Attachment_1_Performance_Work_Statement_v.2.pdf

PERFORMANCE-BASED WORK STATEMENT (PWS)

MILLING A-10 OUTER & CENTER WING SPLICE FITTINGS

U.S AIR FORCE

309TH COMMODITIES MAINTENANCE GROUP (CMXG)

5/1/2019

Milling a-10 outer & center wing splice fittings i

TABLE OF CONTENTS

1 DESCRIPTION OF SERVICES

2 BASIC SERVICES

2.1 A-10 110.00 Splice Fitting Milling

2.2 Wing, Center Panel, (WCP)

2.3 Wing, Outer Panel, (WOP)

2.4 Estimated Workload Data

2.5 Reporting Requirements

3 Service Summary

4 CDRL Summary

Appendix A – Wing, Center Panel, WCP

Appendix B – Wing Center Panel, WCP

Appendix C – Wing outer Panel, WOP

Appendix D – Wing outer Panel, WOP

1 DESCRIPTION OF SERVICES

This performance work statement (PWS) identifies requirements of the 309 Commodities

Maintenance Group (CMXG) at Hill Air Force Base (Hill AFB) for a service contract for

A-10, Wing Station 110.00 Splice Fitting Milling. The milling services shall be performed at the contractor’s facility in support of the 533rd A-10 wing shop located at Hill AFB. The milling services shall be performed in accordance with (IAW) applicable Air Force technical data and engineering drawings, and shall be completed by the contractor within five (5) business days of receipt of wing at the contractor’s facility. Each wing set

(consisting of two (2) Outer Wings and one (1) Center Wing) require a minimum of four

(4) machining setups by the contractor, two (2) for each Center Wing and one (1) for each

Outer Wing. The contractor shall provide all management, tools, supplies, equipment, and labor to perform milling services for the Wing Station (WS) 110.00 splice fitting surfaces of the A-10 Wing Center Panel (WCP) and the Wing Outer Panel (WOP).

2 BASIC SERVICES

2.1 A-10 110.00 Splice Fitting Milling

2.1.1 The Government will provide the contractor a minimum of 24 hours’ notice prior to delivery of the A-10 WCP and/or WOP to the contractor’s facility. The

Government will pack the A-10 WCP and/or WOP for delivery and transport to and from the contractor’s facility within a radius of 50 miles of Hill AFB. The

WS 110 splice fitting shall not be exposed to atmospheric elements after completion of milling.

(Note for Local Restriction* The wings are delivered attached to the 309th

CMXG’s local work and transportation trailers. The entire wing/trailer assembly is delivered on a flatbed semi truck and held down by straps. The government is limiting the range that this truck has to travel to less than 50 miles for a couple of reasons: a) The goverment does not have protective covers for these wings and trailers. Delivering the wings farther than 50 miles increases the risk of road hazard and environmental damage to the wings. Since each wing is delivered and picked up by government personnel and a government truck, CMXG is also limiting the time spent on each delivery. To run long distances costs more in transportation costs and limits the time available for an employee to perform other work required here on Hill AFB. Within a 50 mile radius, it has been determined that CMXG employees can make a round trip delivery or pickup in one day and mitigate the need for TDY orders to be established or per diem costs to be incurred.)

2.1.2 The contractor shall unload and re-load the wings and holding fixtures at the contractor’s facility. The contractor shall be responsible for the wings and holding fixture during unload, reload, and while in possession. Government transportation personnel will be responsible for removing the wing holding fixture tie-downs on the truck upon delivery. Government transportation will re-secure the wing and holding fixture to the truck upon pick up.

2.1.3 The contractor shall complete milling services within five (5) business days after receipt of the WCP and/or WOP, repack in the original packaging or similar manner as the wings were delivered, and notify the 533rd Squadron, A-10 production Flight Chief upon completion.

2.1.4 The contractor shall perform milling services (IAW) applicable Air Force (AF) technical data/engineering drawings, namely, “WING SPLICE INSTL-INBD, OUTBD, WS 110.00”, 160D610101 and PL160D610101 (Parts List).

2.1.4.1 Applicable technical data will be provided by the Government upon contract award. Basic technical requirements are summarized in

Appendices A, B, C, D of this PWS.

2.2 Wing, Center Panel, (WCP)

2.2.1 The contractor shall complete Optical Setup of the WS 110.00 Center Wing

Splice Surface for Milling IAW Appendix A.

2.2.2 The contractor shall complete WS 110.00 Center Wing Splice Surface Milling

Procedures IAW Appendix B.

