TUN_FY13_PBL_OH_PWS.pdf

PR FD2060-12-30506 OH for TUNNER PBL

OVERHAUL

PERFORMANCE-BASED WORK STATEMENT (PWS)

for

TUNNER

NON-AIRCRAFT WEAPON SYSTEM PER AIR FORCE POLICY

DIRECTIVE (AFPD) 10-9

Rev: 12 Oct 2012

The Air Force employs many diverse weapon systems in executing its global mission. The Chief of Staff United States Air Force designates systems as weapon systems and assigns each to a lead command. The Air Force Policy Directive (AFPD) 10-9 assigns weapon system management responsibilities to designated lead commands to ensure all requirements associated with weapon systems receive comprehensive and equitable consideration, and program-associated funding through the Future Years Defense Program as necessary. Lead command (AMC) designation establishes advocacy for weapon systems during their life cycle and clarifies responsibilities for all using and supporting organizations.

Prepared by

AFLCMC/WNZ SUPPORT EQUIPMENT AND VEHICLES ENGINEERING DIVISION

AGILE COMBAT SUPPORT DIRECTORATE

235 BYRON STREET SUITE 19A

ROBINS AFB, GA 31098-1813

DISTRIBUTION STATEMENT C: Distribution is authorized to U.S. Government agencies and their contractors (administrative or operational use) (5 May 2011). Other requests for this document shall be referred to AFLCMC/WNZDA.

1. DESCRIPTION OF SERVICES. This PWS defines the requirements for the overhaul segment of the Tunner contract. Overhaul is defined as overhaul qualification, low-rate overhaul, and full-rate overhaul. Low-rate overhaul is defined as a lesser rate of overhaul that typically occurs in the first two years of production to allow the Contractor time to ramp up to a higher rate (full-rate). Full-rate overhaul is the normal rate expected after two years of low-rate overhaul. Non-Original Equipment Manufacturer (OEM) Contractors shall accomplish the overhaul qualification effort as described in 4.1.7 proceeded by two years of low-rate overhaul.

The Contractor is responsible for Tunner receipt/incoming inspection, overhaul, structural abnormalities identification, overhaul instructions manual maintenance, post overhaul test, and storage, packaging and shipping. Overhaul of the Tunners will preserve the Operational Safety, Suitability, and Effectiveness (OSS&E) baselines (OSSE 60_EP) so the Tunners will be available when needed, perform up to expectations, and perform safely. The Tunner is described by Performance Specification for 60K Loader Vehicle (SP1-9032950).

Some of the major basic overhaul elements are:

a. disassembly of Tunner in three basic sections (cab, deck, and chassis),

b. cleaning,

c. detailed inspections to determine the state of the Tunners,

d. upgrade of Tunners to a common configuration e.g., early production changes (first 40 Tunners), non-Cost Reduction Initiative configuration (CRI) to CRI (updated hydraulic and deck pitch controls), new radiator design, and After Production Corrosion Abatement Modification (APCAM),

e. remove/replace tires,

f. remove/replace electrical cables,

g. remove/replace electromechanical items,

h. remove/replace rubber items,

i. remove/replace batteries,

j. remove/replace non-permanent hardware (nuts, bolts, etc.),

k. remove/replace hydraulic hoses,

l. scuff and paint hydraulic tubes and hydraulic manifolds,

m. overhaul engines,

n. overhaul hydraulic pumps and cylinders,

o. overhaul cab heaters,

p. overhaul fire extinguishers,

q. apply corrosion prevention compounds,

r. re-paint,

s. apply Unique Identification (UID) labels/plates,

t. re-assembly of Tunner, and

u. post testing to ensure quality assurance.

2. SERVICES SUMMARY (SS). The following table summarizes the performance thresholds for the critical objectives of this effort.

Performance Objectives PWS Para. Performance Threshold

Provide thorough and meaningful Earned Value Management System (EVMS) cost and schedule variance analyses in the Integrated Program Management Reports (IPMRs)

4.1.2.2

No more than 3 unacceptable variance analyses per month shall be submitted; all unacceptable variance analyses shall be satisfactorily re-written and re-submitted within 20 calendar days of initial written notification.

