Draft_SOW_F-16_SLEP_Production.pdf

STATEMENT OF WORK (SOW)

FOR

F-16 LEGACY STRUCTURAL SERVICE LIFE EXTENSION PROGRAM

(F-16 SLEP)

CONTRACT NUMBER:

FA8232-18-D-0001

REVISION DATE:

14 December 2016

Prepared By:

F-16 System Program Office (WWM)

Air Force Life Cycle Management Center (AFLCMC)

6061 Gum Lane, Bldg. 1224

Hill Air Force Base (AFB), UT 84056

TABLE OF CONTENTS

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1. SCOPE:

This statement of work defines the requirements necessary to manufacture, assemble, and deliver up to 300 USAF F-16 Block 40-52, C/D-Model and 43 additional F-16 Block 52 D-Model structural modification kits to extend the structural service life of these aircraft, in accordance with Government standards and specifications.

1.1. BACKGROUND:

The F-16 USAF SLEP intends to extend the aircrafts current structural service life from 8,000 equivalent flight hours (EFH) up to 13,856 EFH. The SLEP addresses life limiting, fractural critical, and safety of flight critical structure, which was demonstrated during Full Scale

Durability Test (FSDT).

Through an Engineering and Manufacturing Development effort, structural modification kits were designed and developed to address the known life-limited structural components discovered during the FSDT phase of the program. These modification kits were validated and verified at Ogden Air Logistics Complex (ALC), Hill Air Force Base (AFB), Utah, from 2016-

2017.

Upon receipt of modification kits, provided under this contract, the Government will install them onto selected USAF F-16 aircraft.

The potential exists for foreign military sales and additional USAF requirements, which may increase kit quantities under this effort.

2. APPLICABLE DOCUMENTS:

The following documents are applicable to this Statement of Work and attached Appendices to the extent specified.

2.1. Department of Defense (DoD) Specifications:

Product Number Product Title Date

AS 9100C Quality Management Systems – Aerospace – Requirements 15 Jan 2009

ISO 9001: 2015 Quality Systems – Requirements 15 Sep 2015

2.2. DoD Standards:

Product Number Product Title Date

MIL-HDBK-896 Manufacturing and Quality Program 8 Aug 2008

MIL-STD-129P Military Marking For Shipment and Storage 19 Sep 2007

MIL-STD-130N Identification Marking of U.S. Military Property 16 Nov 2012

MIL-STD-962D Defense Standards Format and Content 1 Aug 2003

DODI 3020.37 Continuation of Essential DoD Contractor Services During

Crisis

06 Nov 1990, Change 1 26

Jan 1996

2.3. Other Government Documents:

AFPAM 91-210 Contract Safety 14 Feb 1994

N/A Aviation Critical Safety Item Management Handbook 16 Mar 2011

AFI 20-106 Management of Aviation Critical Safety Items 25 Jan 2006

OO-ALCI 21-113 Nondestructive Inspection 27 Mar 2013

NAS 410 Certification and Qualification of Nondestructive Test Personnel Rev 4

00-35D-54 USAF Deficiency Reporting, Investigation, and Resolution 1 Oct 2009

3. REQUIREMENTS:

3.1. GENERAL:

3.1.1. This Contractor shall be held solely responsible for requirements defined in this SOW, as the F-16 SLEP Kit Integrator.

3.1.2. The Contractor shall provide a Program Manager for this effort, and address any changes in assignment.

3.2. DETAILED:

3.2.1. KIT INTEGRATOR PROGRAM MANAGEMENT:

This section addresses program management, logistics and system engineering requirements in performance of this contract.

3.2.1.1. All F-16 structural component manufacturers of Critical Safety Items (CSI) (as defined in the TDP, Attachment A’s) shall be a qualified source.

3.2.1.2. The Contractor shall manage Critical Safety Items (CSI) in accordance with the

Aviation Critical Safety Item Management Handbook, and AFI 20-106, Management of Aviation Critical Safety Items and as defined below.

3.2.1.2.1. The Contractor shall deliver a Critical Safety Item Inspection and Material

Certification Report for all Critical Safety Items procured under this contract upon delivery of said items, in accordance with CDRL A001.

3.2.1.2.2. The Contractor shall develop, maintain, implement, and adhere to a notification process for non-conforming CSI, per DFAR 252.246-7003. Reports shall be delivered to the Government as necessary, in accordance with CDRL A002

3.2.1.3. The Contractor shall host an Integrated Program Review (IPR) within 60 days of contract award. The Government team reserves the right to visit all or some of the sub-contractors, to assess implementation of quality management programs and manufacturing processes, and evaluate program risks.

