PWS03Nov.pdf

PERFORMANCE-BASED

WORK STATEMENT

(PWS)

FOR THE

Complete Depot Overhaul of Landing Gear End Items

23 September 2011 Air Force Material Command (AFMC)

Air Force Global Logistics Support Center

Prepared by:

417 SCMS

Hill Air Force Base, Utah 84056

CONTENTS

Section I DESCRIPTION OF SERVICES

1.1

Section II SERVICES SUMMARY

2.1

Section III GOVERNMENT FURNISHED PROPERTY AND SERVICES

3.1

Section IV GENERAL INFORMATION

4.1

Section V APPENDICES

5.1

Attachments

# 1 Contractor Communications Network (CCN) via CAV AF System

#2 Performance Maintenance Work Specification NSN/Part Numbers

#3 AFTO Form 95

#4 AFTO Form 22

#5 AFMC Form 202

#6 AFTO Form 43

#7 SF 364 (Report of Discrepancy)

Section I

1.0 Description of Services

1.1 Scope: This PWS defines depot-level maintenance requirements to sustain U.S. Air Force E-3, C130, and KC135 aircraft landing gear and related components. The objective of this contract is to obtain repair/overhaul services to accomplish the work requirements specified herein. Upon contract award, this PWS will become a binding agreement between the U.S. Government (USG) and the Contractor. The scope of this contract remains in effect under the terms of the basic contract and all applicable modifications until completion of the duration of the contract or exhaustion of the contract ceiling.

1.1.1 This Performance Work Specification establishes the minimum work requirements for complete depot overhaul necessary to return the C-130, KC-135, and E-3 system landing gear and related components repairable end items(s) to a serviceable condition.

1.1.2 All end item repair performed by the contractor will comply with the instructions and technical data requirements contained in this performance work statement.

Any end items deemed to be outside technical specifications identified in the latest applicable Technical Order will be handled under over- and- above work procedures IAW [DFARS 252.217-7028]. All over-and-above work requests must be authorized by the ACO prior to accomplishment. The US Government shall not be held liable for reimbursement for any unauthorized work tasks.

1.1.3 The contractor shall expend no unauthorized effort under this work specification for additional engineering design or development of the end items(s) or components(s).

1.1.4 The functional capabilities for which the end item was designed shall not be changed, modified, or altered without approval from a government engineer via the NCR/202 process (see paragraph 4.4.11).

1.1.5 MICAPS will be identified to the contractor and work priorities will be set by direction of the Program Manager to ensure “repair to demand” versus “batch repairs”. USG will provide the contractor with a weekly priority list detailing mission-impaired capability (MICAP) awaiting parts and high priority items.

1.1.6 Continuation of Essential DoD Contractor Services During Crisis. Contract performance is not mission essential during crisis situations IAW AFI 63-124, paragraph 2.7.1 and DoDI 3020.37.

1.1.7 Foreign disclosure restrictions apply to engineering data, which are export controlled.

1.1.8 The disassembly, inspection, complete depot overhaul/modification/update, test, and assembly of components parts and equipment shall conform to the instructions in this work specification and all applicable technical data/directives listed in Section IV.

1.1.9 The contractor shall maintain complete compliance with all local environmental laws, regulations, and requirements.

1.1.10 The contractor shall not allow any instances of damage to USAF property exceeding $2,000 USD. All safety mishaps over $2,000 USD shall be reported within one hour.

1.1.11 The contractor will not be reimbursed for unused CFM if the USAF terminates the contract in whole or in part the contract prior to its expiration.

1.1.12 A contractor will not need to submit first articles because it was determined that if a contractor has been deemed to be technically acceptable, then they are qualified to accomplish the repair and overhaul. Once on contract, the repair work will be validated by DCMA. There will be no first article testing.

Section II

2.0 Services Summary

Performance Objective PWS Paragraph Performance Threshold Method of Surveillance

Environmental Controls PWS paragraph 1.1.9

100% compliance with all local environmental laws, regulations, and requirements.

The DCMA QAR will perform periodic surveillance.

Safety PWS paragraph 1.1.10

Zero instances of damage to USAF property exceeding $2000 US dollars. All safety mishaps over this threshold shall be reported to the ACO within one hour.

The DCMA QAR will perform periodic surveillance.

Compliance with Technical Data

PWS paragraph 4.4.1

100% compliance with the latest version of all published Technical Data procedures, instructions, and directives

The DCMA QAR will perform periodic surveillance. Customer Complaint

Overhauled and repaired assets shall be delivered without defects.

PWS paragraph 4.1.4 QDR rate shall be <5% of total assets repaired in 1 year.

The DCMA QAR will perform periodic surveillance. Monthly CDRL, and Customer

Complaint

Overhauled and repaired assets pass Acceptance Test Specification (ATS).

PWS paragraph 4.1.5

Pass ATS 100% of the time.

In the event of a failure affecting delivery schedule, notigy Defense Contracts Management Agency (DCMA) Administrative

The DCMA QAR will perform periodic surveillance.

Section III

3.0 Government Furnished Property (GFP) And Services

3.1 All items necessary for the performance of this contract not listed in the Appendix B will be the responsibility of the contractor.

3.2 Please note, for the purposes of this PWS, no Government Furnished Equipment (GFE) will be provided (see definition of GFE, Section V, 5.0).

Section IV

4.0 General Information

4.1 Quality Control

4.1.1 Quality Control Program. In compliance with the clause entitled “Inspection of Services”, FAR 52.246-4, the contractor shall establish a complete Quality Control Program to ensure the requirements of this contract are provided as specified. The ACO will notify the contractor of acceptance or required modifications to the plan before first reparable induction. The contractor shall make appropriate modifications (at no additional cost to the government) and obtain acceptance of the plan by the ACO before the start of the first task order.