2.3 Wing, Outer Panel, (WOP)

2.3.1 The contractor shall complete Optical Setup of WS 110.00 Outer Wing Splice

Surface for Milling IAW Appendix C.

2.3.2 The contractor shall complete WS 110.00 Outer Wing Splice Surface Milling

Procedures IAW Appendix D.

2.4 Estimated Workload Data

2.4.1 The A-10 wing sets consist of two (2) Outer Wings and one (1) Center Wing.

CMXG is projecting the following quantities of wing sets per fiscal year (FY) for the period of performance:

Fiscal Year Quantity

2019 11

2020 11

2021 13

2022 15

2023 16

The estimated quantity could increase up to 30%.

2.5 Reporting Requirements

2.5.1 The contractor shall provide a Works Certificate complete with data for each wing after milling. The documentation shall contain the wing number, measurement showing the flatness of the WS 110.00 splice fitting/face after milling, and verification of conformance to tolerances IAW figures 11 or 12 as applicable. Three (3) electronic copies of the data shall be provided in Microsoft

Office compatible format (CDRL A001).

3 SERVICE SUMMARY

Performance Objective PWS Para Performance Threshold

Threshold The contractor shall complete milling services on the WS

110.00 splice fittings of the

WCP and/or WOP.

2.1.3 Within five (5) business days 80% of the

time.

4 CDRL SUMMARY

Performance Objective PWS Para Submittal Requirement

Works Certificate 2.5.1 The contractor shall submit a Works

Certificate (CDRL A001) for each

WCP or WOP after 110.00 splice fitting/face milling.

APPENDICES

A. Wing, Center Panel, WCP

a. Optical Set Up of WS 110.00 Center Wing Splice Surface for Milling

B. Wing, Center Panel, WCP

a. WS 110.00 Center Wing Splice Surface Milling Procedure

C. Wing Outer Panel, WOP

a. Optical setup of WS 110.00 Outer Wing Splice Surface for Milling

D. Wing Outer Panel, WOP

a. WS 110.00 Outer Wing Splice Surface Milling Procedure

APPENDIX A – WING, CENTER PANEL, WCP

Optical Set Up of WS 110.00 Center Wing Splice Surface for Milling

The following steps describe the optical set up of the WS 110.00 wing splice surface for milling. The WS

110.00 wing splice surface is a critical surface on the wing requiring tight tolerances.

1. Ensure the wing splice mating surface is clean and free from dirt and/or sealant.

2. Stabilize WCP for precision coordinate measurements as follows, see Figure 1.

3. Position WCP at the milling machine location, away from direct sunlight, wind or other potential sources of temperature variation for 24 hours prior to performing the optical set-up.

4. Raise with jacks until each trailer tire has slightly cleared the floor. Trailer must remain stationary during the entire procedure. Each trailer rail must clear the floor by the same distance, ±0.5 inch, when measured from the floor to the trailer rail.

5. Ensure trailer is secure to floor after jacking, using straps and floor tie downs.

6. Using optical measuring equipment, measure each end of the trailer rails to ensure that the trailer is not twisted more than ±0.125 inch. Shim as required under the jack stand(s) to level the trailer.

7. Using optical measuring equipment, create an aircraft coordinate system.

8. Use a precision digital coordinate measuring system to perform the following measurements and establish the nominal datum plane for milling the WS 110.00 splice surfaces.

9. Measure the four wing attach lug bores at WS ± 23.00. The centers of these bores will establish the waterline reference plane, using a best fit of the actual centers. See Figure 4.

10. Measure four points on the aft spar web, at WS ± 80.00, approximately 0.5 inch away from the upper and lower spar cap. The best fit of these four points will establish the rear spar plane. See

Figures 4 and 6 (red arrows show the measurement points).

11. The LH and RH datum planes for milling shall be perpendicular to both the waterline plane and the rear spar plane. They shall be placed at the surface of the inboard most point of the faces of splice fittings 2, 3, 4, or 5. See Figures 1 and 4.

12. Note: The Government may require an alternate datum plane for milling the WS 110.00 splice fitting faces. The existing splice face measurements, with best fit applied, may be used to orient the mill cut when specified by the Government Representative.

13. Measure and record the following points along the wing splice surface using a precision digital coordinate measuring system. The asterisks shown represent the approximate location of each measurement around each hole.

