawings as the manufacturing criteria of the fixture and components. The contractor may recommend design or produce-ability improvements that do not detract from the original intent, design or structural integrity of the fixture and components for government consideration (refer to 18.2).

Any deviations from the original design or material specifications must have written approval in advance from the Air Force process engineers.

The applicable drawings for the manufacture of the items are listed below. The latest revision upon contract award shall be used. A-10 fuselage fixture definition is to be provided via 3D annotated Computer

Aided Design (CAD) models (Model Based Definition, no 2-D drawings) created in NX (Unigraphics) format. All drawing definition

Geometric Dimension and Tolerance (GD&T) is contained within the

NX CAD file drawing. The drawings will be provided via CD/DVD.

CDRL# A005/DI-MISC-80750

2.2 A-10 Fuselage Fixture Data Package below listed items contained in the data package, including a description of what the file is (parent software and basic information). This Data package for A-10 Fuselage Fixture will be provide for quotation:

2.2.1 160D110000-1_RE1_TBOM_5.pdf- This is a PDF document, and is the complete Bill of Materials (BOM) for the Fuselage Fixture including required specifications, hardware, and raw material requirements. The BOM directly reference drawing flags and notes and bodies in the NX (Unigraphics) model files.

2.2.2 160d110000-1_re1_5-sdsup.prt – This is a native NX

(Unigraphics) part file and represents the complete fixture assembly and all of its components. Also contains embedded notes and drawing flags.

2.2.3 160d110000-1_re1_shipping_2-sdsup.prt - This is a native NX

(Unigraphics) part file. The Assembly shown is a visual reference and represents the basic shipping arrangement only. May not reflect the tool configuration 160d110000-1_re1_5-sdsup.prt in this data package.

2.2.4 160d110000-1_re1_storage_2-sdsup.prt - This is a native NX

(Unigraphics) part file. The Assembly shown is a visual reference and represents the basic storage arrangement only. May not reflect the tool configuration 160d110000-1_re1_5-sdsup.prt in this data package.

2.2.5 The step file for this model is split into three parts. to view the complete assembly all (3) parts: 160d110000-1_re1_5-sdsup.stp, 160d110000-1_re1_9004_3-sdsup.stp and 160d110000-

1_re1_9000_3-sdsup.stp, must first be converted and then assembled together to reconstruct the full assembly.

a. 160d110000-1_re1_5-sdsup.stp – This is a STEP file. The file when assembled with 160d110000-1_re1_9004_3-sdsup.stp AND 160d110000-1_re1_9000_3-sdsup.stp, show all solid bodies contained in the Fuselage Fixture

Assembly. The file does not contain any embedded notes or flags, only solid bodies are represented in the STEP file.

b. 160d110000-1_re1_9000_3-sdsup.stp - This is a STEP file.

The file when assembled with 160d110000-1_re1_9004_3-sdsup.stp AND 160d110000-1_re1_5-sdsup.stp, show all solid bodies contained in the Fuselage Fixture Assembly.

The file does not contain any embedded notes or flags, only solid bodies are represented in the STEP file.

c. 160d110000-1_re1_9004_3-sdsup.stp - This is a STEP file.

The file when assembled with 160d110000-1_re1_9004_3-sdsup.stp AND 160d110000-1_re1_5-sdsup.stp, show all solid bodies contained in the Fuselage Fixture Assembly.

The file does not contain any embedded notes or flags, only solid bodies are represented in the STEP file.

d. 160d110000-1_re1_shipping_2-sdsup.stp - This is a STEP file. The Assembly file shown is a visual reference and represents the basic shipping arrangement only. The file does not contain any embedded notes or flags, only solid bodies are represented in the STEP file. May not reflect the tool configuration 160d110000-1_re1_5-sdsup.prt in this data package.

e. 160d110000-1_re1_storage_2-sdsup.stp - This is a STEP file. The Assembly file shown is a visual reference and represents the basic storage arrangement only. The file does not contain any embedded notes or flags, only solid bodies are represented in the STEP file. May not reflect the tool configuration 160d110000-1_re1_5-sdsup.prt in this data package.