4.1.2 Complete records of all inspection work performed by the Contractor shall be maintained by the contractor and made available to the US Government during contract performance.

Contracting Officer (ACO) and Hill AFB Procurement Contracting Officer (PCO) of schedule changes within 24 hours.

On time delivery Rate PWS paragraph 4.4.5

Contractor shall meet contracted flow days 98% of the time with the exception of government caused delays. Non-compliance will result in negative contractor performance information.

The DCMA QAR will do inspections IAW the SCD.

4.1.3 Higher-Level Contract Quality Requirement. In compliance with clause FAR 52.246-11, the Contractor’s Quality Control Program shall comply with ISO 9001:2000/SAE AS 9100 or equivalent.

4.1.4 Quality Deficiencies: The quality deficiency rate shall be < 5% per year. The contractor shall provide full cooperation with USAF personnel when QDRs are identified. No instances of substantiated reports of interference from the contractor with QA inspections conducted by USAF/DCMA personnel will be allowed.

4.1.5 Prior to shipment of completed repair end items, each asset shall pass Acceptance Test

Specifications. In the event of failure affecting delivery schedule, notify Defense Contracts Management Agency (DCMA) liaison or Hill AFB Procurement Contracting Officer (PCO) of schedule changes within 24 hours.

4.2 Quality Assurance

4.2.1 Quality Assurance Personnel (QAP): The Quality Assurance Personnel (QAP(s)) is/are the authorized government representative(s) who will perform assessments of the contractor’s performance. Subsequent to contract award, the identity of the QAP(s), with a letter defining their duties and authority will be promptly furnished to the successful bidder/offeror.

4.2.2 The QAP(s) or alternate(s) will inform the contract manager when discrepancies occur and will request corrective action. The QAP(s) or alternate(s) will make a notation of the discrepancy on their assessment checklist with the date and time the discrepancy was noted and will request the contract manager (or authorized representative) to initial the entry on the checklist.

4.2.3 The QAPs are not authorized to make any changes to the scope, prices, terms and conditions of this contract.

4.2.4 The services to be performed by the contractor during the period of this contract shall at all times and places be subject to review by the Contracting Officer or authorized representative(s).

4.3 Deliverable Data Requirements: REPORTING REQUIREMENTS: Reporting and data requirements are identified in the Contract Data Requirements List (CDRL), DD Forms 1423.

4.3.1 The Contractor is required to use the Government legacy system Commercial Asset Visibility Air Force (CAVAF) in order to provide status of maintenance production, asset management, condemnations, problems encountered, accountability and stock balances of GFP end items and financial accounting and inventory control of GFM. (IAW CDRL A008).

4.3.2 The contractor shall use the AFTO 95 to document repairs made to each item (IAW CDRL A004).

4.3.3 The contractor shall create a Repair/Modification/Overhaul status report that tracks repair of each end item through the repair line. This Repair/Overhaul Status Report should be submitted to the Program Manager weekly (IAW CDRL A002). On this report shall be included a listing of all NSNs on hand by condition code [A = serviceable; F = reparable; G = awaiting parts; M = in work].

4.3.4 The contractor shall establish capability to advise the Program Manager of errors or omissions and other recommended changes to T.O.’s of technical nature, which prevents performance of functions required for mission accomplishment. Submit AFTO Form 22 to Program Manager on a monthly basis, unless a work stoppage is generated, in which case submit report within 24 hours of discovery. (IAW CDRL A001).

4.3.5 The contractor shall establish capability to seek disposition from USAF Engineering when an asset is found to exceed the repair limits established in the applicable T.O. (s) (AFMC Form 202, Attachment 5. Also see Terms Explained for NCR). (IAW CDRL A003)

4.3.6 Product Quality Deficiency Report (PQDR). The SF 364 form (see attachment #7) or other approved format used to record and transmit product quality deficiency data. This Data is information (based on objective evidence) provided by an activity concerning unsatisfactory (government or contractor) materiel. The data can be as simple as the originating point’s internal report form that initially recorded the deficiency. Of prime importance is the requirement for documentation which is based on direct examination, test, procedural review, etc. (IAW CDRL A005)

4.3.7 Transition Phase In: The Phase-In transition period is to be defined as no more than the first 6 months after contract award if the contractor is not currently performing the work.

Transition shall be, but not limited to, the contractor’s preparation period for the purpose of hiring, relocating, and training of personnel (including site familiarization); ordering material and the coordination of all phase-in matters associated with the contractor’s take-over of landing gear overhaul process. It shall be the contractor’s responsibility to acquire any and all required equipment, special tooling, etc. to perform the repair actions necessary to fulfill this contract requirement.

4.3.8 Transition Phase Out: The Phase out transition period is defined as the last 6 months of the contract performance. The incumbent contractor (the contractor that was awarded this LGR2 contract) shall accomplish the following:

4.3.8.1 Within 6 months of termination or completion of the contract, the LGR2 contactor shall provide the assistance and support required to ensure the orderly transition of all logistics support, and transitional planning necessary to commence uninterrupted performance of contractual requirements by the follow-on contractor (the follow-on contractor is TBD and would be a contractor selected upon the end of the LGR2 contract).

4.3.8.2 Within 6 months of termination or completion of the contract, the LGR2 contractor shall ensure cooperation with the Government and any new contractor(s), if applicable, in conducting joint wall-to-wall inventories, ensuring continuity of ongoing overhaul and repair operations during the transition period, executing transfer of responsibility and custody of Government Property (if any) to the new contractor and any other transition tasks as directed by the USG. The LGR2 contractor shall cooperate with a succeeding contractor to ensure an orderly transition and shall continue to manage and maintain accountability of all property in the pipeline until delivered and accepted.

