pws_HW.pdf

1.0 INTRODUCTION:

With aging aircraft hardware, new mission requirements, and a desire to keep weapon systems operational beyond original projections, the Government has an increasing desire to improve safety, reliability and maintainability while driving down the cost of ownership of aircraft systems and subsystems. The Government answers this requirement by funding improvement projects under the Component Improvement Program (CIP).

Secondary Power Systems (SPS) is comprised of those parts which are used to start main engines with start carts, Auxiliary Power Units (APU), or Jet Fuel Starters (JFS) as well as those parts which are integral for continual aircraft power generation via Accessory Drive Gearboxes (ADG) or Aircraft Mounted Accessory Drive (AMAD) gearboxes and Power Take-Off (PTO) shafts.

This performance work statement is specifically tailored for Secondary Power Systems and APUs for which Honeywell is the Original Equipment Manufacturer (OEM). This program will be used to gain improvement on those systems where safety, obsolescence, reliability and maintainability can be positively impacted. The use of sound engineering is required to research and develop fixes, as well as investigate service revealed deficiencies (SRD) as they arise. The identification of systems and subsystems that can be impacted will come from both government and contractor personnel.

The government will be the funding source for these activities. The funding used is research, development, test and evaluation (RDT&E) or what the Air Force calls 3600 funds. This type of funding is incremental and used in one year additive cycles. Funding is provided by the CIP program office in fiscal year increments but the projects are managed by calendar year. This requires the contractor to be flexible and agile to support government needs. Typically a year-to-year program management (PM) and service revealed deficiencies (SRD) project task line will be funded to cover the day-to-day activities for contract support.

2.0 SCOPE OF WORK:

This Performance Work Statement (PWS) outlines the basic services the government expects the selected contractor to render in support of the Component Improvement Program as requested and approved by the appropriate government personnel. These basic services include continuing sustainment engineering efforts, technical data, drawings, change proposals, manpower support, research, design activities, prototype hardware manufacture, testing, product and procedure improvements, reports, conferences, analytical investigations, hardware evaluation, and to include any other expertise and support deemed appropriate.

Primary CIP program objectives are to improve the safety, reliability, durability, operability, supportability, affordability and maintainability of the systems covered. The scope includes both Engineering Services and Research and Development (R&D) type of efforts. Those tasks where a substantial amount of the work to be performed meets the definition of R&D as defined in FAR Part

35.001 shall be considered R&D efforts, all other tasks shall be considered engineering services.

This program may require analytical investigations that arise through what the government terms service revealed deficiencies (SRD). These tasks are usually the result of an operational failure or issue where the contractor’s expertise is required. Typically these tasks require a quick turn-around due to safety related and/or high profile mishaps or accident investigations.

3.0 APPLICABLE DOCUMENTS:

• MIL-HDBK-516 “Airworthiness Certification Criteria”

• AFI 62-601 “USAF Airworthiness”

• AFPD 62-6 “USAF Airworthiness”

• MIL-STD-882 “System Safety”

• MIL-STD-130 “IUID”

• MIL-HDBK-61A “Configuration Management”

4.0 DESCRIPTION OF TASKS TO BE PERFORMED:

Program objectives require the selected contractor to provide the government system managers with continuing expert operational, technical, and engineering support on covered systems identified in paragraph 5.0. Systems need to be kept mission ready and maintained to perform their intended function at all times. Program execution is managed by the government and generated taskings accomplished by the responsible qualified and approved contractor. The approved taskings should improve the system’s safety, reliability and maintainability while trying to optimize ownership costs to the government. Projects should be planned and completed in one year increments; or, the shortest time practical. Specific project task objectives should accomplish engineering and management actions as required per EPD as necessary to; but, not limited to:

