PWS-Troopdoorarmor06Augl.pdf

Paratroop door armor 6 Aug 2009 i

Performance-Based Work Statement (PWS)

For

Paratroop door light-weight armor kit

DATE:

Prepared by:

580th Aircraft Sustainment Group

572nd Aircraft Sustainment Squadron 235 Byron Street Ste 19A

Robins AFB GA 31098

PR Number: FD2060-09-23400 Program Manager: Michael Haramut

DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors (Administrative or Operational Use; 02-23-09). Other requests for this document shall be referred to 572 ACSS/GFLB, Robins AFB, GA. 31098

TABLE OF CONTENTS

Light Weight Armor Cover Sheet…………………………………i Table of Contents……………………………………………………1 Table of Contents……………………………………………………2 Table of Contents……………………………………………………3

1.0 DESCRIPTON OF SERVICES

1.1 SCOPE………………………………………………………

2.0 SERVICES SUMMARY

3.0 GOVERNMENT FURNISHED PROPERTY AND SERVICES

4.0 GENERAL INFORMATION

4.1 DESIGN AND INSTALLATION REQUIREMENTS

4.1.1 Design Package

4.2 PHYSICAL CHARACTERISTICS

4.2.1 Transportability

4.2.2 Storage

4.2.3 Safety

4.2.3.1 System Safety and Hazard Analysis

4.3 SYSTEM QUALITY

4.3.1 Reliability

4.3.2 Maintainability

4.3.3 Structural Life

4.3.4 Fatigue Life

4.3.5 Damage Tolerance

4.4 ENVIRONMENTAL REQUIREMENTS

4.4.1 Environmental Management System (EMS)…………………….7

4.4.2 Climatic Requirements

4.4.3 Temperature

4.5 DESIGN AND CONSTRUCTION

4.5.1 Site Survey

4.5.2 Material and Processes

4.5.3 Value Engineering

4.5.4 Margin of Safety

4.5.5 Corrosion Protection

4.5.6 Drain Holes

4.5.7 Access and Inspection Openings

4.5.8 Lubrication

4.5.9 Human Factors

4.5.10 Weight and Balance

4.5.10.1 Weight and Balance Report

4.5.10.2 Stress Analysis Report

4.5.11 Design Deficiencies

4.5.12 Baseline Aircraft

4.6 TRIAL KIT AND KIT PROOF INSTALLATION REPORT

4.6.1 Trial Install Kit

4.6.2 Kit Proof/Production Kits

4.6.3 Testing

4.6.3.1 Installation Test Plan/Procedures and Reports

4.6.3.2 Functional Test

4.6.3.3 Flight Readiness Review (FRR)

4.6.3.4 Flight Test

4.6.3.5 Dynamic/Static Testing……………………………………………..11

4.6.4 Engineering Support

4.6.5 Installation

4.6.5.1 Retrofit Installation

4.7 KIT PACKAGING, HANDLING, SHIPPING, AND

TRANSPORTATION

4.7.1 Packaging/Handling

4.7.2 Performance Oriented Packaging

4.7.3 Shipping/Transportation

4.7.4 Disposition of Test Assets

4.8 LOGISTICS

4.8.1 Interchangeability/Obsolescence

4.8.2 Parts Selection

4.8.3 Commercial-Off-the-Shelf

4.8.4 Configuration Control

4.9 SPECIFIC DATA REQUIREMENTS

4.9.1 Technical Requirements Document

4.9.2 Engineering Data

4.9.3 Technical Data Package (TDP) Drawing Changes

4.9.4 Technical Orders (TOs)

4.9.4.1 Operational Technical Orders

4.9.4.2 Maintenance Manuals

4.9.5 Certification/Verification

4.9.6 Time Compliance Technical Order

4.9.7 Security

4.10 PROGRAM MANAGEMENT

4.10.1 Documentation

4.10.1.1 Program Schedules and Milestones

4.10.1.2 Status/Financial Reports

4.10.2 Meetings

4.10.2.1 Kickoff Meeting

4.10.2.2 Program Reviews

4.10.2.3 Engineering Data Guidance Conference

4.10.2.4 In-Process Review (IPR) of the TDP

4.10.2.5 Light-weight Armor working Group Meeting

4.10.2.6 Test Plan Working Group

4.10.2.7 Technical Interchange Meetings

4.10.2.8 Preliminary Design Review/Critical Design Review

4.10.2.9 System Orientation/Familiarization

4.10.3 Change Management

4.10.3.1 Engineering Data Updates and Revisions………………………18

4.10.3.2 Configuration Conformity

4.10.3.3 Class I/II Changes

4.10.3.4 Engineering Change Proposal

4.10.4 Deviations and Waivers

4.10.5 Associate Contractor Agreement (ACA)

4.10.6 Relationship of Contractor with Subcontractors/Vendors…...18

4.10.7 Order of Precedence……………………………………………….. 18

4.11 MISSION ESSENTIALITY

4.12 INSPECTION OF SERVICES

4.13 MISCELLANEOUS REQUIREMENTS…………………………….19

5.0 APPENDICES

Appendix A: Applicable Documents Applicable Documents cont’d Appendix B: Acronyms Acronyms cont’d Acronyms cont’d