2.2.6 Upon award of contract, the following data package will be provided:

2.2.6.1 160D110000-1_RE1

2.2.6.2 160D110000-1_RE1_TBOM_5

2.2.6.3 160D110000-1_RE1_0001 thru

160D110000-1_RE1_ 0350 sequentially

2.2.6.4 160D110000-1_RE1_9000 thru

160D110000-1_RE1_9036 sequentially

2.2.6.5 160D110000-1_RE1_NEW LUG

2.2.6.6 160D110000-1_RE1_SHIPPING

CONFIGURATION

2.2.6.7 160D110000-1_RE1_STORAGE TOOL

DETAILS

2.2.7 Fuselage Fixture Review and Acceptance

2.2.7.1 A preliminary review of the fixture will be done

on the first unit at the contractor’s facilities to demonstrate functionality of the fixture, its various components, and verify that all items and requirements in this PS are met prior to shipping. The preliminary review will not be required after first article sets.

2.2.7.2 Final acceptance for the first unit and all

subsequent units will be done after delivery at

Hill Air Force Base (AFB). The contractor shall perform Physical Configuration Audit (PCA)

(section 15.1.4.1), and Functional Configuration

Audit (FCA)(section 15.1.4.2) of the fixture and components.

2.3 Order of Precedence. In the event of a conflict between the text of this

Purchase Specification and the references cited herein, the drawing package provided with this Purchase Specification shall take primary precedence. The text of this Purchase Specification shall take secondary precedence. Nothing in this Purchase Specification shall supersede applicable laws and regulations unless a specific exemption has been obtained.

3.0 Special Requirements

3.1 All openings will be appropriately capped, plugged or covered by the contractor during production and shipment to prevent foreign material from entering any lines or hoses.

3.2 Contract shall provide any special tooling if required for assemble and teardown of Fixture

4.0 Lubrication.

4.1 All mechanisms requiring lubrication including gears, slide ways, and bearings (except sealed-for-life type) shall be appropriately lubricated by the contractor prior to or upon delivery. Provide applicable MSDS on lubrication material used. CDRL# A001/FED-STD-313D

5.0 Nameplates

5.1 A Corrosion-resistant nameplate (or laser etched, need to see what the drawings shows for marking) shall be securely attached to each component per the drawing. The nameplate shall contain the information listed below:

2.2.5.1 Name of Test Stand (e.g. A-10 Fuselage Fixture )

2.2.5.1 Manufacturer’s name

2.2.5.1 Government part number

2.2.5.1 Air input (Max psi, required flow rate)

2.2.5.1 Contract number or order number

2.2.5.1 Date of manufacture (day month and year)

5.1.2 To include DFAR 252.211-7003: UID reference solicitation

6.0 Deliverables

6.1 These items are to be delivered to the Project Manager for review of accuracy and adherence to this purchase specification and supporting documentation.

TABLE II (deliverables)

Item Deliverable CDRL # PS Section 1 FED-STD-313D, Federal Standard

Material Safety Data, Transportation

Data and Disposal Data for

Hazardous Materials Furnished to

Government Activities

A001 4.1

2 DI-MISC-81356 Certificate of

Compliance

A002 6.2.1

3 DI-RELI-80322 Quality

Conformance Inspection and Test

Procedures

A003 6.2.2 and

15.1.4

4 DI-MGMT-80368A, Status Report A004 15.1.

5 DI-Misc-80750,Technical Data

Package Review Report

A005 2.1 and18.2

6.2 Documentation Requirements

6.2.1 The contractor will provide material certifications and/or specifications for materials used in the manufacture of the fixture and components upon delivery of each unit to the government.