4.3.9 The government requires regular submission of the USAF Standard Form 1428 (Inventory Schedule B) for all detailed parts and end item material condemnations incurred each month. The reports will be sent to the PM at the end of each month (IAW CDRL A009).

4.3.10 The Government requires a small business participation report to be reported on a semiannual (twice yearly) basis. The report shall be sent to the LGR2 contracting officer on the Microsoft Excel worksheet provided by the Contracting Officer.

4.4 Depot Repair Requirements

4.4.1 The contractor shall receive, disassemble, inspect, perform complete depot overhaul/modification/update, and test each end-item and all associated components, when applicable, to restore the item to a serviceable condition IAW the latest version of applicable TOs.

4.4.2 Parts or material used shall meet the requirements of technical data cited herein. In the event deviation from the technical data is required, an approval request in letter form (see paragraph 4.4.11 [form 202]) shall be submitted through the government engineer for approval. The contractor is not authorized to make any Class I or Class II changes.

4.4.3 Reworked component parts of the end-item shall meet serviceable criteria IAW technical data cited herein.

4.4.4 Serviceable precision matched or mated component parts shall be handled in a manner to ensure their reinstallation as a matched set.

4.4.5 Maintenance on the repairable end-item(s) and component(s) shall be accomplished using only technical data cited herein and shall be completed IAW contracted flow days 98% of the time with the exception of government caused delays. Flow days means induction and overhaul of assemblies, within negotiated time frame, of receipt of the assemblies.

4.4.6 If any applicable technical data is changed, revised, amended, or supplemented after award of contract, and an increase or decrease in work requirements is involved, the ACO and PCO will be informed. If the change drives increased cost to any of the line items, the repair cost for the affected items will be renegotiated.

4.4.7 The contractor shall check for any unauthorized or unacceptable maintenance performed on the end items by other sources. If unauthorized or unacceptable maintenance is suspected or verified, notify the ACO.

4.4.8 The contractor is authorized to retain all condemned end items for use in cannibalization down to the Shop Repair Unit (SRU) level for use in the repair process. Approval to proceed with cannibalization shall be routed through the cognizant ACO and PCO. Upon approval, the contractor is authorized to use parts from other similar end items on hand in order to expedite the turnaround of the end item.

4.4.9 Unless specifically prohibited by the controlling T.O., the contractor will be allowed to move components among repairable end items to expedite repair, versus maintaining serial number integrity. The contractor is authorized to rob back Shop Repair Units (SRU) from Line Repair Units (LRU) in order to repair the LRU for the purpose of expediting deliveries. This rob-back is accomplished when the schedule is critical and the part within the LRU in work is unserviceable and will take an unacceptable amount of time to repair or order and replace. Approval to proceed with rob back procedures shall be routed through the cognizant ACO. The contractor shall not remove components to the point that the end items are not repairable and require condemnation.

4.4.10 The Contractor shall be responsible for identification, selection, ordering, and stocking of required parts to support all repairs. All commercially procured parts shall be from approved sources and shall not alter the configuration of the end item. The Contractor shall establish a parts control program IAW industry standards. The Government makes no representation that any previous vendor of an item will sell, or agree to sell, such articles to the Contractor. Audit trails for the manufacture of all parts must be maintained for all components procured in support of this contract.

4.4.10.1 Substitution of parts not listed in the TOs shall be submitted via ACO for approval by the cognizant government engineer on a case by case basis.

4.4.10.2 Replacement of failed parts shall not result in an item’s configuration changing to an older configuration (downgrading/deconfiguration).

4.4.10.3 Configuration updates could occur. If the configuration change is a minor change, there will be no cost. However, if there is a major change, then there will be a modification done to the contract to cover the costs. This will allow requests for equitable adjustment for configuration updates that are considered major changes.

4.4.11 Non Conformity Reports (NCRs/202/Engineering Change Proposals (ECPs))

4.4.11.1 In the event that the contractor identifies that a part is not in conformance with the specifications defined in the technical orders or other related documents and requires additional work, an NCR is prepared. (CDRL A003)

4.4.11.2 Contractor’s engineering section will e-mail a copy of the NCR to the ACO, USG PM and cognizant Hill Engineer for engineering review and approval. The ACO will confirm that funding is available at time of approval. Once approved by Hill Engineering, the NCR will be returned to contractor by the Hill Engineer for completion of the work. DCMA QAR validates the work. All NCRs are submitted to the GQAR (Government Quality Assurance Representative) for their approval after Hill engineering has approved it. A copy of the NCR is attached to the work process to ensure conformity of the end product when it is inspected by GQAR.

4.4.11.3 Upon completion of work, contractor will e-mail a NCR summary of the completed NCRs to ACO (cc to PCO and PM). Upon review (i.e. appropriate rates and sufficient funding verification) of the NCR summary, the ACO will confirm to contractor for approval/disapproval.

4.4.11.4 Items which have been identified as having a recurring non-conformity and which have not been incorporated into a T.O. change would qualify as “over and above” IAW DFARS 252.217-7028, Contractor will request that USG engineers validate the NCR for a six-month authorization period. Contractor will issue a monthly NCR to cover repairs performed during the month according to the six month NCR repair authorization. The invoicing authorization process will follow the above-mentioned procedure.

4.4.12 Receipt of Property at Facility

4.4.12.1 HANDLING: The contractor shall exercise care to prevent damage to Government Furnished Property while in its possession.

4.4.12.2 The contractor shall store all Government Furnished Property in a secure area to provide protection against damage, pilferage, or loss. Storage areas shall provide protection against all adverse environmental conditions. Costs associated with such storage shall be included in the cost of the end item repair.