3.2.1.3.1. The following program documents/plans shall be developed and delivered to the

Government 15 business days prior to the IPR for review.

˗ Initial Production Report/Delivery Schedule (A003)

˗ Initial Program Risk Management Status Report (A004)

˗ Program Integrated Master Schedule (A005)

3.2.1.3.2. Following the IPR, the contractor has 10 business days to submit changes to appropriate documents and plans, to the Government for final acceptance.

3.2.1.3.3. All plans and schedules defined in para 3.2.1.3.1 shall be updated, maintained, and delivered to the Government for the duration of the period of performance (PoP) of this contract, according to the schedule in paragraph 3.2.5.

3.2.1.4. Following successful Government acceptance of all designated documents and plans from the IPR, the Contractor shall support, as a minimum, a bi-weekly (every two weeks) teleconference meeting with the Government program team until successful

Government acceptance of the first production kits, following successful First Article

Test (FAT). This meeting addresses contract status, risk, schedule, or other

Government agenda items. Subsequent reviews shall be at the discretion of the

Government program team.

3.2.1.5. At the Government’s discretion, the Contractor shall host a semi-annual (twice a year) program review at their facility. The Government will notify the Contractor in writing, 30 days prior to a planned review, and the Contractor shall provide a final agenda no later than 5 days prior to this review.

3.2.1.6. Following Government acceptance of 1st Article Test assets, the Contractor shall deliver a weekly production (kit delivery) report in accordance with (IAW) CDRL

A003. Reporting shall begin 45 days following receipt of a Purchase Order (PO) and weekly thereafter, until completion of final delivery of all kits required under that PO.

This requirement remains in effect for the duration of the contract.

3.2.1.7. The contractor shall develop and maintain an integrated risk management program with the Government program team in attendance (teleconference) on a monthly basis. The initial contractor program risk assessment, with issues and mitigation, shall be delivered to the Government 45 days following receipt of a PO, IAW CDRL

A004. Subsequent reports shall be provided within 5 business days following each integrated risk assessment, until completion of final delivery of all kits required under that PO. This requirement remains in effect for the duration of the contract.

3.2.1.8. The Contractor shall develop, maintain and deliver an initial integrated master schedule, with critical path, within 45 days of initial contract award and monthly thereafter IAW CDRL A005.

3.2.1.9. The contractor shall implement an effective monitoring process of the supply chain and the material and manufacturing industrial base for Diminishing Manufacturing

Sources and Material Shortages (DMSMS). The contractor shall report issues, along with recommended corrective actions, which may impact execution of this contract to the Government within 30 days of identification.

3.2.1.10. The Contractor shall define all warranties (stated and implied) for all kits, material, and workmanship.

3.2.1.11. The Contractor shall conduct a quality assurance program that complies with ISO

9001:2015 & AS 9100C for U.S Government delivered kits.

3.2.1.11.1. For kit shipments to NATO countries: The Contractor shall conduct a quality assurance program that complies with NATO standards agreement (AQAP-2120).

3.2.1.12. The Contractor shall develop and maintain a process to report, track and resolve kit discrepancies IAW T.O 00-35D-54, USAF Deficiency Reporting, Investigation, and

Resolution.

3.2.1.12.1. The Contractor shall resolve all discrepancies within 30 calendar days at contractor’s expense, and future kit deliveries shall be free of previously identified discrepancies.

3.2.1.13. The Contractor shall have a thorough understanding of IUID marking requirements, databases, engineering evaluation requirements, verification, and data and configuration management relating to IUID marking.

3.2.1.13.1. The Contractor shall ensure all appropriate components and modification kit containers meet Item Unique Identification (IUID) requirements IAW MIL-STD-

130N and DFARS 252.211-7003.

3.2.1.13.2. The Contractor shall report IUID compliance using the US Government’s IUID

Registry.

3.2.1.14. The contractor shall be responsible for shipment of all kits to FB2029, Hill Air Force

Base, where the Government will accept (DD250) them within 5 business days. The

SLEP Government Program Manager will be the focal point for completing DD250s in Wide Area Work Flow (WAWF).

3.2.1.14.1. The Contractor shall be responsible for appropriately packaging and delivering all modification kits in compliance with general overseas shipment requirements.

3.2.1.14.2. All kits shall be delivered to the designated U.S Government kit manager, as directed by contractual instructions. However, the Government intends to distribute some of these kits to overseas depot facilities throughout performance of the contract.