1.0 DESCRIPTION OF SERVICES.

1.1 SCOPE: To provide modification kits for the U.S. Air Force MC-130 E/H/P/W aircraft by replacing current troop door armor with light weight armor. The armor will weigh a minimum of 50% less than the current armor of 8 pounds per square foot (psf). The armor will meet or exceed the current USAF specification for aircraft armor of 7.62mm X 54R, Light penetrating steel (LPS) (steel ball core) at 100 yards-2600 feet per second (fps). The armor will be installed easily and allow the opening of the door without armor removal. The solution will not impede with either an emergency egress from the aircraft or with the proposed loadmaster crashworthy seat installation. Replacing the current spring with a larger lift capacity spring will be required. New protective tiles are to be the same size as the original to allow the new armor tiles to be assembled and installed in the same manner as the original armor. The armor will be secured so it remains safely in place while the paratroop door is open and will not fall on personnel passing underneath the door. The contractor shall design the armor kit installation which is airworthy, crashworthy, does not degrade aircraft integrity or performance and does not impede aircraft cargo or personnel operations. The design of the armor kit will be substantiated through analysis and testing. The contractor shall develop engineering drawings of the armor-aircraft interface and the armor kit. The contractor shall develop a Time Compliance Technical Order (TCTO) for any required aircraft modifications and a Commodity Technical Order for the armor and spring mechanism. The contractor shall fabricate and install one armor kit for Trial Installation. The contractor shall fabricate and support installation of one armor kit for Kit Proof. The service provided by the contractor benefits the Air Force by proving a reliable source for this paratroop door armor modification which saves A/C weight and makes it easier to open the door. The war fighter will benefit by having more aircraft available with a fully protected paratroop door to perform the Special Operation Forces (SOF) and Combat Search and Rescue (CSAR) missions.

2.0 SERVICES SUMMARY (SS).

PWS Performance Objectives PWS Para Performance Threshold

1 Tests 4.6.3, 4.6.3.1, 4.6.3.2, 4.6.3.3, 4.6.3.4

The armor kit shall pass all verification and functional testing in three (3) or less attempts. In the event of three failed attempts, the contractor shall provide the Government a written report, within three (3) working days, of actions to be taken to correct the deficiency. The contractor shall have 15 working days after Government acceptance of corrective action to retest the armor kit.

2 Adhere to Integrated Master Schedule (IMS) milestones

4.10.1.1 Any Integrated Master Schedule (IMS) milestone

shall not slip more than 30 days. Modification kits shall be delivered at a rate of four Group A and four Group B kits every month.

3 Data Deliverables Quality 4.1.1, 4.3.3, 4.2.3.1, 4.5, 4.5.1, 4.5.11, 4.5.11.1, 4.5.11.2, 4.6.3, 4.6.3.1, 4.6.3.2, 4.6.3.3, 4.8.4, 4.9.1, 4.9.2, 4.9.4, 4.9.4.1, 4.9.4.2, 4.9.6, 4.10.1.1, 4.10.1.2, 4.10.2.2, 4.10.2.3, 4.10.2.4, 4.10.2.5, 4.10.2.6, 4.10.2.8, 4.10.2.9, 4.10.3.4, 4.10.5

Each Data Deliverable shall be reviewed by the applicable person and meet the requirements of its Contract Data Requirements List (CDRL).

Only one rejection letter shall be allowed for each deliverable. The contractor shall have five (5) working days to correct the deficiency after receipt of rejection letter.

3.0 GOVERNMENT FURNISHED PROPERTY AND SERVICES.

3.1 The 572 ACSS/GFLB will provide access to one of the SOF/CSAR aircraft mission design series (MDS) as required, to develop the TCTO and supporting technical data. In general, the 572 ACSS/GFLB will arrange access to these aircraft at the owning unit on a non-interference basis so that normal operations are not affected. Access to a MC-130E/H/P/W will be at Hurlburt Field, FL, Canon AFB, NM or Duke Field, FL, based on aircraft availability. The 572 ACSS/GFLB will provide access to an aircraft for a trial installation (TI), and for kit proof installation (KP). Any Government furnished property will be returned to the Government after completion of this contract.

3.2 The contractor shall be required to have access to the Joint Engineering Data Management Information & Control System (JEDMICS) data base and access to the Technical Order (T.O.) library.

4.0 GENERAL INFORMATION:

4.1 DESIGN AND INSTALLATION REQUIREMENTS

The contractor shall be responsible for the completion of all tasks required by this PWS. These tasks include the non-recurring engineering, technical documentation trial installation, ground/flight testing support, kit proof, kit manufacture, labor in support of trial kit and kit proof installation, operational assessment, and production kit manufacture. The contractor shall implement all plans required by this PWS and shall not deviate from an approved document without explicit permission from the Program Office, Program Manager before final approval from the Procurement Contracting Officer (PCO). Existing data, documentation, reports, or other data that apply to this program shall be used to the fullest extent possible as authorized by the procuring activity.

4.1.1 Design Package: The TDP will provide the design, engineering, manufacturing, testing, and quality assurance information necessary to enable the manufacture or procurement of items defined by the TDP, without additional non-recurring engineering effort or recourse to the original design activity. The contractor is responsible for preparing the Technical Design Package, and the TDP represents the contractor’s design efforts. The Contractor shall attend a Government kickoff meeting and requirements review upon initiation of the program as outlined in the PWS. The Contractor shall conduct a Preliminary Design Review (PDR) and a Critical Design Review (CDR) with the Government to obtain design approval and issue resolution as outlined in the paragraphs herein. Each Data Deliverable shall be reviewed by the applicable person and meet the requirements of its Contract Data Requirements List (CDRL). Only one rejection letter shall be allowed for each deliverable. The contractor shall have five (5) working days to correct the deficiency after receipt of rejection letter. (CDRL A001)

4.2 PHYSICAL CHARACTERISTICS

4.2.1 Transportability: When installed on the MC-130E/H/P/W the armor kit will not alter existing cargo handling procedures without specific approval of the lead and using commands.

