SOW_F_16_SLEP_Mod_Kit_v2.pdf

STATEMENT OF WORK (SOW)

FOR

F-16 LEGACY STRUCTURAL SERVICE LIFE EXTENSION PROGRAM

(F-16 SLEP)

PRODUCTION MODIFICATION KIT CONTRACT

CONTRACT NUMBER:

FA8232-18-R-0001

REVISION DATE:

4 December 2017

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

FOR OFFICIAL USE ONLY (FOUO): This electronic message and its attachment(s) contain restricted, sensitive, non-public information, including acquisition/source selection information. The information is not intended for disclosure outside official government channels and is exempt from release under the Freedom of Information Act, 5 U.S.C. 552(b)(2) and (4). Further distribution is prohibited without the approval of the author of this message.

1. SCOPE:

This statement of work defines the requirements necessary to manufacture and/or procure, assemble, and deliver up to the estimated maximum quantity of 841 F-16 Block 40-52, C/D-

Model SLEP modification kits necessary to extend the structural service life of these aircraft, in accordance with Government standards and specifications defined in the Technical Data Package

(TDP).

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 life-limiting 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 select USAF F-16 aircraft. There is also a likelihood of Foreign Military Sales

(FMS) interest in leveraging this contract to procure SLEP modification kits.

The estimated quantities represent the “maximum” possible aircraft to receive SLEP (USAF and FMS) over the performance period of this Indefinite Delivery/Indefinite Quantity (ID/IQ), firm-fixed price supply contract. The minimum quantity buy is four (4) kits to support First

Article Test (FAT) and Low Rate Initial Production (LRIP).

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

MIL-STD-2073-1E Standard Practice for Military Packaging w/ Change 1 7 Jan 2011

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

SLEP IFM 392-

Critical Safety Items Impacted by SLEP Design 14 Sep 2016

3. REQUIREMENTS:

3.1. GENERAL:

3.1.1. The Contractor shall be held solely responsible for requirements defined in this SOW.

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. PROGRAM MANAGEMENT:

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

3.2.1.1. The mod kit contractor shall be responsible for manufacturing and/or procuring, assembling, and delivery of the structural aircraft modification kits referenced in

Appendix A.

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

3.2.1.3. 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.

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

Certification Report for all Critical Safety Items procured under this contract (DI-

SAFT-81933, CDRL A001).

3.2.1.3.2. The Contractor shall develop, maintain, implement, and adhere to a notification process for non-conforming CSI, per DFAR 252.246-7003. (Critical Safety Item

Characteristics and Critical Defect Report, DI-SAFT-80970A, CRL A002)

3.2.1.4. 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.

3.2.1.5. 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, which follows successful completion of First Article Test (FAT). This meeting addresses contract and delivery status, program risks, schedule status, or other Government agenda items. Subsequent reviews shall be at the discretion of the Government program team.

3.2.1.6. 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 and briefing charts.

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

MGMT-81867, CDRL A003.

3.2.1.8. The contractor shall develop and maintain an integrated risk management program and conduct monthly risk assessments with the Government program team in attendance (teleconference). The contractor shall deliver a monthly program risk assessment, with issues and mitigations, IAW DI-MGMT-81809, CDRL A004.

3.2.1.9. The Contractor shall develop, maintain and deliver an initial integrated master schedule, with critical path analysis IAW DI-MGMT-81861A, CDRL A005.

3.2.1.10. 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.

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

3.2.1.12. The Contractor shall conduct a quality management program that complies with ISO

9001:2015 & AS 9100C (or equivalent quality management approach) for U.S

Government delivered kits. This program shall address the applicable processes and procedures used in the quality management and handling of CSI components. It shall also address their proposed ISO 9001 (or equivalent) quality management approach, which compares it to the elements in ANSI/ASCQ-Q9001 and is correlated to the reduction of program risk.

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

3.2.1.13. 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. Tracking and reporting shall be included in the Monthly Production

Report (DI-MGMT-81867, CDRL A003).

3.2.1.13.1. 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.

3.2.1.14. 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.

3.2.1.14.1. 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.

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

Registry.

3.2.1.15. 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).

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

MIL-STD-2073-1E w/ Change 1. The contractor shall not modify or re-configure any structural component Special Packaging Instruction (SPI) container which is included in these kits.

3.2.1.15.2. 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.

3.2.1.16. 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).

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

3.2.1.17. 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.

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

3.2.1.19. For the initial purchase order of four (4) complete aircraft sets of modification kits, FAT is required for all CSI and non-CSI manufactured parts. Additionally, from the initial four (4) sets of delivered aircraft kits, the Government will randomly select one of each modification kit to complete FAT. The initial test will be funded by the

Government. Any subsequent “re-testing” as a result of non-confirming or non-qualified parts will be conducted at the contractor’s expense.