1. Immediately resolve or mitigate safety of flight problems.

2. Improve system maintainability and reliability.

3. Increase mission operational readiness.

4. Investigate and incorporate industry advancements.

5. Extend hardware service life.

6. Monitor trends in performance.

7. Investigate, analyze, and resolve in-service related deficiencies.

8. Reduce cost of weapon system ownership and upkeep.

9. Respond rapidly to field reported problems.

10. Provide sustaining engineering support.

11. Design new support and test equipment.

12. Develop new inspection and repair methods.

13. Provide project support documentation.

14. Design, create, and test prototype hardware.

15. Improve engineering support data.

16. Create and deliver progress and final reports.

17. Solve obsolescence issues.

18. Perform Analytical Condition Inspection (ACI) tear downs and evaluations.

19. Accomplish Accelerated Mission Tests (AMT).

20. Perform Engineering Investigations (EI) and/or Product Quality Deficiency Reviews (PQDR).

21. Support Operational Safety, Suitability, and Effectiveness (OSS&E) functions.

22. Perform Program Management (PM) for day to day support.

23. Update interface control documentation.

24. Perform Failure Modes and Effects Criticality Analysis (FMECA).

25. Support system safety program.

26. Environmental risk management.

27. Support airworthiness certification.

28. Provide project management.

5.0 CIP REQUIREMENTS

The Component Improvement Program (CIP) shall be performed in accordance with requirements defined in this document and implemented through individually approved Engineering Project Descriptions (EPD). The contractor shall provide the necessary personnel, administration, facilities, knowledge, reports, drawings, studies, hardware, resources, and materials; other than those specified as government furnished materials (GFM), needed to successfully complete approved projects in a timely manner and as required by the Contract Data Requirement’s List (CDRL), Statement of Objectives (SOO), and/or EPD. CIP projects are defined by and submitted as an Engineering Services Memorandum (ESM).

It is preferred that all documentation be delivered in electronic media in a fashion that is acceptable to both the contractor and the government; and submitted through the Contracting Officer.

Primary weapon systems covered by this CIP program are:

F-15 JFS, CGB, AMAD

C-130 APU

Ground Carts APU

B-2 APU

C-5 APU

A-10 APU

E-3 APU

B-1 APU, LH ADG, RH ADG

F-16 TPU

Navy Aircraft As Required

Army Aircraft As Required

Over time, specific weapon systems may be dropped or may be added to those covered as required by the government and as needed to support the Air Force or other defense departments.

5.1 ENGINEERING REQUIREMENTS

5.1.1 Engineering Services Memorandum (ESM)

The contractor shall submit a proposed CIP project as an Engineering Services Memorandum (ESM) along with the Engineering Project Description (or Notification) (EPD or EPN) to the government; or, shall prepare and submit one at the request of the government. Each proposed project should be uniquely identified and self-contained. The EPD/EPN describing the project should contain as a minimum a tracking number, title, project description, task milestones outline, schedule, cost, implementation method/cost, Life Cycle Cost (LCC) benefit analysis (as required), the expected cost (as required) to incorporate any ECP or Notice of Revision (NOR) that will be required as a result of approval and implementation, and should identify if the project is considered a research and development or an engineering services type of effort. Typically, the following year’s worth of proposed EPD/EPNs will be submitted as a preliminary planning package for consideration and review during the month of February. (A001: DI-MISC-80748)

5.1.2 Final Reports

The contractor shall submit a final report after the completion or cancellation of each EPD/EPN or phase of the EPD/EPN. The final report should summarize and document all project efforts while providing enough detail such that the conclusions and recommendations of the report can be verified. Supporting scientific and technical data, charts, graphs, photographs, inspection results, trials, and related documents should be included. A report can also be tied to a specific task; something similar to what would be in an SRD task. For example, the government may request to have analysis performed on the lubrication system of a gearbox. A draft copy of the report shall go to the government for review 45 days before the performance period ends. (A002: DI-MISC-80048)

5.1.3 Test Plans, Procedures, and Reports

The contractor shall prepare and submit test plans and procedures to the government for approval as required by an individual EPD/EPN prior to the start of any testing activities. The contractor shall submit test reports to the government as required by an individual EPD/EPN when testing is completed. The test reports shall include a description of the test facilities & equipment used, a description of the testing completed, and a copy of all of the data collected & results from the testing. The test report should summarize all aspects of the effort and provide sufficient data such that the government can verify the test results and conclusions. As required in an individual EPD/EPN the test report may be submitted in electronic and/or paper copy. (A003: DI-NDTI-80566, DI-NDTI-80809)

5.1.4 Failed Item Analysis Report

As required on an individual EPD/EPD (often as part of an SRD task), the contractor shall submit a Failed Item Analysis Report that provides documented results of investigation/inspection findings of a failed end item or part. This could be a teardown findings report, or the government may require the contractor to evaluate specific failed hardware. This report presents the results of failure analysis, methods of analysis, failure histories and corrective action taken or recommended. (A004: DI-RELI- 80253)