4.4.12.3 Reusable shipping containers, packaging, and crating material in which the Government Furnished Property is received shall be handled with care. The contractor shall package all end items IAW SPI data. The contractor may choose to reuse existing packaging and accomplish any associated repair of such packaging, or build new packaging. The contractor shall be responsible for ensuring that containers are in serviceable (reusable) condition. It is understood that the cost associated with such container repair shall be included in the cost of the end item repair.

4.4.12.4 INVENTORY INSPECTION: An inspection shall be performed on the end-item upon its receipt at the contractor’s facility for the following:

(a) Proper identity

(b) Damage

(c) Completeness (item physical configuration).

(d) Any deficiencies found as a result of the above inspection shall be brought to the attention of the ACO, and disposition shall be as directed through the ACO (IAW CDRL A005).

4.4.13 Work Requirements

4.4.13.1 Work Requests (WRs): Contractor identifies that work is required which would qualify as “over and above” IAW DFARS 252.217-7028. A Work Request (WR) is then prepared.

4.4.13.2 A copy of the WR is sent to the PM (cc to ACO/PCO). The PM will verify that the work is required and the ACO will negotiate costs, verify reasonableness and that sufficient funding is available.

4.4.14 End Item Returns and Rework

4.4.14.1 Upon receipt of end item returns the QAR and contractor shall undertake the investigation to determine the cause of the defect. The investigation report will be forwarded to Hill engineer for review and concurrence (IAW CDRL A005). The final report will be provided to the ACO, PCO, PM. Based on the findings the normal over and above work request procedures will apply for incurred costs.

4.4.15 Condemnations of End Items

4.4.15.1 Condemnations: Authorization to accomplish condemnation shall be obtained through the ACO/CO from the Engineer for end item(s) determined to be uneconomical to return to a serviceable condition (FAR Part 45.6, DFAR part 245.6, DOD 4160.21-M-1, DOD 4100.39-M). It shall be considered uneconomical to accomplish repair on an end item when the total cost for parts, materials, and labor exceed 75% of the applicable Stock List Price IAW 5352.291-9005 (End Items Beyond Economical Repair), or as amended or modified with approval of the appropriate Air Force Item Manager. If the asset reaches the point where it is BER (Beyond Economical Repair), the contractor will submit an NCR to the Engineer. If the engineer concurs and the end item includes salvageable GFM component parts, the engineer or program office should provide disposition instructions for the salvageable parts. The contractor will submit the Work Request to include costs incurred to the point of condemnation and the cost to salvage GFM component parts. The contractor will route the request through the ACO for authorization to accomplish repair or to condemn the item.

4.4.15.2 The contractor will generate a report with detailed parts and end item material condemnations incurred each month (IAW CDRL A009). The reports will be sent to the PM at the end of each month. All other GFM requirements will be addressed as per Appendix B.

4.4.15.3 When an end item is going through repair, if it reaches the point where the asset is beyond economical repair (BER), the contractor will submit an NCR to the engineer (IAW CDRL A003).

4.4.16 GFM Replacement

4.4.16.1 At the completion of the Disassembly and Inspection (D&I) process, certain sub-components of an end item assembly may be condemned. If the condemned sub-components are to be supplied as GFM under the terms of the contract, contractor will requisition the necessary parts through normal USAF procedures (See Appendix B). The remaining reparable components will proceed through the repair and overhaul line. If at the end of the repair process, GFM is not available and information received from the PM reveals that the parts will not become available in the foreseeable future; the repaired components of the end item assembly will be boxed, properly marked and returned per disposition instructions provided by the PM. This will be handled on a case-by-case basis under the over and above work requests procedures.

4.4.17 Other Direct Costs

4.4.17.1 Receipt & Shipment of end Items and GFM: Under the terms of this contract, contractor is required to receive unclassified landing gear assemblies and components from various U.S. military installations, perform repair and overhaul services as required and return the completed assets to the Ogden Air Logistics Center or their designated locations. In addition to repairable assets, contractor also receives Government Furnished Material (GFM), which is utiliized to complete the repair and overhaul process. All incoming USAF material is received and secured at contractor’s primary or supplemental address central location that permits contractor to consolidate several shipments from various sources on any given day. All outgoing USAF shipments will be shipped each week per the direction of DCMA on a Government Bill of Lading (GBL) or as otherwise directed.

4.4.17.2 The contractor shall provide any and all parts support other than GFM at their own expense (as Contractor Furnished Material (CFM)).

4.4.17.3 Misdirected and Mis-identified Material: Upon receipt of misdirected or mis-identified material, contractor will submit a Report of Discrepancy (ROD) to DCMA and for disposition. DCMA will determine whether any additional costs incurred as a result of the handling and/or storage of these items, will be authorized to be paid with Over & Above funding and whether such funds are available.

4.4.18 Upon completion of the work, contractor will submit a Material Inspection & Receiving

Report via Wide Area Work Flow (WAWF) invoice to DCMA QAR or delegated QAR for inspection and acceptance of the completed work. After inspection and acceptance, the contractor shall submit the documentation to the ACO. Contractor will verify that the invoice is properly submitted using the overtime premium specified in the contract, reconfirm that funding is available and forward the invoice for payment. The contractor shall submit this report via Wide Area Work Flow (WAWF) electronic form (DFAR 252.232- 7003 (b)). Exceptions (DFAR 232.7002) to using WAWF system to submit reports are as follows:

(a) Contractors shall submit payment requests and receiving reports in electronic form, except for—

(1) Purchases paid for with a Governmentwide commercial purchase card;

(2) Awards made to foreign vendors for work performed outside the United States;

(3) Classified contracts or purchases when electronic submission and processing of payment requests could compromise the safeguarding of classified information or national security;

(4) Contracts awarded by deployed contracting officers in the course of military operations, including, but not limited to, contingency operations as defined in 10 U.S.C. 101(a)(13) or humanitarian or peacekeeping operations as defined in 10 U.S.C. 2302(8), or contracts awarded by contracting officers in the conduct of emergency operations, such as responses to natural disasters or national or civil emergencies;

(5) Purchases to support unusual or compelling needs of the type described in FAR 6.302-2;

(6) Cases in which DoD is unable to receive payment requests or provide acceptance in electronic form; or

(7) Cases in which the contracting officer administering the contract for payment has determined, in writing, that electronic submission would be unduly burdensome to the contractor.