4.2.2 Storage: During storage, the complete system shall be capable of withstanding exposure to ambient temperature extremes of 140 F and minus 60 F for a period of 48 and 24-hours respectively without incurring irreversible damage or being rendered non-functional.

4.2.3 Safety: The safety criteria and considerations set forth in MIL-STD-882D shall be used to establish system safety design features. Warning notices shall be provided where applicable for high voltage electrical sources, noise and explosive devices. Special attention shall be given during the design process to prevent injury during installation. This data shall be submitted as a risk assessment. (DI-SAFT-80101B) (CDRL A002)

4.2.3.1 System Safety and Hazard Analysis (SSHA): A SSHA shall be performed in accordance with MIL-STD-882D. The analysis shall cover all electrical, mechanical, and human interfaces affected by the modification. This analysis shall consider safety hazards associated with installation, removal, and normal use. (DI-SAFT-

80101B) (CDRL A002)

4.3 System Quality The contractor’s quality system shall meet the requirements of SAE AS-9100B, Quality Management Systems Aerospace Requirements, or ANSI/ASQC 9001 and the cognizant Government representative will approve. A calibration system program shall be established and maintained IAW ANSI/NCSL Z540-1, or IS0 10012-1 or equivalent. The contractor shall also include the following quality aspects in the design process.

4.3.1 Reliability: The system shall be designed to consistently perform reliably throughout its expected life to maximize reliability and the contractor shall provide a list of sub-system components with their estimated Mean Time Between Failure (MTBF). The contractor shall identify any anticipated high failure items.

4.3.2 Maintainability: The system shall be designed for ease of servicing and maintenance.

4.3.3 Structural Life: All non–wearing parts shall have unlimited life. Where wearing parts are installed, they shall be provided with sufficient material to permit four (4) such reworks.

4.3.4 Fatigue Life: Moving parts that are subjected to Low Cycle Fatigue (LCF) loads, in addition to High Cycle Fatigue (HCF) loads, shall be designed considering the effect of LCF damage on the material HCF life. One cycle equals the attachment and removal of the paratroop door armor, or the opening and closing of the paratroop door.

4.3.5 Damage Tolerance: The light-weight armor kit shall incorporate material, stress levels, and structural configurations that will minimize the probability of loss of the system due to damage of a single structural element or due to propagation of undetected flaws, cracks, or other damage. Designs to maximize slow crack growth, crack arrestment, and redundant load paths shall be used to achieve this capability.

4.4 ENVIRONMENTAL REQUIREMENTS

4.4.1 Environmental Management System (EMS): Any contractor employee working on Robins Air Force Base or any Air Force Installation will require EMS training within 30 days of beginning work. The prime contractor is responsible for ensuring that all subcontractors comply with this requirement. Training will be provided by the 78 Civil Engineering Group Environmental Management Division (78 CEG/CEV). Training is computer based and takes approximately 11 minutes to complete. Training can be obtained through: Logon with Common Access Card (CAC) to 78 CEG/CEV website and click on EMS Awareness Training, chose option 1.

Without a CAC, request a copy of EMS training from 78 CEG/CEV Workflow mailboxes. 78ceg.cev.FrontOfc@robins.af.mil Link for EMS training: https://cev.robins.af.mil/EMSTrainingOptions.asp. If a company is ISO 14000 certified, the contractor does not have to complete Robins AFB EMS Awareness Training; however, the contractor must submit documentation to the Contracting Officer (CO) stating ISO 14000 Certification.

4.4.2 Climatic Requirements: Maximum protection shall be provided to prevent damage due to temperature, humidity, dust, sand, rain, and saltwater spray. This protection shall not interfere with the efficient operation of the equipment.

4.4.3 Temperature: The system shall perform satisfactorily from minus 60 F to

140 F.

mailto:78ceg.cev.FrontOfc@robins.af.mil https://cev.robins.af.mil/EMSTrainingOptions.asp

4.5 DESIGN AND CONTRUCTION

The contractor shall perform a design stress analysis and test of the areas affected by this modification addressing as a minimum the aircraft structure, attaching structure, control systems, and installation changes. The contractor shall utilize an approach to airworthiness certification of the final aircraft configuration that complies with the intent of Air Force Policy Directive (AFPD) 62-6. The contractor shall develop modified tailored airworthiness certification criteria (MACC) in accordance with (IAW) MIL- HDBK-516A Chapter 9, to identify the specific certification criteria that apply to the modified aircraft. The contractor shall deliver Airworthiness Verification Plans and Airworthiness Substantiation Report that documents the certification process. The Government will then accomplish the Airworthiness Certification. (DI-MISC-80711A)

(CDRL A003)

4.5.1 Site Survey: The contractor shall travel and perform aircraft site surveys to adequately document and photograph all key technical details pertaining to the installation of the armor kit. The Contractor shall furnish a digital picture book of the survey and provide pictures, in .jpg format, on CD- ROM. The contractor shall prepare a site survey report after completion of the surveys. (DI-MISC-80711A and DI-MISC-80169) (CDRL’s A003, A004)

4.5.2 Materials and Processes: All materials and processes used in the design shall be of suitable quality and type so as to ensure all requirements in this specification are satisfied. All welding shall conform to MIL-STD- 2219A, Class A. Materials shall be selected and specified in accordance with Metallic Materials Properties Development and Standardization (MMPDS) DOT/FAA/AR-MMPDS. Materials not contained in MMPDS may not be used without written Government approval.

4.5.3 Value Engineering: When appropriate, the contractor shall implement value engineering to reduce cost and improve quality and performance of the system.