5.1.5 Safety Assessment Report (SAR)

As required on an individual EPD/EPN, the contractor shall submit a Safety Assessment Report that details a comprehensive evaluation of the safety risks being assumed prior to test or operation of the system. This will identify all the safety features of the system, design, and procedural hazards that may be present in the system being acquired. (A005: DI-SAFT-80102C)

5.1.6 Airworthiness Specification

As required on an individual EPD/EPN, the contractor shall submit an Airworthiness Specification. This report will document the airworthiness certification basis: applicable airworthiness certification criteria, compliance standards/requirements, and methods compliance. The specification will be used to support the government’s airworthiness type certification of the aircraft design. It will be tailored to fulfil airworthiness requirements with results from CIP projects. (A006: DI-SESS-81766)

5.1.7 Airworthiness Certification Criteria Report

As required on an individual EPD/EPN, the contractor shall submit an Airworthiness Certification Report, the purpose of the Airworthiness Certification Criteria Report is to provide airworthiness certification criteria verification results. The data will be used to support program managers’ airworthiness type certification of aircraft. (A007: DI-SESS-81768)

5.1.8 Ozone Depleting Substances (ODS)

The Contractor shall not incorporate into nor use any Class I or Class II ODS in the manufacture of items provided for in this contract, unless specifically approved by the Government’s representative. If an EPD potentially requires use of an ODS for mission critical requirements for which economically and technically feasible substitutes are not available, it will be evaluated by the Government and considered for approval.

5.1.9 Study/Analysis

The Contractor shall develop, manage and document analysis and methodology necessary to complete the requirements of each approved EPD. The Contractor shall report methods used and results of study/analysis in a technical report. (A008: DI-MISC-80508)

5.2 CIP PROGRAM MANAGEMENT

5.2.1 Program Progress Report

The contractor shall provide a Quarterly Status Report (QSR) on each open individual EPD/EPN and the program in general. A combined report may be submitted. Status reporting shall include progress to date, problems, open issues, current status, schedule update, spend update and expected completion date. The contractor program manager should meet with government personnel monthly, or as needed, to insure the program communication is clear, concise, and timely. (A009: DI-MGMT-80555A)

5.2.2 Five Year Project Plan

The contractor will work with government program management to maintain a five year project plan for each weapon system (as required). This shall be developed by the contractor and government. It shall be maintained and updated by the contractor and submitted with each QSR. (A010: DI-MISC-80748)

5.2.3 Contract Funds Status Report (CFSR)

The contractor shall provide a monthly contract funds status report. The report shall provide financial status including but not limited to the EPD/EPN title, contracted amount, amount spent, amount invoiced, balance remaining, percent of work completed, completion date per contract, adjustments expected or needed in cost or schedule, current status, and other relevant comments. Tasks and projects which have expended 75% or more of its allocated funds shall be noted in a submittal cover letter, the letter shall also indicate if the allocated funding is sufficient to complete the task under the expected period of performance (POP). The contractor shall immediately notify the government

Contracting Officer at the time it is suspected that a project will require additional funding and/or POP to be completed than was allocated. (A011: DI-MGMT-81468)

5.2.4 Conferences /Reviews

The contractor shall conduct an annual program review at a time and location mutually agreed upon by the government and the contractor. The program review shall provide a comprehensive status report on each EPD/EPN currently active, review of recently completed projects, discussions of proposed future projects and other programmatic issues. Other technical reviews (Preliminary Design Reviews, Critical Design Reviews, Test Readiness Reviews, etc.) may be required per individual orders. The contractor shall record conference/review minutes and actions and provide a program review report which would also fill the quarterly status report requirement.

Prior to any technical review, the contractor shall provide an entry criteria checklist and show that each item is accomplished or will be accomplished by the time of the review. After the review, the report shall provide documentation showing the exit criteria and how/why it was accomplished.

The contractor shall provide a conference agenda and the entry criteria checklist 2 weeks prior to the scheduled program review. (A012: DI-ADMN-81249 B, DI-ADMN-81250, DI-ILSS-81335)

5.2.5 Meeting Minutes

The contractor shall provide formal published meeting minutes for formal design reviews and major program reviews as required in individual EPD/EPNs. The contractor shall provide a conference report within 2 weeks after each conference/review is held. For informal telecoms, monthly project status meetings, etc. the contractor is not required to submit formal published meeting minutes, but shall submit informal minutes/action items via email directly to the government project manager within 2 working days after the meeting. (A013: DI-ADMIN-81250)

5.2.6 Contractor Manpower Reporting

The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the USAF via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil. Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar year. Contractors may direct questions to the CMRA help desk.