4.5 Program Management Review (PMR) Frequency

4.5.1 A PMR will be held bi-annually, as dictated by the Program Manager (PM) and may involve alternate venues. The purpose of the PMR is to review cost/schedule/performance metrics and address significant program/technical issues.

The agenda shall be prepared by contractor and coordinated with the USAF. The agenda shall be provided NLT fourteen days prior to meeting; minutes/action items shall be provided within seven working days after the meeting. All action items shall be tracked until closure or resolution. The PMR must address program risks and avenues or alternatives for mitigation. (Ref CDRLs A006 & A007).

4.5.2 Program Status Reporting will be biweekly at a minimum and the contractor shall conduct teleconferences with USAF/DCMA personnel to address any/all relevant issues. The agenda shall be prepared by the contractor and coordinated with USG. The agenda shall be provided twenty-four hours in advance; the minutes shall be provided within two working days after the conclusion of the teleconference. The Weekly Status Report (Ref

CDRL A002) shall be delivered NLT the last week day of each month, highlighting program progress, status, and risk/problem areas.

4.6 MICAP, Critical Items and Surge:

4.6.1 In the event that the DoD experiences an unplanned spike, sudden increase in demand due to major theater warfare, or a national emergency (also know as surge), the contractor is willing to work to meet and sustain this demand for quantity levels above and beyond normal peacetime requirements. After being notified of the surge demand in writing, the contractor will allow the DoD to place additional orders and/or elevate the priority status of current orders.

4.6.2 USAF will provide contractor with a weekly priority list detailing Mission Impaired Capability Awaiting Parts (MICAPs) and Joint Chief of Staff (JCS) or other high priority backorders. In response, contractor will provide the USG Program Manager (PM) with a weekly projected 4-week production delivery schedule (Ref CDRL A002). Upon review of this schedule, the PM will determine if MICAP procedures will be activated and if overtime is required follow paragraph 4.6.3.

4.6.3 The Premium Time/Overtime contract line item is used to support Accelerated Delivery Requests (ADRs) for MICAP, JCS and other high-priority backorders. The contract line item will be funded when there exists a need to expedite repair through the contractor facility in order to support ADR requirements as directed by the government. Upon activation of the ADR procedures, contractor will provide USG with an Estimated Delivery Date (EDD) for each item within one working day. The contractor shall, to the maximum extent possible, expedite delivery without increasing cost through such measures as realigning existing workload. If the EDD is not satisfactory, the Program Manager will request contractor to provide an amended schedule utilizing overtime. The following criteria for each ADR item group will be used in the development of this schedule:

(a) The work unit, department or section in which the requested overtime will be used together with present workload, staffing and other data of the affected unit sufficient to permit the PM to evaluate the necessity for the overtime;

(b) The effect that denial of the request will have on the contract delivery or performance schedule;

(c) The extent to which approval of overtime would affect the performance in connection with other Government contracts; and

(d) Estimated cost. Upon determining that overtime is required, the PM will request the PCO to solicit a proposal from contractor(if not already received), negotiate the number of labor hours involved and then multiply those negotiated hours by the contracted labor rate shown for applicable CLIN (subsequent years) to arrive at a total amount of overtime dollars required. The PCO will obtain the necessary funding for this effort and will modify the applicable delivery order by adding the negotiated overtime dollars to applicable CLIN (subsequent years) of the order. At that time, the contractor is authorized to proceed with the overtime effort.

4.7 Over and Above Procedures

4.7.1 In accordance with DFARS PGI 217.77, negotiations shall be in IAW DFARS Clause

252.217.7028. Request for consideration of O&A shall be made in writing to the

ACO/PCO.

4.8 Time Compliance Technical Order (TCTO)

4.8.1 The contractor shall comply with urgent action, immediate action, and safety TCTOs which are due to rescind and are supportable with kits/parts (if applicable) that are outstanding or generate while the landing gear components are in work.

4.8.2 The contractor shall accomplish all TCTO’s specified by the Delivery Order. The government shall negotiate all TCTO accomplishment tasks not already included in the contract. If missing (unaccomplished) TCTO’s are discovered on landing gear, submit an AFMC 202 and notify the ACO for disposition.

4.9 Specific Work Requirements:

4.9.1 The general work requirements in this landing gear repair effort include, but are not limited to the following: complete disassembly, cleaning and paint removal, nondestructive inspection, reassembly, testing, repainting, machining, grinding, stripping of plated coatings, and re-plating.

4.9.2 Table 1 lists the general overview of the processes required and the frequency of occurrence. The various technical orders and process specifications listed in section V will define all of these processes.

4.9.3 Note that many of these processes are regulated in the United States under Occupational Safety and Health Administration (OSHA)and Environmental Protection Agency (EPA) regulations. Reference to a regulated process under either OSHA or EPA is not intended to be the only regulated processes. It is the contractor’s responsibility to identify the affected process and comply with all applicable regulations.