4.5.4 Margin of safety: For all components of the armor system as well as the aircraft structure, the minimum acceptable margin of safety shall be non-negative. High residual margins of safety add unnecessary weight to the system. The best design solution will be that which has the minimal residual margin of safety and therefore the minimum weight while meeting all requirements of this PWS.

4.5.5 Corrosion Protection: The materials, coating and processes employed in the design, and manufacture of the complete system shall be corrosion resistant per guidelines set forth in MIL-STD-889B and FED-STD-595C (1).

To prevent a starting point for corrosion, fabrication processes, which might affect the basic grain structure or surface condition, shall be avoided. The system manufacturer shall identify and submit a list of all protective treatments for approval.

4.5.6 Drain Holes: In non-water tight structure, drain holes shall be cut and water courses provided to prevent the accumulation and retention of liquids, if necessary.

4.5.7 Access and Inspection Openings: Equipment and assemblies shall be designed for ease of operation, maintenance and test, when installed.

4.5.8 Lubrication: Means of lubrication of all moving parts shall be provided. All required lubrication points shall be easily accessible and long-term lubrication shall be provided wherever practicable.

4.5.9 Human Factors: The principles, criteria and procedures of human factors engineering shall be applied to the design of the system IAW the guidelines established in MIL-STD-1472F, Human Engineering. The armor kit shall not affect crew egress or survivor insertion/extraction operations without Government approval.

4.5.10 Weight and Balance: The Contractor shall perform an initial weight and balance analysis prior to kit installation. This analysis shall identify any impact of changes to the original design and update aircraft weight and balance data as required. Final aircraft weight and balance shall be documented IAW T.O 1-1B-50 and be within the constraints defined in the designated aircraft TO. (DI-MISC-80711A) (CDRL A003)

4.5.10.1 Weight and Balance Report: The Contractor shall develop basic weight and balance information for this modification per the aircraft TO(s). This data shall be summarized and presented at the Critical Design Review (CDR) for Government concurrence, and shall be sufficient for inclusion in the Time Compliance Technical Order (TCTO) and the aircraft weight and balance book which includes Chart “C”. Contractor shall ensure the aircraft weight and balance will not be outside the flight manual gross weight and center of gravity envelope.(DI-MISC-80711A) (CDRL A003)

4.5.10.2 Stress Analysis Report: The Contractor shall perform and document a complete stress analysis of the armor kit including aircraft structure, attaching structure, and installation surfaces affected by this design. The contractor shall determine that the existing aircraft structure used as installation surfaces is of sufficient strength to carry any modifications required by the system mounted thereon under the maximum acceleration expected in the aircraft under all normal and emergency operating conditions of the subject aircraft. The analysis shall verify that the installation structure can withstand normal flight loads and crash loads in accordance with the Aircraft Specification for each fixed wing aircraft. The structural integrity of the aircraft shall not be degraded by the design structural changes. All parts of the armor kit design and modified aircraft structure require substantiation and documentation through analysis (either classical and/or Finite Element Analysis (FEA)). If used, the FEA shall be validated by classical methods. (DI-MISC-80711A) (CDRL A003)

4.5.11 Design Deficiencies: The Contractor shall correct all Trial Installation kit deficiencies and drawing changes that are revealed by the trial installation at no additional cost to the Government.

4.5.12 Baseline Aircraft: The baseline aircraft for the design specified in this PWS is the MC-130E/H/P/W. Under no circumstances shall the contractor’s efforts degrade the baseline aircraft’s functional and operational capabilities. The contractor shall ensure that there is no physical interference between the current equipment installations and the modification components.

4.6 TRIAL KIT AND KIT PROOF INSTALLATION SUPPORT

The contractor shall provide technical and engineering support during the trial installation and the kit proofing on the SOF/CSAR fixed wing aircraft. The contractor shall perform operational checkout of the light-weight paratroop door armor kit following trial install and kit proof. Trial installation and kit proof will be accomplished at a location to be determined by the government.

4.6.1 Trial Install Kit: The contractor shall be responsible for the manufacture and installation of trial installs.

4.6.2 Kit Proof/Production Kits: The contractor shall be responsible for the manufacture of kits for kit proof kit. The contractor shall be responsible for retrofitting the trial install kit to the production configuration upon completion of kit proof.

4.6.3 Testing: The contractor shall participate in all test activities as indicated in the following paragraphs. All formal contractor conducted tests, shall be open for government observation and government approval. The contractor shall ensure all ground testing has been completed successfully and all outstanding deficiencies resolved before proceeding to flight test, if necessary. The contractor shall support Test Plan Working Groups (TPWGs). The contractor shall prepare and submit test plans and procedures, test reports, and system safety analyses. The contractor shall ensure that test aircraft are configured and integrated correctly to accomplish each test event. The contractor shall provide qualified engineering supervision to support flight-testing as required. The contractor shall provide quick look summaries to the Government sufficient to allow a preliminary assessment of test success. The quick look summaries shall be substantiated with collected performance data in a format approved by the program office. The contractor shall be provided access to Government test facilities and test personnel. The armor kit shall pass all verification and functional testing in three (3) or less attempts. In the event of three failed attempts, the contractor shall provide the Government a written report, within three (3) working days, of actions to be taken to correct the deficiency. The contractor shall have 15 working days after Government acceptance of corrective action to retest the armor kit, depending on availability of aircraft. (DI-NDTI-80809B, DI-SAFT-80101B, DI-NDTI-80566, DI-QCIC-81536, DI-NDTI-80603A) (CDRL’s A00J, A00K, A002, A005, A006)

4.6.3.1 Installation Test Plan/Procedures and Reports: The

Contractor shall prepare a test procedure including testing requirements, both ground and flight (as determined by the engineer) for the purpose of accepting the kit installation. The content of the test procedure shall include Pre-Mod and Post-Mod operational ground-tests and a Post-Mod flight test. The test procedure shall cite existing operational checks contained in the appropriate Maintenance TOs to verify proper installation and functionality of the System and disturbed existing systems.