CDRL# A002/DI-MISC-81356A

6.2.2 The contractor will provide a written dimensional inspection report of key characteristics as identified on the drawing, showing measured results to be within drawing tolerances. CDRL#

A003/DI-RELI-80322

6.2.3 Key characteristics are defined in the CAD NX model file.

7.0 Shipping / Delivery Requirements

7.1 The contractor will be responsible for all costs associated with shipping from the contractor’s facility to the government delivery destination.

7.2 Any damage incurred until final acceptance will be repaired by the contractor at the contractor’s expense.

7.3 Items that are susceptible to corrosion during shipment will be treated will an appropriate corrosion preventative compound to prevent corrosion during shipment.

7.4 Main fuselage fixture

7.4.1 The fixture will be delivered in shipping configuration.

7.4.1.1 The contractor will provide all necessary

hardware to reconfigure the fixture from the shipping configuration to the “in-use” configuration.

7.4.2 The fixture shall be shipped using adequate dunnage/packaging material and shall be appropriately protected from damage during shipment.

7.5 Additional removable and loose components.

7.5.1 All components in addition to the fixture will be packed appropriately to preclude damage during shipment, including components that are normally stored “on-board” the fixture.

7.6 Delivery

7.6.1 The contractor shall ship, offload, set-up, and perform the PCA and FCA on the Fuselage Fixture and associated components at

Hill AFB, Utah. Forklift support may be provided by the government at the request of the contractor.

7.6.2 The Fuselage Fixture and associated components shall only be offloaded under the supervision of a representative of the contractor.

7.6.3 Contractor shall make all arrangements necessary, provide all equipment necessary, and cover all costs to deliver and off load fixture, fixture components, and any other job related equipment.

Contractor shall coordinate delivery and off-loading with 309 th

AMXG through the Program Manager as required Any damages incurred during shipping, off loading, and/or storage are contractors’ responsibility to repair at no additional cost to the government.

8.0 Installation

8.1 The final delivery destination at Hill AFB, UT will be provided to the contractor upon shipping notification.

8.2 The contractor shall ship, off-load, and install the fuselage fixture and components at its final location. The contractor shall instruct the carrier that the fuselage fixture shall be off-loaded only under the supervision of a representative of the contractor, and a representative of the government.

8.3 All material, components, and base fuselage fixture shall remain the property of the contractor until it is accepted by the Government at Hill

AFB.

8.4 All costs associated with the installation, testing and preparation of the fuselage fixture for final acceptance at Hill AFB shall be the responsibility of the contractor.

8.5 The contractor shall be responsible to furnish all tools and equipment required for final assembly of the fuselage fixture to demonstrate fixture functionality for final acceptance. The Government shall furnish no tools or equipment.

8.6 Special equipment, measuring equipment, and machine alignment equipment etc., required by the contractor to assemble and align the fuselage fixture shall be furnished by the contractor and shall remain the property of the contractor.

8.7 The Utility services of the building may, in general, be used without reimbursement while performing work under this contract, if available.

9.0 Acceptance

9.1 Any damage incurred during shipment will be annotated (see section

7.0)

9.2 At the government facility upon delivery, the contractor shall unpack the fixture from the shipping material, assemble all components, demonstrate functionality of the fixture, and exhibit the inclusion of all components defined in the drawing package.

9.3 Any items deemed not in compliance with the drawings or this purchase specification by the government upon delivery will be provided in writing to the contractor for resolution. The contractor will have 30 calendar days to bring the item into compliance except as specifically negotiated otherwise with the government.

9.4 Government acceptance shall be performed at the government delivery location within 15 working days of delivery and after completion of a

FCA (Functional Configuration Audit 15.1.4.2) and a PCA (Physical

Configuration Audit 15.1.4.1) of the fuselage fixture.

9.5 Formal government acceptance of each delivery will be provided in writing to the contractor.

10.0 Foreign Object Damage (FOD) Safety Requirements: FOD is any foreign object which causes damage to an aircraft. To ensure no construction materials become FOD the contractor is required to; ensure all deliveries and construction vehicles are properly covered and clean prior to entering the industrial area, ensure all work areas are cleaned daily, ensure all construction debris is contained within the Contractor Work Zone, thoroughly clean all installed products and all construction areas prior to turn over to government..