Provide on time loader deliveries per the task order schedules

4.1.1

Shall complete early or on schedule 100% of the overhaul deliveries in accordance with the task order baseline schedule. No more than 14 loaders shall be in work at any one time.

3. GOVERNMENT FURNISHED PROPERTY AND SERVICES. The Government will provide two Tunners (OEM not applicable) for the Overhaul Qualification. The Government will provide up to 32 Tunners annually for future low-rate and full-rate overhaul activities. The Government will provide historical Online Vehicle Interactive Management System (OLVIMS) data for the Tunners provided for overhaul.

3.1. Reporting loss of government property.

(a) Definitions. As used in this clause—

“Government property” is defined in the clause at FAR 52.245-1, Government Property.

“Loss of Government property” means unintended, unforeseen, or accidental loss, damage, or destruction of Government property that reduces the Government’s expected economic benefits of the property. Loss of Government property does not include purposeful destructive testing, obsolescence, normal wear and tear, or manufacturing defects. Loss of Government property includes, but is not limited to—

(1) Items that cannot be found after a reasonable search;

(2) Theft;

(3) Damage resulting in unexpected harm to property requiring repair to restore the item to usable condition; or

(4) Destruction resulting from incidents that render the item useless for its intended purpose or beyond economical repair.

“Unit acquisition cost” means—

(1) For Government-furnished property, the dollar value assigned by the Government and identified in the contract; and

(2) For Contractor-acquired property, the cost derived from the Contractor’s records that reflect consistently applied, generally acceptable accounting principles.

(b) Reporting loss of Government property.

(1) The Contractor shall use the Defense Contract Management Agency (DCMA) eTools software application for reporting loss of Government property. Reporting value shall be at unit acquisition cost. The eTools “LTDD of Government Property” toolset can be accessed from the DCMA home page External Web Access Management application at http://www.dcma.mil/aboutetools.cfm.

(2) Unless otherwise provided for in this contract, the requirements of paragraph (b)(1) of this clause do not apply to normal and reasonable inventory adjustments, i.e., losses of low-risk consumable material such as common hardware, as agreed to by the Contractor and the Government Property Administrator. Such losses are typically a product of normal process variation. The Contractor shall ensure that its property management system provides adequate management control measures, e.g., statistical process controls, as a means of managing such variation.

(3) The Contractor shall report losses of Government property outside normal process variation, e.g., losses due to—

(i) Theft;

(ii) Inadequate storage;

(iii) Lack of physical security; or

(iv) “Acts of God.”

(4) This reporting requirement does not change any liability provisions or other reporting requirements that may exist under this contract.

4. GENERAL INFORMATION. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

4.1 Program administration. The Contractor shall have overall responsibility for the conduct of Tunner overhaul in accordance with this PWS. Data in the Integrated Master Schedule (IMS), Earned Value Management System (EVMS), and Enterprise Resource Planning (ERP) system shall correlate.

4.1.1 Integrated master schedule. The Contractor shall develop, implement, maintain, manage and analyze an Integrated Master Schedule (IMS) for this contract effort. The IMS shall contain measurable tasks and their interdependencies. The Contractor shall develop task descriptions and schedules from this PWS. The IMS shall contain all critical milestones, measurable tasks, prerequisite events and activities, and their interdependencies as deemed necessary for effective management of this segment by the Contractor. The IMS shall include major subcontractor activities, if any. For Contractors other than the OEM, the IMS shall include the preparation of successful transfer of overhaul responsibility to include the lower level objective criteria of 4.1.7.

The Contractor shall develop descriptive listings for the above measurable tasks and milestones.