5.2.7 Integrated Master Schedule

The IMS is a time-based schedule containing the networked, detailed tasks necessary to ensure successful program/contract execution. The IMS shall be used to verify attainability of contract objectives, to evaluate progress toward meeting program objectives, and to integrate the program schedule activities with all related components. The work breakdown structure should be tied to the projected schedule and updated periodically throughout the project. The contractor shall establish an IMS for each project/EPD to help manage and track progress. It should be delivered within 2 weeks after a new order is signed and updated monthly. (A014: DI-MGMT-81861)

5.2.8 Government Furnished Property, Material and Equipment (GFP/GFM/GFE)

The Contractor shall manage U.S. Government furnished property, material and equipment according to FAR 52.245-1 in Section I of the basic contract. The Contractor shall provide an inventory report at the end of each calendar year. (A015: DI-MGMT-81453)

5.3 CONFIGURATION MANAGEMENT

5.3.1 Technical Publication Manual Requirements

The contractor shall develop and submit technical publication source data for engineering, hardware, and procedural methods developed under this contract as required by individual EPD/EPN project descriptions. Source data format shall be identified by the individual EPD/EPN. Technical publication source data includes, but is not limited to the following:

1. Illustrated Part Breakdown (IPB)

2. Required Parts Supply Technical List (RPSTL)

3. Operating Procedures

4. Inspection Procedures

5. Repair/Overhaul Procedures

6. Assembly/Disassembly Procedures

7. Test Procedures

8. Support Equipment Operation

9. Time Compliance Technical Orders (TCTO)

10. Commercial Service Bulletins

(A016: TMCR 86-01)

5.3.2 Engineering Change Proposals (ECP)

ECPs shall be prepared and submitted by the contractor per Mil-STD-973. ECPs shall be submitted to the government as required by an EPD/EPN, when appropriate, or at the request of the government. For class 1 changes, a Drawing Change Notice (DCN) shall be submitted and approved by the government cognizant engineering authority prior to implementation. At the government’s request, an ECP may be required for class 2 changes, reference MIL-HDBK-61A for class 1 and 2 definitions. Funding to incorporate an approved ECP or DCN should be budgeted for under its associated EPD/EPN when possible. The ECP shall be in a format that is mutually agreed upon by the government and contractor. It shall be submitted to the government for review and approval 60 days prior to period of performance closure. It shall also be submitted to the government prior to incorporating any changes. (A017: DI-

CMAN-80639)

5.3.3 Item Unique Identification (IUID)

All items designed, developed, or delivered to the Government as part of the CIP that are subject to DFARS mandated IUID shall specify or contain (for delivered items) a machine readable data matrix symbol. Markings shall be legible with human and machine-readable information per MIL-STD-130N, “Identification Marking of U.S. Military Property”. The identification markings shall be visible during normal handling, shall be readable, shall withstand the specified environment and cleaning processes, and shall be as permanent as the service life of the unit or at least to the unit’s point of rebuild. The barcode shall contain, at a minimum: (1) Applicable Enterprise Identifier (2) Serial Number (3) Part Identification Number. Information will be provided to verify that IUID markings have been incorporated. This can be shown with the ECP or through updated end item drawings. (A018: DI-MGMT- 81803)

5.4 DATA MANAGEMENT

5.4.1 Product Drawings and Associated Lists

The contractor shall provide the government with product drawings and associated lists as needed to document and to incorporate detailed design changes developed under this contract into the specified model engineering parts list and as required by individual EPD/EPN project descriptions. The drawings and associated lists should be provided at a manufacturing level of detail and technical direction. (A019:

DI-SESS-81000)

5.4.2 Notice of Revision (NOR)

The contractor shall notify the government of any revisions that must be made to technical documentation controlled by another contractor or Government activity using an NOR. A NOR typically is submitted in conjunction with an Engineering Change Proposal. A NOR describes the proposed changes to a technical document, associated list, or other applicable document(s) so they can make the required documentation changes. As necessary, the contractor shall also provide support towards incorporation of the revisions. (A020: DI-SESS-80642)