11.0 Working Around Aircraft:

11.1 The aircraft maintenance area is defined as the entire secure (or controlled) area behind the pacer protect fence (also known as the red line area) and includes the flight line, tarmac and all facilities. No person shall enter the aircraft maintenance area without first obtaining permission, obtaining appropriate badges (or escorts), knowing the rules and agreeing to conform to the rules governing the area. WARNING:

The area classified as the flight line has additional restrictions and requirements. The boundary of the flight line is indicated by a double yellow dashed line. Access to the aircraft maintenance area does NOT grant access to the flight line. All persons entering the flight line must receive additional appropriate training prior to entering.

11.2 When working in the aircraft maintenance area, the Contractor may be required to work in close proximity to aircraft and shall use extra caution to insure that activities do not endanger aircraft or personnel nor delay aircraft maintenance activities. Special rules and regulations exist when working around aircraft. The contractor will be required to adhere to these rules and regulations. Highlights include, but are not limited to:

No work will be allowed over the aircraft

Tool control requirements

No privately owned vehicles in pacer protect area

Contractor vehicle restrictions

Restrictions of Driving/parking to close to aircraft

Flight Line restrictions

No food/beverages except in designated areas

No smoking except in designated areas

Restrictions on phones, cameras, and electronic devices

Obtaining access badges and/or security escorts

Time restrictions for unescorted work

12.0 Security Requirements

12.1 The contractor will not be required to obtain a Controlled Area Badge.

The contractor will be escorted at all times within a controlled area.

13.0 Training

13.1 There are no training requirements associated with this contract.

14.0 Facilities

14.1 The Air Force shall provide a source of 100 psi shop air and

110/120VAC power. Any other facility requirements must be agreed upon in writing during the post-award conference at Hill AFB.

15.0 Performance Summary

15.1 Events. To ensure that work is progressing on schedule and that the requirements defined in this specification are being properly addressed, the contractor shall participate in the following below: CDRL#

A004/DI-MGMT-80368A

Event Timeline Location Milestone Achievements

Post Award

Conference

<1 month

ARO

Hill AFB

1. Completed Engineering Data Guidance conference.

2. Baseline project schedule / timeline

3. Identification of project team members and their roles and responsibilities

Plans and

Schedule Reviews Monthly Teleconference

Address any issue and review schedule

100%

Manufacturing

Complete, Prior to shipping

TBD

Contractor

Facility

1. Verify that all components are correct

2. Review the dimensional inspection reports of key feature

3. Review the overall physical configuration, and functional configuration of the fixture.

Final Acceptance

Upon completion of shipping and final assembly of fixture

Hill AFB

1. Physical Configuration Audit

2. Function configuration Audit

Note: Schedule is tentative and may be adjusted by written agreements between contractor and Hill AFB Program Manger.

15.1.1 Post Award Conference. The purpose of this conference will be to review the requirements of this purchase specification and the applicable technical orders, drawing package, and provide the opportunity for the contractor to ask questions. The duration of this conference will be brief and should not exceed eight (8) hours. At the conclusion of the conference, both the contractor and Hill AFB should have a clear understanding of how the project is to proceed and a project schedule.

15.1.1.1 Plans and Schedules. The contractor shall

prepare a program plan that coordinates all activities related to this purchase specification to assure successful and timely completion. The program plan shall be presented to the government for review and approval, and shall illustrate an overall accomplishment plan, allocating responsibilities, and identifying interdependencies and agreements with all parties involved. A master milestone chart for the program shall be generated as part of the plan, detailing major events and reviews to include time involvement criteria for all participants. This chart will serve as the basis for future work scheduling and will provide a reference to track progress. Program success shall be measured by comparing the milestone chart to actual accomplishment dates. Any major discrepancies shall be brought to the attention of the Contracting Officer (CO) along with a plan to get the project back on schedule.