Results of the testing shall be documented in a final test report. All parts of the armor kit design require substantiation through testing.

(DI-NDTI-80603A and DI-NDTI-80809B) (CDRL’s A005, A006)

4.6.3.2 Functional Test: The contractor shall perform the approved Quality Test and Evaluation (QT&E), to exercise all functions, operating modes, and critical parameters to ensure performance requirements of the System are achieved. (DI-MISC-80711A)

4.6.3.3 Flight Readiness Review (FRR): The Contractor shall support the Flight Readiness Review with the Government and/or their representatives prior to flight test to review the installation and operational ground test results and the preliminary flight test procedures. (DI-MISC-80711A)

4.6.3.4 Flight Test: The Contractor is responsible for participating in Test planning and supporting Flight Test in accordance with the requirements presented in this PWS. The contractor shall ensure that all test procedures include a method of verifying successful system performance, acceptable to the government.

4.6.3.5 Dynamic/Static Testing: The contractor shall ensure, through the static and dynamic tests, the armor system meets the requirements as stated in paragraph 4.6.4.

4.6.4 Engineering Support: The contractor shall provide engineering support during the trial installation, kit proofing, operational assessment, all testing described within this PWS, and perform the systems operational and maintenance checkout for the modification after trial installation.

4.6.5 Installation: Installation of the production kits shall be made by U.S.A.F.

personnel.

4.6.6 Retrofit Installation: Based on the expected time for installation, U.S.A.F.

personnel shall retrofit fielded aircraft.

4.7 KIT PACKAGING, HANDLING, SHIPPING, AND TRANSPORTATION

The contractor shall be responsible for the Kit Packaging, Handling, Shipping, and Transportation IAW the following paragraphs.

4.7.1 Packaging/Handling: The contractor shall package and mark the kits per the guidelines as specified on Air Force Materiel Command (AFMC) Form 158 Packaging Requirements, as incorporated in section J of the contract.

To facilitate the installation, the kits shall be packaged by individual installation drawing with the appropriate parts/hardware, and a packing list of comprised material in each installation sub-kit.

4.7.2 Performance Oriented Packaging: (Reserved)

4.7.3 Shipping/Transportation: The contractor shall ship the production kits by traceable means to locations provided below, if the design of the spring allows for installation by service members, as incorporated in section J of the contract.

D035K Depot Supply

DDWG-ER-DLA

Central Receiving 455 Byron Street Robins AFB GA 31098 “This is a D4M Production shipment. Please post to the FLB RIC.”

4.7.4 Disposition of Test Assets:

Upon completion of the static and dynamic testing and acceptance by the government of the written test results, the Group A and Group B light weight armor kits shall be considered the first production kit and shall remain with the aircraft.

4.8 LOGISTICS

4.8.1 Interchangeability/Obsolescence:

Interchangeability: All parts having the same manufacturer’s part number and cage code shall be functionally and dimensionally interchangeable and replaceable with each other. Any deviations shall be discussed and agreed upon by contractor and the Government, and incorporated into a revised

PWS.

Material or Manufacturing Obsolescence: Contractor shall be responsible for the identification, description and recommended replacement or alternate solutions for the items affected by obsolescence that are required to accomplish the paratroop door armor modification.

4.8.2 Parts Selection: The contractor shall consider material selected for the design in the following precedence:

National Stock Listed (NSL) parts common with the platforms discussed in Section 1.0 Commercial-Off-the-Shelf (COTS) Reverse engineering (NOTE: Any deviations from the above shall be discussed with and approved by the Government, and incorporated into a revised PWS.)

4.8.3 Commercial Off-The-Shelf (COTS): The contractor shall purchase COTS hardware when required for execution of this modification.

4.8.4 Configuration Control: Contractor shall be responsible for documenting and maintaining configuration control for any item affected by this modification. The Contractor shall update existing technical data (drawings, drawing trees, etc) affected by this modification. When optional requirements are exercised, the contractor shall also provide configuration control as associated with the exercised option(s). Configuration Control is defined as any change to Form, Fit, and Function of hardware or software.

4.9 SPECIFIC DATA REQUIREMENTS

4.9.1 Technical Requirements Document (TRD): The Contractor shall document all requirements and issues presented at the guidance conference and requirements review discussed in paragraphs herein. The

Contractor shall prepare, for Government approval, a TRD that defines the required system installation, functionality, aircrew operation, system limitations, and level of integration with existing aircraft systems.

(DI-MISC-80711A) (CDRL A003)

4.9.2 Engineering Data: The contractor shall develop/produce/maintain a Technical Data Package (TDP) that accurately depicts the final product.

The TDP is the contractor’s design and the contractor’s responsibility. The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement or manufacture of an interchangeable item that duplicates the physical and performance characteristics of the original product, without additional design engineering effort or recourse to the original design activity. Product data shall reflect the approved, tested, and accepted configuration of the defined delivered item. All engineering data created as a result of this contract shall be considered a part of the TDP.

This data includes, but is not limited to CAD data, models and model based definition data sets, and Gerber data. [DI-SESS-81000C/T]

4.9.3 Technical Data Package (TDP) Drawing Changes: The contractor shall (and shall cause subcontractors and vendors to) update and maintain engineering data for the item(s) designed/developed/modified/produced by this contract for the life of this contract and shall incorporate all changes in accordance with the following:

a. All engineering changes shall be incorporated into the applicable engineering data within 90 days after engineering release/Government concurrence or at intervals of five changes, whichever occurs first, except a change involving safety, which shall be incorporated immediately.

b. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of data for review.

c. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of final media (this includes all engineering orders (EO’s) generated as a result of the preliminary data review).