5.4.3 Support Equipment Recommendation Data (SERD)

The Contractor shall develop and submit Support Equipment Recommendation Data (SERD) for all SE/Standard/Modified/Handtool Lists and Test Measurement and Diagnostic Equipment (TMDE), including Peculiar Support Equipment (PSE) and Common Support Equipment (CSE), that are required for Government operation and sustainment (to include organic supply and repair). The Contractor shall consider life cycle cost when selecting SE. SERD/Standard/Modified/Handtool Lists will be submitted in a format and schedule as required in accordance with the CDRL under the direction of the government technical representative. (A021: DI-SILSS-80118C)

5.4.4 Data Rights

Data rights shall be determined in accordance with DFARS clause 252.227-7013 and DFARS clause 252.227-7015. In the event any Contractor proprietary data approved to be incorporated by the Government in any such technical data, the Government retains no rights in such Contractor Proprietary information except for such rights as may be specifically negotiated between the Government and Contractor.

5.4.5 Data Management Planning/Execution

The Contractor shall prepare, maintain, and track the contract data status and schedule.

The Contractor shall submit all CDRL documentation through electronic media. The Contractor shall ensure that contractual electronic data are delivered using Secure Web-based Electronic Acquisition Program (SWEAP), unless waived by the Government Contracting Officer. The Contractor shall verify that adequate numbers of personnel possess and utilize SWEAP accounts to demonstrate timely CDRL delivery.

6.0 SCHEDULE

Engineering Project Descriptions (EPDs) are generally prepared by the contractor in response to a government furnished Statement of Objectives (SOO) before October to be ready for obligation in January. Funding is received at the start of the government fiscal year (October) while projects are managed according to the calendar year. Proposals should be prepared in one year blocks to be incrementally funded at the start of the calendar year and then again at the start of the fiscal year. After funds are obligated, planning must begin to prepare for the next year’s project submittals. Each spring, the CIP program office holds an Engine CIP Working Group (ECWG) where continuing projects and new projects are presented for approval. The five year plan is used to submit projects to this working group.

After project approval, the contractor will work with the Air Force Program Manager to prepare EPDs for the next year’s obligation period.

Throughout the year, the contractor will be required to report on financials through a Contract Funds Status Report (CFSR). They will also be required to support the Air Force by holding regularly scheduled teleconferences as a form of program management to review each project. The contractor will be required to hold an annual program review with the Air Force.

7.0 Period of Performance

Funding is requested for a calendar year’s period and may only be available in incremental amounts throughout the year; and subject to change. Therefore, the government can only obligate funding that is actually on hand. The planned period of performance for projects will be cited on each individual order.

If not completed, the period of performance on projects with remaining funding may be extended at the request of the contractor or government; only with the approval of the government Contracting Officer via a modification. The government Contracting Officer may require considerations depending on the circumstances for the extension. As reasonable, expensive or longer term projects should be broken down into one-year increments and reflected as a continuing project in the five-year plan. Only those projects approved by the government will be funded. The government reserves the right to terminate any project at any time without cause.

8.0 Performance Standards

Performance Objective

Performance Standard

Acceptable Quality Level

(AQL)

Monitoring Method

Engineering Project Description (EPD)

-Delivered 6 weeks of official request

(SOO)

-2 weeks of official request for SRD task

-95% on time

-95% on time

COR Surveillance

Quarterly Status Report

Quarterly (Sept, Dec, Mar, June)

100% on time COR Surveillance

5 Year Plan Quarterly (Sept, Dec, Mar, June)

100% on time COR Surveillance

Contract Funds Status Report

(CFSR)

Due on the 20th of each month

90 % on time COR Surveillance

Annual Program Review

Held in September -Agenda

-100%

COR Surveillance

-Report -100% EPD deliverables Per EPD requirements -Per Period of Performance (95% on time) -Government Quality Rejects (pass 95%)

-COR Surveillance

-Government Technical Representative

Cost Control Within 10% of Estimated Costs

95% COR Surveillance

Contractor Invoicing

-Prior Month Expenses invoiced by 10th of each month

-95% on time

COR Surveillance

Meeting Minutes -Delivered 2 days after each informal meeting

-Delivered 2 weeks after each formal meeting

COR Surveillance eCMRA -Input data before Oct 31

-100% COR Surveillance

GFP/GFM/GFE List -Submit list annually

-100% COR Surveillance

Integrated Master Schedule

-Updated with

QSR

-100% COR Surveillance