TABLE 1 Work Requirements Summary

PROCESS OCCURRENCE COMMENT

1.Complete disassembly 100% Disassembly includes removal of bushings unless specifically exempted by the specific component technical order. May require special tools and equipment to accomplish.

2. Clean and paint removal 100%

May use either abrasive blast or chemical paint removal techniques. Will produce a regulated hazardous waste stream.

3. Chrome, Cadmium and anodize strip

As required if chemical paint removal used.

100% if abrasive blast is used.

Cadmium removal may require compliance with OSHA standards for cadmium exposure.

4. Non-destructive inspection

(NDI)

100% initially and as required by additional processing.

The primary inspection methods are fluorescent penetrant for non-ferrous components and fluorescent magnetic particle for ferrous components. Other methods will be as required by specific component technical order. All inspectors shall be certified per NAS410, Level II.

Certifying officials shall be level III certified.

4a. Temper etch inspection 100% following grinding and/or machining of steel heat-treated above 180 ksi.

5. Hydrogen embrittlement relief bakes

100% on steel heat treated over 180,000 psi following processes with potential hydrogen generation.

Bakes are either 4 or 23 hours depending on the process and usually must start within 4 hours of the embrittling process. The usual bake temperature is 375+/-25 degrees F.

Other bake criteria may be required or authorized by specific process specifications. A bake is required following stressing operations such as grinding.

6. Evaluation 100%

Determines the further processing required.

This involves visual examination of the component and various dimensional checks.

A temperature controlled inspection area is required. Temperature control must be such that part tolerances can be accurately measured and maintained.

7. The following processes are typical of the processing most parts will require. The requirement is established during the evaluation.

Machining Grinding (based metal) Stripping of various electroplated and anodic coatings Shot peening Reapplication of coatings such as:

Chrome Nickel Electroless Nickel Cadmium nickel or IVD Aluminum Anadize Phosphate coating Conversion Coatings Grinding coating to finish size

As determined by the evaluation step.

Most of these processes are governed by specifications. The process and coating must meet the specifications.

The process control requirements of the specifications must be complied with (Reference the general strut technical order 4S-1-182 for use in lieu of process control).

8. Bushings Installation 100% for those components that had bushings removed during disassembly.

New bushings are required except as authorized by the specific component technical order.

9. Assembly 100% as required by the end item.

May require special tools and fixtures.

10. Test As required by the technical data.

May require special test stands and equipment.

11. Paint 100% as required by the end item.

Most components or assemblies require painting. Some minor components do not.

4.9.4 Table 2 lists typical processes and the accompanying routing that most components will require. Specifically, it shows typical process routes for steel and aluminum components since they are the most predominate. Other alloys will have their own routing. These tables are not a complete list of processes. They are intended to give an idea of the processing required.

DISASSEMBLY

CLEAN AND PAINT STRIP

TABLE 2

STEEL ALUMINUM

Cadmium strip Bake

FMPI(1)

E & I (3) Machining Strip plating Initial grinding Temper etch Bake (4 hrs within 8 hrs) Shot peen Hone Re-plate* Bake (4 or 23 hrs with 4 hrs)*

Anodize strip FPI(2)/eddy current Conductivity inspection E & I (3) Machining Shot peen Grind/hone Anodize, Type II & III Hone Install bushings Assemble Test Paint

Final Grind* Bake (4 hrs)* (*Per applicable TO’s instructions) All areas requiring plating)

FPI (2)

Cadmium plate or IVD aluminum coat Bake (23 hrs w/in 4 hrs, cadmium only)

FMPI (1)

Install bushings Assemble Test Paint

(1) Fluorescent magnetic particle inspection

(2) Fluorescent penetrant inspection

(3) Evaluation and inspection

4.10 Clarification Statements: Due to improvements in repair processes, NSNs might change. The item itself does not change. When the Federal Stock Class (FSC) changes but the NIIN does not change, treat the CLIN as the same item.

4.11 Technical Orders and Other Directives

4.11.1 Technical Data Requirements: The contractor shall maintain all T.O.s applicable to this work requirement in a current status IAW T.O. 00-5-1, distribution IAW T.O 00-5-2. The contractor shall comply with the latest dated T.O.s and other directives used or issued during the time the work is being accomplished and perform a timely review of all updated T.O.s and other directive changes applicable to the work requirement. The review will consider the impact on work requirements, cost, and schedules with backup data for those changes. Increases or decreases in work, which impact the maintenance facility or the government, will be sent through the ACO to the CO for negotiation and approval, prior to beginning work.

4.11.2 Applicable Technical Orders:

4S-1-182 General Overhaul and Maintenance Instruction, Aircraft Landing Gear Components.

33B-1-1 Nondestructive Inspection Methods 1-1-1 Operation Instructions, Cleaning Of Aerospace Equipment 1-1-8 Application and Removal of Organic Coatings Aerospace and Non Aerospace Equipment 1-1A-8 Structural Hardware 1-1-691 Cleaning and Corrosion Prevention Control, Aerospace and Non Aerospace Equipment

00-5-1 AF Technical Order System 00-20-5 Covers processing of AFTO 95’s 00-25-260 Asset Marking and Tracking Item Unique Identification (IUID) Marking Procedures 00-25-195 Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems 44B-1-2 General Maintenance Instructions – Airframe Antifriction Bearings 00-25-234 General Shop Practice Requirements for the Repair, Maintenance and Test of Electrical

Equipment 1-1-4 Air Force Standard Exterior Finishes 1-1-2 Corrosion Control and Treatment for Aircraft and Missiles

4.11.3 SPECIFIC T.O’s:

KC-135: 4A4-12-3/ 4A4-12-4/ 4S2-30-3/ 9H2-3-30-3/ 4SA6-5-3/ 4A4-12-23/ 4SA3-7-13/ 9H2-2- 39-3/ 4S1-56-3/ 4S1-49-3/ 4S1-56-4/ 4S1-56-13/ 4S1-56-14/ 4A4-12-24/ 4A4-29-4/ 4S1-119-3/