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

Kit deliveries from the proposed new manufacturer will not be accepted until successful completion of FAT. Testing shall be accomplished at the Governments 1st article test lab, Hill AFB, Utah, and at the contractor’s expense.

3.2.2. MODIFICATION KIT DELIVERY

3.2.2.1. The contractor shall deliver fully assembled kits between 12 and 24 months following receipt of a purchase order, in accordance with the Governments delivery schedule, as defined in the contract. Early deliveries are acceptable, upon prior Government approval.

3.2.2.2. If multiple purchase orders are levied within the same fiscal year (1 Oct to 30 Sep), each purchase order shall have its own delivery schedule. Additionally, each purchase order awarded within the same fiscal year, shall reset the quantity discount buy level to zero (not cumulative based on previous orders), unless bi-laterally negotiated and approved prior to award.

3.2.2.3. For multiple purchase orders received during the same fiscal year, the Government is willing to discuss extended delivery schedules, when cumulative orders exceed 60 aircraft modification kits over a 12 month rolling average.

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

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

3.2.4. GOVERNMENT FURNISHED EQUIPMENT / PROPERTY / MATERIAL

(GFE/GFP/GFM):

3.2.4.1. The Government will provide five (5) 5”x 33”x 85” aluminum-lithium rolled plates

(Al 2.8 Cu – 1.5 Li) per FMS-4097 as GFM within 30 days of the initial contract award to support manufacturing of five (5) FS479 bulkheads. All subsequent procurement of Al-Li material shall be at the responsibility of the contractor.

3.2.5. MISSION ESSENTIAL STATEMENT

3.2.5.1. 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.

3.2.6. Contract Data Requirements List Table

CDRL DID Title Of Data SOW Reference

A001 DI-SAFT-

81933

Critical Safety Item

Inspection and

Material Certification

Report

3.2.1.3.1

A002 DI-SAFT-

80970

Critical Safety Item, Characteristic and

Critical Defect Report

3.2.1.3.2

A003 DI-

MGMT-

81867

Production (kit delivery) Report

3.2.1.7

A004 DI-

MGMT-

81809

Risk Management

Status Report

3.2.1.8

A005 DI-

MGMT-

81861A

Integrated Master

Schedule

3.2.1.9

APPENDIX A

Modification Kit Listing

CLIN

MKPL No KIT NSN Nomenclature

0001 MK5420 A 1560K01042 39A WF Replace 16B5250 FS 341 Lwr Blkhd & mod Fuel Shelf Web

0002 MK5420 B 1560K01042 39B WF Replace 16B5250 FS 341 Lwr Blkhd & mod Fuel Shelf Web

0003 MK5420 C 1560K01042 39C WF Replace 16B5250 FS 341 Lwr Blkhd & mod Fuel Shelf Web

0004 MK5420 D 1560K01042 39D WF Replace 16B5250 FS 341 Lwr Blkhd & mod Fuel Shelf Web

0005 MK5438 A 1560K01042 37A WF Mod 16W1014 LH/RH Wing Assy

0006 MK5437 A 1560K16024 35A WF Mod 16W1030 Wing Box Assy - Left Hand

0007 MK5437 B 1560K16024 35B WF Mod 16W1030 Wing Box Assy - Right Hand

0008 MK5425 A 1560K01042 44A WF Mod 16B5135 BL 54 Closure Rib

0009 MK5433 A 1560K01042 40A WF Mod 16B5132 Closure Beam

0010 MK5453 A 1560K01022 67A WF Mod 16D4037 Bracket Installation

0011 MK5426 A 1560K01042 34A WF Mod 16B5235/16B5245 FS 309/325 Lower Bulkhead

0012 MK5423 A 1560K01042 43A WF Mod 16B6827 Outbd Horizontal Tail Support Beam

0013 MK5460 A 1560K01021 80A WF Replace 16B1130 Canopy Sill Longeron F-16C

0014 201716924-10 1560K01021 18A WF Replace 16B2101/16B2103 Canopy Sill Longeron F-16 D

0015 201716924-30 1560K01021 18B WF Replace 16B2101/16B2103 Canopy Sill Longeron F-16 D

0016 MK5441 A 1560K01042 45A WF Mod 16B5316 Ctr Fuselage Upper Skin

0017 MK5441 B 1560K01042 45B WF Mod 16B5316 Ctr Fuselage Upper Skin

0018 MK5414 A 1560K01042 38A WF Replace 16B6224 FS 479 Upper Bulkhead

0019 MK5459 A 1560K01022 68A WF Mod 16B5113 BL 8 Upper Web Assy

0020 MK5427 A 1560K01042 41A WF Mod 16B5401 Keel Beam