The Contractor shall clearly depict critical elements throughout the entire period of this contract on selected schedule formats. Progress to date shall be based upon percentage of effort complete, whenever possible. Contractor’s schedule shall have the capability to roll up or roll down. In its reporting hereunder, the Contractor shall provide the necessary schedule and performance risk assessments, to include required program impact and related recovery schedules. The Contractor shall complete early or on schedule 100% of the overhaul deliveries in accordance with the task order baseline schedule. The Contractor shall have no more than 14 loaders in work (i.e., inducted into the overhaul line) at any one time. The period of performance for each annual buy for low-rate and full-rate overhauls shall not exceed 17 months. The time between the delivery dates of the first loader inducted into the overhaul line and the last loader for each contract year shall not exceed 12 months. (DI-MGMT-81861/T, X00C)

4.1.2 Performance and financial reporting. The Contractor shall utilize EVMS.

4.1.2.1 Compliance. All work shall be performed using a criteria-compliant EVMS that correlates cost and schedule performance with technical progress and program content activity.

Progress and problems shall be presented and discussed in periodic program management reviews. Technical and program content issues shall be covered in terms of performance goals, exit criteria, schedule progress and/or cost impact.

4.1.2.2 Reporting. The Contractor shall report monthly EVMS status using the Integrated Program Management Report (IPMR) formats, or Contractor internal documents which provide the same essential information and which have been approved by the Procuring Contracting Officer (PCO) or designated representative (rep). The Contractor shall report monthly, the Contract Funds Status Report. The level of detail to be reported shall be at level 3 of the Contract Work Breakdown Structure (CWBS). The Contractor is responsible for developing CWBS levels 3 and below as necessary to accomplish all tasks. When change is necessary to the CWBS and CWBS dictionary, the Contractor shall update them. Contractor shall provide variance analyses that adequately explain all variances that exceed the specified variance thresholds of the data item description tailoring document; explanations clearly identify the nature of the problem, significant reasons for cost or schedule variance, effect on the immediate task, impact on the total contract, and the corrective action taken or planned. The PCO or designated rep will review the variance analyses and notify the Contractor in writing of any unacceptable ones. The Contractor shall not provide more than 3 unacceptable variance analyses per month; all unacceptable variance analyses shall be satisfactorily re-written and re-submitted by the Contractor within 20 calendar days of initial PCO or designated rep written notification.

(DI-MGMT-81861/T, X00C) (DI-MGMT-81468, X00D) (DI-MGMT-81334C/T, X00B)

4.1.2.3 Business process utilization. The planning, execution and reporting of schedule and cost of labor and material on business processes required to support overhaul shall be down to the lowest practical disassembly, rework, and reassembly level. These business processes include EVMS and configuration management.

4.1.2.4 Time standards utilization and development. The Contractor shall develop and complete type 3 time standards for all manufacturing tasks required down to the lowest practical disassembly, rework and reassembly level before start of low-rate overhaul. Type 3 standards are typically developed by manufacturing engineers before actual task accomplishment using their knowledge of the system, equipment, and past experience to perform educated estimates.

These time standards shall be the basis for the establishment of a budgeted cost work schedule (BCWS) for the EVMS. The Contractor shall develop and complete type 2 time standards before start of full-rate overhaul. Type 2 time standards shall be based upon known actual labor times and efficiencies from actual work task accomplishments. The Contractor shall develop and complete type 1 time standards within 12 months after start-up of the full-rate overhaul. Type 1 time standards are based on time and motion studies. Implementing time standards and metrics, and understanding lean manufacturing principles, can result in substantial increased productivity through efficiency gains.

4.1.2.5 Changes. The Contractor shall notify the Government in writing of changes affecting the accepted EVMS System Description. The Contractor shall provide the Government all changes to the work breakdown structure (WBS) Dictionary. The Contractor shall provide its Program Work Breakdown Structure (WBS) and Contract WBS Dictionary 10 days after the award of the task order.

4.1.2.6 Access. The Government shall have access to pertinent records and data associated with the EVMS, including all records which directly feed, but are not officially a part of, the EVMS.

4.1.2.7 Documentation. The Contractor shall develop an EVMS System Description.

4.1.3 Product data. All data associated with overhaul starting with the Tunner receipt/incoming inspection through overhaul and acceptance test/outgoing inspection, including as-built data, shall be captured in the Metric database.

4.1.4 Program quality assurance. The Contractor shall establish and maintain a Tunner quality program in accordance with International Standards Organization (ISO) 9001:2008 and the Tunner Configuration Management Plan (CMP).