15.1.2 Monthly Plans and Schedule Reviews Teleconference: The purpose of this Teleconference will be to provide an opportunity to address any issues in the assembly and manufacturing of the fuselage fixture. And to confirm that the contractor is on schedule with manufacturing and delivery timeline. Contractor will update schedule.

15.1.2.1. Reports. The contractor shall prepare and

submit to government personnel a monthly status report, due 3 business days prior to monthly teleconference. This report shall summarize tasks or activities concluded during the month, the tasks started, the tasks in progress, percentage complete, and the tasks that are planned to be started during the next reporting period. A breakdown by individual tasks shall be used to best reflect progress as it relates to each development.

Any project concerns or issues that are or may impact resources or schedule shall be reported along with the projected impact to the schedule. In addition to presenting impacts, the contractor shall present a plan to correct or mitigate these impacts.

15.1.3 100% Complete, Manufacturing Complete Prior to shipping

(required on first Fuselage fixture and optional on following units).

The purpose of this visit will be to allow for the government to review the completed Fuselage Fixture and verify that all components are correct and available prior to shipping to the government facility. Also to review the dimensional inspection reports of key feature, and review the overall physical configuration, and functional configuration of the fixture. Any deviation found will be repaired by the contractor prior to shipping the fixture to government facility for final acceptance.

15.1.4 Final Acceptance will be completed after delivery, assembly, verification of required delivery documents (dimensional inspection report and material certification report), and completion of a physical configuration audit, and functional configuration audit of the assembled fuselage fixture. CDRL#

A002/DI-MISC-81356A and CDRL# A003/DI-RELI-80322

15.1.4.1 Physical Configuration Audit, will verify that all

components specified in the drawing package are present and meet the intent of the drawing requirements and the intent fixture.

15.1.4.2 Functional Configuration Audit, will verify that

the fixture as a whole operates in the way it was designed. All components can be installed correctly. Verification that the fixture shall attach correctly to the Aircraft, and interact correctly per the defined function.

16.0 Warranty. Unless noted otherwise, contractor to provide a written warranty which warrants all products provided under this contract, under normal use, will be free from defects in materials and workmanship and that each unit/system will perform its design function for a period of no less than one (1) year. Warranty period to start from date of final acceptance of each installed unit. Any defects in materials or workmanship or failure of any product or component to perform its designed function during the warranty period shall be fixed by the contactor at no additional cost to the government. Warranty shall include the cost(s) of mobilization, parts, shipping and labor. Warranty repairs which present a safety hazard are to be repaired within 7 calendar days of notice of failure. Non-safety related warranty repairs are to be fixed within 30 calendar days of notice of failure.

17.0 GENERAL INFORMATION

17.1 Subcontractor Requirements. A list of all intended subcontractors that will be used for any part of the design, build, installation, and testing shall be provided with the proposal. Hill AFB reserves the right to approve/disapprove all subcontractors’ access to work on this project.

Contractors are responsible to insure all subcontractors meet the same specifications and agreements as the prime contractor.

18.0 Engineering Data

18.1 Information Disclosure. Any developments, devices, or technical information furnished in connection with this equipment or resulting from development of this equipment shall not be disclosed to other than authorized Hill AFB personnel. Fixture design is owned by the

Government and should be treated as proprietary.

18.2 Any proposed changes by the contractor for produce-ability / manufacture-ability shall be documented by providing the government with a detailed drawing that fully defines the proposed change. The drawing and any other engineering data, if approved, will be owned by the Government. CDRL# A005/DI-MISC-80750

18.3 Relationship of Contractor with Subcontractors/Vendors: The contractor shall levy on sub-contractors and sub-vendors the same requirements for

Technical Data Packages as are levied on them by this contract. This requirement shall apply at all tiers of sub-contractor/vendor levels associated with the program.

Figure 1: Fuselage Fixture