14. Measure three points at each upper forward splice fitting hole. See Figure 1.

15. Measure three points at each upper aft splice fitting hole. See Figure 1.

16. Measure ten points along aft flap track No. 7 surface starting at the top working down. See Figure

2.

17. Measure three points near each lower aft splice fitting hole. See Figure 1.

18. Measure three points near each lower forward splice fitting hole. See Figure 1.

19. Measure ten points along forward angle No. 6 splice surface. See Figure 3.

20. The LH and RH nominal datum planes defined in step 11 are located to the inboard-most point along the splice surface of the wing splice fittings, 2, 3, 4, and 5 that have not been replaced. See

Figure 1.

21. Analyze LH and RH measured points from steps 13 - 19 to the datum plane.

22. Expected results should provide the amount of material required to be removed to achieve a flat surface at the milling datum plane.

APPENDIX B – WING CENTER PANEL, WCP

WS 110.00 Center Wing Splice Surface Milling Procedure

The wing splice surface at WS 110.00 LH/RH is a critical surface requiring tight tolerances. Careful measurements must be taken before, during and after milling operations are performed to ensure these tolerances are met. Milling all the splice surfaces must be performed during the same operation (where possible) to minimize material removed and to better ensure splice surfaces meet the tight tolerances. See

Figures 1 and 5.

1. Measure and record the thickness of the following to the thousandths of an inch (X.XXX). See

Figure 5.

2. Lug-hole node thickness for each hole, #1-41. See Figure 5.

3. Five evenly-spaced points near hole locations (approximately every third hole) in the splice surface of angle 6. See Figure 5.

4. If the inboard most point of the splice fitting splice surface is marked “RESURFACE” adjust the datum plane inboard 0.005 inch to allow for cleanup of the splice surface.

5. If any of the parameters in Sections 3.2.5 or 3.2.6 will not be met, discontinue this procedure and contact the GR at Hill Air Force Base for additional repair instructions.

6. Determine the minimum thickness of WS 110.00 wing splice nodes. See Figure 1. If after milling the thickness of the upper nodes will be less than 0.405 inch, or if the thickness of the lower nodes will be less than 0.540 inch, do not mill the splice fittings. Contact the GR.

7. Mill the WS 110.00 splice surface to match the datum plane established in Section 3.1.6.

Compare the WS 110.00 surface to the established datum plane. The milled plane shall meet or exceed the specifications of applicable engineering drawing requirements. This includes:

8. The WS 110.00 splice surface shall be milled to within +0.005 inch inboard/ -0.000 inch outboard of the datum plane.

9. The flatness of each splice surface (i.e. upper and lower splice fittings, front spar angle and flap track splice surface) shall not exceed 0.002 inch total flatness, and shall have no variation greater than 0.0002 inch-per-inch after milling. See Figure 1.

10. The step between adjacent splice surfaces shall not exceed 0.002 inch.

11. Upper Node thickness: 0.405 inch minimum.

12. Lower Node thickness: 0.540 inch minimum.

13. Thickness of angle 6 flange across splice surface shall not be less than 0.120 inch after milling.

See Figures 1, 4 and 5.

14. Surface roughness of all milled splice surfaces: Maximum RHR of 125 micro-inches (excluding holes).

15. Treat wing splice surfaces and splice attach holes where milling has been performed with

Chemical Conversion Coating MIL-DTL-5541/81706 Type I Class 1A (reference TO 1-1-691).

APPENDIX C – WING OUTER PANEL, WOP

Optical setup of WS 110.00 Outer Wing Splice Surface for Milling

The following steps describe the optical set up of the WS 110.00 wing splice surface for milling. The WS

110.00 wing splice surface is a critical surface on the wing requiring tight tolerances.

1. Ensure the wing splice mating surface is clean and free from dirt and/or sealant.

2. Stabilize WOP for precision coordinate measurements as follows:

3. Position WOP at the milling machine location, away from direct sunlight, wind or other potential sources of temperature variation for 24 hours prior to performing the optical set-up.

4. Raise with jacks until each trailer tire has slightly cleared the floor. Trailer must remain stationary during the entire procedure. Each trailer rail must clear the floor by the same distance, ±0.5 inch, when measured from the floor to the trailer rail.

5. Ensure trailer is secure to the floor after jacking, using straps and floor tie downs.

6. Using optical measuring equipment, measure each end of the trailer rails to ensure that the trailer is not twisted more than ±0.125 inch. Shim as required under the jack stand(s) to level the trailer.

7. Measure and record the following points along the wing splice surface using a precision digital coordinate measuring system.