4.1.5 Program management reviews (PMRs). The performance of the Overhaul segment, including overhaul qualification when applicable, shall be discussed during the Tunner program management reviews (PMRs) currently executed under the MM segment of this contract.

4.1.6 Status Reviews. The Contractor shall brief the Tunner Program Office on current status of tasks and associated performance stated herein. These status meetings shall be conducted by telephone conference or video teleconference. By mutual agreement, a status briefing may occur in person at a designated site. These status meetings shall be held monthly and should not exceed 1 hour in duration. The Contractor shall use visual aids necessary to convey the overhaul status to the Government. The Contractor shall record minutes of each status review and attach any visual aids used. (DI-ADMIN-81250, X00E)

4.1.7 Overhaul Qualification and Progress/Readiness Reviews. For Contractors other than the OEM, the Contractor shall perform overhaul qualification in order to receive future low-rate and full-rate overhaul task orders. For overhaul qualification, the Contractor shall receive two GFE Tunners from the US Air Force; establish an overhaul line; successfully overhaul the two GFE loaders in accordance with 4.3 within 17 months after contract award; obtain Government acceptance of both loaders; successfully brief readiness to start low-rate overhaul, and successfully brief a plan for full-rate overhaul; and receive acceptance by the Government for the transfer of overhaul responsibility.

For Contractors other than the OEM, the Contractor shall perform all tasks necessary to prepare for successful transfer of overhaul responsibility at 18 months, and shall brief on a regular basis their progress toward being ready for the transfer. The Contractor shall brief their final status

(Readiness Review) to the Government at Contractor’s location 470 (+7) days (review start date) after contract award of the Contractor’s readiness to accept low-rate and full-rate overhaul responsibility 18 months after contract award. Prior to the Readiness Review, the Contractor shall brief their progress toward the Readiness Review to the Government at Contractor’s location 180 (+7) days and 330 (+7) days after contract award. The Contractor shall use Power Point charts for the reviews and provide to the Government prior to or at the beginning of the briefing. The Contractor shall present charts, written processes, and hardware/software, for discussion and inspection, and the Contractor shall demonstrate implementation of processes to comply with the requirements, and establishment of employee training, for the following eleven key exit criteria elements (as a minimum):

1- IMS to include all major activities required to prepare for the transfer of responsibility, 2- overhaul management, 3- adequate facilities and layout, i.e., equipment, facilities square footage, placement of workstations, workflow processes, work area for onload/offload of oversized transport vehicles, work area for inspection, work area for wash rack, work area for test, warehousing of parts, parts flow throughout the plant, etc., 4- compliance with Overhaul Instructions Manual, 5- preparation for low-rate overhaul start-up, 6- planning for full-rate overhaul, 7- translation of overhaul instructions manual and writing of manufacturing instructions unique to Contractor, 8- time standards for all tasks, 9- overhaul line efficiencies gain to reduce labor hours, 10- continuous improvement, and

11- employees with the correct skills and tools, in place.

The Contractor shall report status for the eleven key elements above by further breaking down each key element into lower level objective criteria; the Contractor shall update status of each objective criterion at each review by providing percentage of completion of each as compared to the IMS submitted within the proposal for this effort.

The Contractor must receive approval from the Government to proceed with low-rate or full-rate overhaul after 547 days (or 18 months) after contract award. The Contractor shall record minutes documenting the reviews, and include the briefing charts in the minutes. Each review shall take no more than five days and the days shall be consecutive, and no more than 8 hours per day shall be allowed. (DI-ADMIN-81250, X00E)

4.2 Systems engineering. Execution of this PWS shall not at any time violate the Government technical baseline. The Contractor shall be responsible for proactively identifying and resolving overhaul issues/deficiencies to support the overhaul line, support the Tunner System Sustainment Availability (TSSA) requirement, and to maintain OSS&E baseline performance. The Contractor shall change processes, equipment, etc. as necessary for continuous improvement in efficiency gains on the overhaul line resulting in reduced labor hours. The Contractor shall ensure performance of the Tunners will not be degraded by any actions taken.