4.9.4 Technical Orders (TOs): The Contractor shall develop the TO change pages necessary for the operation, maintenance, and support of the modification in accordance with the requirements of TM-86-01N and IAW TO 00-5-1. The Government will retain the right of approval of the final TOs through the Certification and Verification process and the pre-pub review.

(TM-86-01N). (CDRL A00H)

4.9.4.1 Operational Technical Orders: The contractor shall review the applicable SOF/CSAR Operational Technical Orders and prepare properly formatted data IAW the TM 86-01J, Technical Manual Contract Requirements (TMCR). (TM-86-01J) (CDRL A00H)

4.9.4.2 Maintenance Manuals: The contractor shall review the

applicable SOF/CSAR Maintenance Technical Orders and prepare properly formatted data IAW the TM 86-01N, Technical Manual Contract Requirements (TMCR). (TM-86-01N) (CDRL A00H)

4.9.5 Certification/Verification: The Government will be permitted to witness Data Certification. The Contractor shall notify the Government two weeks prior to Certification beginning. A Certification shall be conducted on the

Trial Installation aircraft, and Air Force Verification of hands-on procedures shall be conducted on the Kit proof aircraft. The Contractor shall provide support in all areas prescribed by the Government for the Verification phase.

4.9.6 Time Compliance Technical Order: The Contractor shall

develop a new routine TCTO to document the final configuration of the modification and instructions for removal of the existing systems (if required). The TCTO shall be prepared in accordance with TO 00-5-15, MIL-PRF-38804C, and the applicable Air Force Materiel Command (AFMC) Form 873 Time Compliance Technical Order Requirements. The TCTO Verification shall be accomplished during Kit Proof installation. (TM-86-01N) (CDRL A00H)

4.9.7 Security: The security level of Contractor personnel shall be at the highest level of the security classification listed in the Security Classification Guides of the systems listed in this PWS. The contractor shall be required to safeguard equipment and/or information classified up to the level of SECRET. Specific security requirements will be specified on Department of Defense (DD) Form 254.

4.10 PROGRAM MANAGEMENT

The contractor shall establish a formal project organization responsible for both development and production phases of the program. The contractor shall identify and maintain throughout the contract period a list of key personnel who have management and task accomplishment responsibilities, including key personnel of any major subcontractors. The contractor shall have the responsibility for the management, administration, financial control, engineering, manufacturing, procurement, testing, and quality assurance activities associated with this effort. The contractor shall serve as the point of contact on all contractual and technical matters. All program management requirements of the contract shall extend to the effort required by this PWS.

4.10.1 Documentation: In accordance with DoD policy, every effort shall be made to provide paperless copies. All data shall be delivered on electronic media in an approved version of a Microsoft Office product format. All Final data deliverables will be accompanied by two (2) hard copies. Other formats are acceptable upon prior approval of the Government.

4.10.1.1 Program Schedules and Milestones: Program performance will be in accordance with an Integrated Master Schedule (IMS), jointly approved at time of award and updated at Program Management Reviews (PMRs). The IMS shall be updated to show progress against the baseline and submitted along with the Status Report each month. Any change to the Program Master Schedule* (PMS) and milestones shall require concurrence from both the Government and contractor. Any Integrated Master Schedule (IMS) milestone shall not slip more than 30 days. Four (4) modification kits shall be delivered no more than 45 days ARO.

Subsequent kits shall be delivered at a rate of four kits every month. (DI-MGMGT-81650, DI-MGMT-80368A) *Note-IMS and PMS are used interchangeably.

(CDRL A00B)

4.10.1.2 Status/Financial Reports: The contractor, in accordance with the Contract Data Requirements List (CDRL), shall prepare and submit status reports in accordance with the CDRLs that detail work performed the previous month. The contractor shall identify tasks to be performed during the next reporting period in each status report. The status report shall include financial expenditure information (burn rate). The financial status shall be reported as both cumulative and for the specific reporting month. This report should compare program progress with the program schedule milestones and shall identify problems/risks and propose effective solutions. (DI-MGMT-80368A), (CDRL A00A)

4.10.2 Meetings/Travel: The contractor shall be responsible to attend/host meetings IAW the following paragraphs. All travel, both CONUS and OCONUS, must be concurred by the 572ACSS/GFLB Program Manager (PM) and approved by the Procurement Contracting Officer (PCO), at least five days, in advance of the travel. Contractor personnel agree that while flying commercial air travel allocable to this contract, to use air coach, tourist class, or similar accommodations to the extent consistent with the successful and economical accomplishment of the mission for which the travel is being made. All travel by the contractor in support of this PWS shall be performed IAW the Joint Travel Regulation (JTR).

4.10.2.1 Kickoff Meeting: A kickoff meeting shall be at the contractor’s facility or a location deemed necessary by the Government no later than 30 days after contract award. The purpose of the kickoff meeting is to review and evaluate the basic contractual requirements and to provide necessary direction and guidance.