8. Measure at least three points at each splice fitting hole, as represented in Figures 7, 8, 9 and 10.

The asterisks shown represent the approximate location of each measurement around each hole.

APPENDIX D – WING OUTER PANEL, WOP

WS 110.00 Outer Wing Splice Surface Milling Procedure

The wing splice surface at WS 110.00 LH/RH is a critical surface requiring tight tolerances. Careful measurements must be taken before, during and after milling operations are performed to ensure these tolerances are met. Milling all splice surfaces must be performed during the same operation (where possible) to minimize material removed and to better ensure splice surfaces meet the tight tolerances.

1. The Contractor shall establish a reference plane with the following basic requirements for Outer

Wings:

2. Establish a WS 110.00 LH/RH reference plane per “Best Fit” method using the existing node surface measurements. Only surface measurements from original fittings, 1, 2, 3, and 4 are to be used for the best fit alignment. If one or two fittings have been replaced, do not use surface measurements from these to establish the reference plane.

3. Readjust datum plane to the inboard-most point along the splice surface of wing splice fittings1, 2, 3 and 4. See Figure 7.

4. If the outboard-most point of the splice surface is marked “RESURFACE”, adjust the datum plane outboard 0.005 inch to allow for resurfacing of the splice surface.

5. If any of the parameters in Sections 4.2.3 or 4.2.4 will not be met, discontinue this procedure and contact the GR at Hill Air Force Base for additional repair instructions.

6. Determine the minimum thickness of WS 110.00 wing splice nodes. See Figure 8. If after milling the upper nodes will be less than 0.405 inch thick, or if the lower nodes will be less than

0.540 inch thick, do not mill the splice fittings. Contact the GR.

7. 4.2.4 Mill the WS 110.00 Splice surface to match the reference plane established in this document, Section 4.2.1.1. Compare the WS 110.00 surface to the established reference plane.

The milled plane shall meet or exceed the specifications of applicable engineering drawing requirements. This includes:

8. Surface measurements shall not deviate more than 0.005 inch from the datum plane.

9. The Flatness of each splice fitting surface (i.e. upper and lower splice fittings, front spar angle, and rear spar angle) shall not exceed 0.002 inch total flatness, and shall have no variation greater than 0.0002 inch-per-inch after milling. See Figure

10. The step between adjacent splice fitting surfaces shall not exceed 0.002 inch.

11. Upper Node Thickness: 0.405-inch minimum.

12. Lower Node Thickness: 0.540-inch minimum.

13. Surface Roughness of all milled surfaces: Maximum RHR of 125 micro-inches (excluding holes).

14. Treat wing splice surfaces and splice attach holes where milling has been performed with

Chemical Conversion Coating MIL-DTL-5541/81706 Type I Class 1A (reference TO 1-1-691).

Figure 1. Wing Splice Set up, WS 110.00

U p p e r S p li c e

F it ti n g

T y p ic a l O p ti c a l M e a s u re m e n t P o in ts

L o w e r S p li c e

F it ti n g

T y p ic a l

O p ti c a l M e a s u re m e n t P o

L o w e r S p li c e

F it ti n g

T y p ic a l

O p ti c a l M e a s u re m e n t P o

Figure 2. Wing Splice Set up, WS 110.00 for Flap Track, No. 7.

NOTE: The number denotes a hole

Figure 3. Wing Splice Set up, WS 110.00, Angle No. 6.

NOTE: The number denotes a hole.

Figure 4. Wing Splice Set up, WS 110.00

Rear Datum Plane

See Figure 6

Best Fit Plane

WL 66.75, FS 407.15

Centers of two of the four wing attach lug bores

Figure 5. Wing Splice Set up, WS 110.00 NOTE: The number denotes a hole.

Figure 6. Photograph of Rear Datum Plane.

See Figure 4, top view, for location of the Rear Datum Plane.

Measurements to be taken at the tips of the arrows

Figure 7. Wing Splice Optical Set-Up, WS 110.00

NOTE: Numbers denote hole locations.

Figure 8. Wing Splice Set Up, WS 110.00

L o w e r S p li c e

F it ti n g

T y p ic a l

O p ti c a l M e a s u re m e n t P o

U p p e r S p li c e

F it ti n g

T y p ic a l O p ti c a l M e a s u re m e n t P o

Figure 9. Wing Splice Set Up, WS 110.00, Fitting 7.

Figure 10. Wing Splice Set Up, WS 110.00, Angle 5.