4A4-30-3/ 4S1-118-3/ 4S1-110-3/ 4SA6-33-3/ 4SA3-7-13

E-3: 4S2-78-3/ 4S1-102-3/ 4A4-25-3/ 4S2-79-3/ 4SA2-51-3/ 4S1-107-3/ 4A4-24-13/ 4S1-106-3/

4S1-104-3/ 4S1-105-3/ 4S1-103-3/ 4BA4-116-3/ 44H3-1-3/ 44B-1-102

C-130: 16G1-182-3/ 16C1-12-10-13/ 4S1-37-3/ 4S1-37-4/ 4SA3-26-3/ 4S2-23-3/ 4S2-23-4/ 4S1- 69-13/ 9H2-2-80-3/ 4SA6-7-3/ 16G3-2-87-3/ 4S1-37-4/ 16G1-152-3/ 44B-1-3/ 16G1-151-3/

4.11.3.1 The contractor shall be responsible to maintain an account with the applicable Technical Order systems with electronic access. See below paragraphs for procedures on accessing this system.

4.11.3.1.1 Establishing USAF Technical Order Distribution Offices (TODOs): The contractor must establish TODOs by processing an AFTO Form 43, (TODO) Assignment or Change Request. The IBM Lotus version of the AFTO Form 43 can be downloaded at http://www.e-publishing.af.mil/.

Alternatively, prospective contractor TODOs may download and use the Word version of the AFTO Form 43 at https://techdata.wpafb.af.mil/toprac/forms.htm. All versions of the form include detailed completion instructions.

NOTE: Before they can process an AFTO Form 43, TODO personnel require a CAC card or External Certificate Authority (ECA) certificate and Air Force Portal Access. Procedures for contractors to obtain an ECA certificate are found at:

http://iase.disa.mil/pki/eca/docs/Becoming_an_ECA_vendor.pdf. DoD approved ECA certificates are issued from VeriSign (http://www.verisign.com/verisign-business-solutions/public-sector-solutions/public-sector-ieca/) or ORC (http://www.eca.orc.com/) and http://www.e-publishing.af.mil/ https://techdata.wpafb.af.mil/toprac/forms.htm http://iase.disa.mil/pki/eca/docs/Becoming_an_ECA_vendor.pdf http://www.verisign.com/verisign-business-solutions/public-sector-solutions/public-sector-ieca/ http://www.verisign.com/verisign-business-solutions/public-sector-solutions/public-sector-ieca/ http://www.eca.orc.com/

Identrust (http://www.identrust/certificates/eca/index.html). Air Force Portal access procedures are found at https://my.af.mil, including the need for, at a minimum, a favorable National Agency Check (NAC).

4.11.3.1.2 Contractor TODOs: Because ETIMS access is required to establish and manage TODO accounts, prospective TODO POCs must first obtain a CAC or an External Certificate Authority (ECA) with a minimum of a favorable national agency check (NAC) to establish Air Force Portal access needed for ETIMS. The AF portal ID of the prospective, primary TODO POC is entered into block 6 of the AFTO Form 43. The designated Contracting Officer representative must confirm an approved DD Form 2345, Militarily Critical Technical Data Agreement (AFI 61-204, Disseminating Scientific and Technical Information) is on file prior to approving the AFTO Form 43. The approved AFTO Form 43 is then submitted to the OC- ALC/ENGLA. If government support contractors maintain a separate company-owned TO library, the company shall process a separate AFTO Form 43 to establish the contractor owned and operated TODO.

NOTE: Beause IBM Lotus software is required to view the AFTO Form 43 available on e-publishing, contractor personnel may use the MS Word version of the AFTO Form 43 available at https://techdata.wpafb.af.mil/toprac/forms.htm. Once contractor TODO accounts are established, the contractor TODO uses ETIMS to directly order and receive the TOs required under the contract. The GAA should request TO account information of the contractor TODO whenever they wish to audit the account.

4.11.3.1.3 TODO Actions: Upon receipt of the approved AFTO Form 43, the primary TODO should access and use the ETIMS account associated with the JCALS TM account number on the AFTO Form 43 to establish and manage their unit’s TO/eTO requirements. The primary TODO must also enter the shipping address from block 3 of the AFTO Form 43 in ETIMS. This is performed using the address button on the Office screen. For assistance in updating addresses in ETIMS, consult the procedural document at the following AF Portal link https://wwwd.my.af.mil/afknprod/DOCView.asp?DocID=4609165. If the TODO was designated a lead TODO on the AFTO Form 43, the TODO will know they have been assigned the eTool administrator role by 754 ELSG/ILMT when the “eTool Admin” button on the ETIMS “TO Viewer” screen becomes active. 4.3.4.2 The primary TODO POC will maintain a file copy of the approved AFTO Form 43 for future reference and audit support.

http://www.identrust/certificates/eca/index.html https://my.af.mil/ https://techdata.wpafb.af.mil/toprac/forms.htm https://wwwd.my.af.mil/afknprod/DOCView.asp?DocID=4609165

4.11.3.2 The contractor shall be responsible to acquire technical drawings as required. This data may be acquired by request through the contracting officer.

4.11.4 APPLICABLE DIRECTIVES:

MIL-STD-865: Selective (Brush Plating) Electro deposition

MIL-STD-868: Nickel Plating, Low Embrittlement, Electrodeposition

MIL-STD-871: Electro-Chemical Stripping of Inorganic Finishes

MIL-STD-866: Grinding of Chrome Plated Steel and Steel Parts, Heat Treated to 180,000 PSI or over.