4.10.2.2 Program Reviews: The Government and the contractor shall participate in Program Reviews as defined in the Program Master Schedule*. At a minimum, these meetings shall occur quarterly. If possible, the Program Reviews and technical meetings will be combined at a location deemed necessary by the Government at task order level. The contractor shall conduct program reviews for the purpose of presenting program status to the Government. The contractor shall be responsible for distributing agenda topics, recording minutes, and recording action items for all hosted meetings, conferences, reviews, and/or audits. The contractor’s program management team, including appropriately cleared personnel from the contracts, quality assurance, data/ configuration management, engineering, reliability and maintainability, system safety and integrated logistics system (ILS) organizations shall be available for all formally scheduled program status reviews conducted at the contractor’s facility. For meetings conducted at the Government facility, only the required contractor personnel will attend. Contractor representatives at these meetings, conferences, reviews, and audits shall include at least one person with authority to commit the contractor. The minutes shall be recorded by the contractor and include significant questions, deviations from the agenda, conclusions and action items resulting from the reviews. The minutes shall constitute the review report and shall require approval of the Program Manager and Procuring Contracting Officer (PCO) prior to distribution. (DI-

ADMN-81249A and DI-ADMN-81250A) * Note – IMS and PMS are used interchangeably. (CDRL’s A00C, A00E)

4.10.2.3 Engineering Data Guidance Conference: The contractor shall support and co-chair a Guidance Conference for engineering data within 60 days after contract award. The Conference shall be convened at a site and on a date agreed upon by the Government program manager and the contractor. The contractor shall prepare an agenda and record the minutes of the Guidance Conference.

The contractor shall address, discuss, and provide status on the following: [DI-ADMN-81249A, DI-ADMN-81250A]

a. Understanding of all CDRL requirements, applicable DIDs, specifications and standards.

b. TDP review requirements and schedules.

c. TDP delivery requirements and schedules.

d. Contractor's drafting practices/procedures/TDP drawing formats.

e. The contractor's quality assurance procedures relating to TDP documents, including quality control of subcontractor and vendor data.

f. The role of subcontractors and vendors who may deliver TDP documents under this contract.

g. The contractor's configuration management system, including methods for releasing documents, approving documents, and incorporating changes into documents.

h. Digital Technical Data Package (TDP) deliverables.

(CDRL’s A00C, A00E)

Note: Guidance Conference may be held in conjunction with other meetings or conferences.

4.10.2.4 In-Process Review (IPR) of the TDP: The contractor shall host, support, and co-chair an IPR of the engineering drawings and associated lists and other documentation to be included in the TDP. The IPR shall be conducted only after the contractor's quality assurance personnel have completely reviewed the data and determined that data are of sufficient quality that Government time will be effectively utilized during the review. IPR may be scheduled when data has reached the 50% percent completion point and shall be held, when possible, in conjunction with other reviews (i.e., PDR, CDR). The contractor shall notify 584 CBSS /GBHAD a minimum of 30 days prior to the anticipated date of completion point. The IPR shall focus on the contractor's progress in the preparation of the TDP. The contractor shall support and provide the necessary resources, i.e., meeting agenda, conference room, applicable data, minutes, and appropriate personnel available to answer any questions to perform the IPR effectively.

The contractor shall correct all discrepancies identified in the IPR.

All subcontractor/vendor data shall be made available for review.

If the quantity of subcontractor/vendor data is of sufficient magnitude, the Government may schedule a separate IPR at the subcontractor's/vendor's facility. (CDRL’s A00C, A00E)

[DI-ADMN-81249A, DI-ADMN-81250A]

4.10.2.5 Light-weight Armor Working Group Meeting (LAWG): The Government will host an armor meeting at a location determined by the Government to coordinate location of system components for the light-weight paratroop door armor system installation. This meeting will be held before Contractor begins the detailed engineering process and develops the preliminary technical design package. The contractor shall be responsible for distributing agenda topics, recording minutes, and recording action items for all hosted meetings, conferences, reviews, and/or audits.

(DI-ADMN-81249A and DI-ADMN-81250A) (CDRL’s A00C, A00E)

4.10.2.6 Test Plan Working Group (TPWG): The contractor’s program manager, systems engineer, and test director shall attend a Government TPWG at the contractor’s facility or location determined by the Government. The contractor shall brief his test plans, procedures, test schedule, status, and problem areas at the meeting. The contractor shall be responsible for distributing agenda topics, recording minutes, and recording action items for all hosted meetings, conferences, reviews, and/or audits.

(DI-ADMN-81249A and DI-ADMN-81250A) (CDRL’s A00C, A00E)

4.10.2.7 Technical Interchange Meetings: The Government and the contractor shall participate in technical meetings and integration efforts as defined in the Program Master Schedule*. At the least, these meetings shall occur quarterly. If possible, the Program Reviews and technical meetings will be combined. The contractor shall be responsible for distributing agenda topics, recording minutes, and recording action items for all hosted meetings, conferences, reviews, and/or audits. The location of these meetings will be determined by the Government. (DI-ADMN- 81249A and DI-ADMN-81250A) *Note - IMS and PMS are used interchangeably.

4.10.2.8 Preliminary Design Review (PDR)/Critical Design Review (CDR): The Contractor shall conduct a Preliminary Design Review (PDR) and Critical Design Review (CDR) with Government representatives in attendance at the contractor’s facility.