3.2.1.15. The Contractor shall clearly mark packages IAW contract requirements. External marking requirements shall include the: contract number (with delivery order #), Kit

National Stock Number (NSN), master kit parts list (MKPL) number, kit description/nomenclature, box number (i.e. 1 of 3, 2 of 3, etc.), and total weight. The package will include an inventory list (including NSN, part number, nomenclature, Cage code, and quantities).

3.2.1.15.1. Individual modification kits shall be bundled, banded, combined, and/or identified and delivered as a single kit under the Kit NSN.

3.2.1.16. The potential exists for engineering changes throughout performance of the contact.

Therefore, the Contractor shall establish, maintain, implement, and adhere to a configuration control process to ensure only the latest technical data is used to manufacture parts and assemble kits.

3.2.1.17. The Contractor shall be capable of incorporating and tracking kit changes via supplemental kit releases.

3.2.1.18. If a manufacturing source changes during the performance of this contract, a FAT is required on the first production asset manufactured under the change (as specified in in the Aviation Critical Safety Item Management Handbook).

3.2.2. CONTRACTOR FURNISHED EQUIPMENT / MATERIAL (CFE/CFM):

3.2.2.1. The Contractor shall provide all facilities, equipment, materials, and manpower to accomplish all work activities.

3.2.3. GOVERNMENT FURNISHED EQUIPMENT / PROPERTY / MATERIAL

(GFE/GFP/GFM):

3.2.3.1. The Government will provide sufficient near-net shapes of Aluminum-Lithium (Al-

Li) plate as GFM, within 30 days of the initial contract award to support manufacturing of assets for First Article Test (FAT). All subsequent procurement of

Al-Li material shall be at the responsibility of the contractor.

3.2.4. MISSION ESSENTIAL STATEMENT

3.2.4.1. In accordance with DoDI 3020.37, Continuation of Essential DoD Services During

Crisis, the Functional Direction determined that this effort is not considered mission critical and will not continue in the event of a crisis.

3.2.5. Contract Data Requirements List Table

CDRL DID Title Of Data SOW Reference Delivery Requirement

A001 DI-SAFT-

81933

Critical Safety Item

Inspection and

Material Certification

Report

3.2.1.2.1 For every Critical Safety

Item delivered under the contract…due upon delivery of said items.

A002 DI-SAFT-

80970

Critical Safety Item, Characteristic and

Critical Defect Report

3.2.1.2.2 When CSI characteristic

or critical defect is identified.

A003 DI-

MGMT-

81867

Production (kit delivery) Report

3.2.1.6 Initial report is due 45

days following initial contract award and weekly thereafter, until final PO kits are received by the Gov’t. Same schedule for all subsequent purchase orders under this contract.

A004 DI-

MGMT-

81809

Risk Management

Status Report

3.2.1.7 Initial contractor risk

assessment is due 45 days following initial contract award. Subsequent risk assessments will accomplished monthly

(with the Gov’t program team), and reports delivered within 5 business days.

A005 DI-

MGMT-

81650

Integrated Master

Schedule

3.2.1.8

Within 45 days following initial contract award and monthly thereafter until completion of the purchase order. Same schedule for all subsequent purchase orders under this contract.

APPENDIX A

Modification and Tool Kit Listing

Mod Kit # ECP # TCTO Mod Kit Description

MK5420 D401 1F-16-2728 Lower FS 341 Bulkhead and Fuel Shelf Joint Kit

MK5437A

D403

16W9-13-

Left 16W1101 Upper Skin Replacement and 16W1102 Lower Skin Repair Kit

MK5437B Right 16W1101 Upper Skin Replacement and 16W1102 Lower Skin Repair Kit

MK5438 1F-16-2726 Wing Replacement Hardware Kit

MK5425 D404 1F-16-2733 16B5135 Strake Closure Kit

MK5433 D405 1F-16-2729 16B5132 Closure Beam kit

MK5453 D406 1F-16-2779 FS 357 Lower Bulkhead Cold Work Kit

MK5426 D407 1F-16-2725 Lower FS 309/325 Bulkhead Shear Web Cold Work Kit

MK5423 D408 1F-16-2732 Horizontal Tail Support Beam Replacement Kit (LH & RH)

MK5460

D409

1F-16-2775 Canopy Sill Longeron Replacement Kit (C-Model)

TBD 1F-16-2770 Canopy Sill Longeron Replacement Kit (D-Model)

MK5441 D410 1F-16-2734 16B5301/5303/5304 Upper Fuselage Skin Cold Work Kit

MK5414 D411 1F-16-2728 FS 479 Upper Bulkhead

MK5459 D412 1F-16-2780 16B5113 Web Repair Kit

MK5427 D413 1F-16-2730 Centerline Keel Beam Repair Kit

APPENDIX B

Safety (TBD)