MIL-STD-1503: Preparation of Aluminum alloys for surface Treatments on Inorganic coating

MIL-HDBK-1568: Materials and processes for corrosion prevention and control in aerospace weapon systems

MIL-STD-45662: Refer to ISO 10012-1 an ANSI-Z540-1 as Alternatives to STD-45662, Calibration systems requirements

MIL-STD-83488: Coating, Aluminum, High purity

MIL-C-26074: Coating, Electroless Nickel

MIL-C-15074: Corrosion Preventive, Fingerpoint Remover

MIL-PRF-81322: Grease, Aircraft, General purpose, wide temperature range

MIL-PRF-81773: Sealing and coating compound, corrosion inhibitive

MIL-STD-1504: Abrasive Blasting

ASTM-E1444: Inspection, Magnetic particle

MIL-A-8625: Anodic coatings for aluminum and aluminum alloys

MIL-C-5541: Chemical conversion coatings on aluminum and aluminum alloys

MIL-PRF-16173: Corrosion preventive compound, solvent cutback, cold-application

MIL-C-11796: Corrosion preventive compound, petrolatum, hot application

SAE-AMS-H-6088: Heat treatment of aluminum alloys

MIL-PRF-23377: Primer coatings: Epoxy, High-solids

MIL-R-46082: Retaining compounds, single component, Anaerobic

SAE-AMS-S-13165: Shot Peening of metal parts

ASTM-E1417: Inspection, Liquid Penetrant

NAS847: Caps and plugs, Protective, dust and Moisture Seal

SAE-AMS-C-8837: Coating, Cadmium (Vacuum Deposited)

MIL-PRF-85285: Coating, Urethane, Aliphatic isocyanate, for aerospace applications

SAE-AMS-H-6875: Heat treatment of steel raw materials

TT-P-1757: Primer coating, alkyd base, one component

MIL-PRF-83936: Remover, paint, tank type; for Aircraft wheels, Landing gear components, and other Aircraft and support equipment

MIL-STD-869: Flame Spray

MIL-STD-1500: Cadmium-titanium plating, low Embrittlement, Electrodeposition

MIL-STD-867: Temper etch inspection

MIL-STD-870: Cadmium plating, low Embrittlement, Electrodeposition

MIL-STD-1501: Chromium plating, low Embrittlement, Electrodeposition

AIA/NAS 410: NAS Certification and Qualification of Nondestructive Test Personnel

MIL-G-23827: Grease, Aircraft & Instrument, Gear & Actuator Screw, NATO Code Nr. G-354, Metric

MIL-H-6083: Hydraulic fluid, Petroleum Base For Preservation and Operation

MIL-PRF-87257: Hydraulic Fluid, Fire Resistant, Low Temperature, Synthetic Hydrocarbon Base, Aircraft and Missile

MIL-S-7742: Screw Threads, Standard Optimum Selecte4d Series: General Specification For

DOD-P-16232: Phosphate Coating, Heavy Manganese or Zinc Base

MIL-D-9063: Solvent

MIL-H-83282: MIL-H-5606/Hydraulic fluid

MIL-I-6868: Magnetic-Particle Inspection (Magnaflux)

NAS 410: NAS Certification and Qualification of Nondestructive Test Personnel

4.11.4.1 Technical order/manuals, technical directives and other applicable publications required to accomplish the work effort, but not in possession of the contractor, shall be acquired as authorized and directed by the ACO.

NOTE: Primary source for military specifications and standards is:

https://assist.daps.dla.mil/quicksearch/

AF Drawing 200310641 (98747) Coatings, Tungsten Carbide on High Strength Steel Using High Velocity Oxygen Fuel (HVOF) Process

AF Drawing 200310642 (98747) Grinding of High Velocity Oxygen Fuel (HVOF) Sprayed Tungsten Carbide Coatings

Section V

5.0 TERMS EXPLAINED:

Accelerated Delivery Request (ADR): AFMC Form 200, used to process accelerated delivery requirement to support high-priority backorders and MICAPs.

Acceptance Test Specifications (ATS): as spelled out in applicable Technical Orders.

Administrative Contracting Officer (ACO): Contracting officer who performs actions delegated by the Procurement Contracting Officer at the initiating activity.

Assembly: Two or more parts or subassemblies joined together to form a complete unit, structure, or other article.

Air Force Technical Order (AFTO)

Batched Repairs: Repaired items are not reported as complete or shipped until a pre-determined quantity of items are produced.

Beyond Economical Repair (BER): Repair exceeds value of item.

Cannibalization: Removal of a specific assembly, subassembly, or part from one weapon sytem, support system, or equipment end-item for installation on another end-item to meet priority mission requirements with an obligation to replace the removed item.

Commercial Asset Visibility Air Force (CAVAF)

Contract Line Item Number (CLIN):

Contracting Officer (CO)

Component: Subsystem, assembly, subassembly or other major element of an end item.

Condemned Item: When a reparable item can no longer be repaired to serviceable condition, it is condemned.

Contractor Furnished Material (CFM): Contractor furnished material to complete repair of end items.

Defect: Any nonconformance with specified requirements.

Disassemble: To remove the components that make up the end-item in accordance with disassembly instructions in the government approved contractor technical data.

Disassembly & Inspection (D&I): Process to determine what is required for repair of the end item or repair/replacement of components.

Electronic Technical Order (eTO)

Engineering Change Proposal (ECP): See Non Conformity Report.

Estimated Delivery Date (EDD)

External Certificate Authority (ECA): Certificate required in order to process government AFTO Form 43 (to set up a Technical Order Distribution Office).

Federal Supply Classification (FSC): First 4 numeric digits of…