Government approval of the minutes of the CDR shall constitute approval of the PDR/CDR. Government review/approval/acceptance of the contractor’s design does not shift responsibility for the design to the government at any point in time.(DI-ADMN-81249A, DI-ADMN-81250A, and DI-MISC-80711A) (CDRL’s A00C, A00E, A003)

4.10.2.9 Systems Orientation/Familiarization: The contractor shall identify familiarization requirements if needed, and shall obtain or develop light-weight paratroop door armor system orientation/familiarization programs. The contractor shall develop familiarization manuals and other familiarization documentation or aids as required. Electronic familiarization applications such as video-teleconferencing and computer-based familiarization shall be employed to enhance the effectiveness of familiarization materials and courses when cost-effective. The contractor shall be capable of conducting initial familiarization for Government personnel to ensure proper operation maintenance, repair, and testing of equipment and systems. (CDRL A00C)

4.10.3 Change Management: Change control will be processed as defined herein.

4.10.3.1 Engineering Data Updates and Revisions: The contractor shall (and shall cause subcontractors and vendors to) update and maintain engineering data for the item(s) designed/ developed/modified/produced by this contract for the life of this contract and shall incorporate all changes in accordance with the following:

a. All engineering changes shall be incorporated into the applicable engineering data within 90 days after engineering release/Air Force concurrence or at intervals of five changes, whichever occurs first, except a change involving safety, which shall be incorporated immediately.

b. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of data for review.

c. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of final media (this includes all Engineering Orders (EO's) generated as a result of the preliminary data review.)

4.10.3.2 Configuration Conformity: The contractor’s quality assurance and manufacturing procedures shall ensure each item, as built, delivered, and installed conforms to applicable engineering standards.

4.10.3.3 Class I/II changes: Any proposed Class I/II change shall be submitted to the Government for concurrence on the class of the change.

4.10.3.4 Engineering Change Proposal: The Contractor shall provide Class I or Class II Engineering Change Proposals (ECP) to address changes to the TDP within 10 work days of change. (DI- CMAN-80639C and DI-CMAN-80642C) (CDRL’s A00D, A00F)

4.10.4 Deviations and Waivers: The Contractor shall document deviations and waivers to established configuration baselines. The Contractor shall prepare Request for Deviations and Waivers for end items or components that incorporate a known departure from the approved TDP, within 10 working days of known deviation. (DI-CMAN-80640C) (CDRL A00G)

4.10.5 Associate Contractor Agreement (ACA): The Contractor shall establish ACAs, as required.

4.10.6 Relationship of Contractor with Subcontractors/Vendors: The contractor shall levy on subcontractors/vendors the same requirements for Technical Data Packages (TDPs) as are levied on them by this contract.

This requirement shall apply at all tiers of sub-contractor/vendor levels associated with the program.

4.10.7 Order of Precedence:

Priority I Documents mandated for use by law or regulation pursuant to law.

Priority II Performance Oriented Documents: (a) Non-Government Standards; (b) Commercial Item Descriptions; (c) Federal Specifications and Standards;

(d) Military Specifications and Standards.

Priority III Design Based Documents: (a) Non-Government Standards; (b) Federal Specifications and Standards; (c) Military Specifications and Standards

Priority IV Standards, specifications and related publications issued by the Government outside the military or federal series for the non-repetitive acquisition of developmental items.

Priority V Company Specifications

4.11 MISSION ESSENTIALITY

The Functional Director has identified that none of the services performed under this contract are “Essential DoD Contractor Services” as defined and described in DoD Instruction (DoDI) 3020.37, “Continuation of Essential DOD Contractor Services during Crises.”

4.12 INSPECTION OF SERVICES:

FAR 52.246-4 and 52.246-5 Inspection of Services - Fixed Price or FAR 52.246-6 Inspection - Time and Material and Labor - Hour will be invoked by the PCO when and if contractor fails to perform as required.

4.13 MISCELLANEOUS REQUIREMENTS: The following are user requirements.

a. The design shall provide for in-flight armor installation and adjustment with a minimum of hand tools (prefer no tools required)

b. Each kit will consist of a set of protective tiles and its respective attachment system, along with the spring for the left paratroop door and the right paratroop door.

c. Armor shall be designed for extended use in flight

d. Armor shall be stowable onboard the aircraft

e. Armor needs to be mounted on paratroop door to allow for maximum performance.

f. Armor will not interfere with the handle on door.

g. Paratroop Door will still be usable for both ground and in-flight egress.

h. Paratroop Door will be usable for personnel airdrop using static line airdrop procedures.

5.0 APPENDICES

Appendix A – TOs and DIRECTIVES http://www.dtic.mil/whs/directives/corres/html/302037.htm

Applicable Documents The documents listed, in the table below, Military Specifications, Military Standards, Military Handbooks, Other, and T.O.s, form a part of this PWS to the extent specified herein and are provided as guidance only. The contractor is free to propose alternative commercial standards and solutions to achieve the Government’s “Best Value” performance requirements.

Military Standards, Military Specifications, Military Handbooks, Other, and T.O.’s:

Name Title Date Section

MIL-PRF-38804C Time Compliance Technical Order Preparation

19 Dec 07 All

MIL-STD-129P Military Marking for Shipment and Storage

19 Sep 07 All

MIL-STD-130N Identification Marking of U.S.

Military Property

11 Dec 07 All

MIL-PRF-49506 Logistics Management Information 18 Jan 05 All

MIL-STD-882D System Safety 10 Feb 00 All

MIL-STD-889B(3) Dissimilar Metals

17 May 93 All

MIL-STD-

1472F(1)

Human Engineering 5 Dec 03 Para 5.6 and 5.7

MIL-STD-2073-1E DoD Material, Procedures for Development and Application of Packaging Requirements

23 May 08 All

MIL-STD -

2219A(1)

Fusion Welding for Aerospace Applications

16 Jun 08 All

MIL-HDBK-516A Airworthiness Certification Criteria 1 Feb 05 Ch 9

ASME Y-14-100 Types and Applications of Engineering Drawings

2004 All

DOT/FAA/AR-

MMPDS

Metallic Materials Properties Development and Standardization

(MMPDS)

1 Apr 05 All

TO 1-1A-8 Structural…