4.2.1 Operational safety, suitability, and effectiveness (OSS&E). The Contractor shall establish and maintain an OSS&E program in accordance with the Tunner OSS&E Execution Plan, and shall include full compliance with the latest Tunner CMP. The Contractor shall change the OSS&E Execution Plan and CMP, and processes as necessary for continuous improvement.

PCO approval is required for OSS&E Execution Plan and CMP changes since they are part of the Government technical baseline maintained in the PES segment of this contract.

4.2.2 Maintenance of the overhaul instructions (OI) manual. The OI Manual, 9032950-OI, is the overhaul material and labor content definition document developed under the overhaul demonstration accomplished earlier. The OI Manual was derived from the OEM’s Manufacturing Instruction Set (MIS) developed during the past overhaul demonstration phase of the Tunner Overhaul Program. The Contractor may utilize its own detailed manufacturing instructions to overhaul the Tunners provided they fully comply with the Government-approved OI Manual. Any errors discovered in the OI Manual shall be recorded for the next manual update. Any changes desired, for any reason, to the OI Manual must be approved by the Government. The Contractor’s manufacturing instructions shall always track with the Government-approved OI Manual. The Contractor shall utilize the system review board (SRB) and Configuration Management processes to accomplish and control changes to the OI Manual (9032950-OI). At least once a year the OI Manual shall be updated and published, and the revision designation (or date) of the OI Manual changed. All requested changes to the OI Manual shall be submitted as a Configuration Audit Summary Report. (DI-CMAN-81022C/T, X001) (MIL-PRF-32216, X012)

4.2.3 Thirty-six high cost reparable parts. Weibull Analysis was used to help construct a Table (see Appendix B Reparable parts/assemblies for historical purposes) that is used as a guide for determining when the highest-cost reparable parts (36 parts) need to be repaired. The Table allows decisions to be made for each Tunner individually based on accumulated hours. The Table has been incorporated in the OI Manual.

4.2.4 Structural abnormalities identification. The Contractor shall identify to the Government structural abnormalities discovered during overhaul within seven calendar days after discovery.

The Contractor shall provide their recommended repair actions for each structural abnormality, and indicate if approved repair procedures exist. Existing non-technical order (NTO) and technical order (TO) repair procedures are considered approved repair procedures. For the purposes of this PWS, structural abnormality is defined as any abnormal condition of the Tunner structure that affects the structural integrity, e.g., bent, twisted, cracked, broken, heavily corroded, or missing structural components. Structural components are: cab shells, deck extrusions, chassis longitudinal rails, chassis cross members, suspension castings, and lift links;

and, associated hardware. The contractor shall also provide any schedule (flow days) impacts associated with these repairs. The Government may request a rough order of magnitude (ROM) for each repair and implement the repair in a separate task order. Any schedule delays caused by ROM generation or awaiting Government direction or approval shall not impact the incentive fees related to the performance of this contract.

4.3 Overhaul. This section states the tasks necessary for overhaul of GFE Tunners. Material pipeline for overhaul may be an expansion of the MM material pipeline in order to take advantage of economic order quantity, etc., and is at the Contractor’s discretion how to expand or duplicate the MM pipeline for overhaul support.

4.3. 1 Tunner receipt/incoming inspection. The Contractor shall arrange for receipt of inbound shipments, including off-loading the Tunners upon arrival. The Government shall, at its expense, deliver the Tunners to the Contractor’s location. The Contractor shall receive each Tunner from the Government, and reconfigure it to Normal Operational Mode in accordance with TO 36M2-3-35-11, Operation and Operator Maintenance Instructions. The Contractor shall perform a receiving (incoming) inspection, including an inspection for shipping damage and missing parts, and conduct a functional operational inspection. The Contractor shall identify to the Government any issues, or concerns that affect the Contractor’s ability to complete the tasks of this PWS, and identify any shipping damage. These inspections shall be conducted for and on behalf of, and under the cognizance of, the DCMA resident quality assurance representative (QAR). Any resolution of identified problems must be approved by the Government.

4.3.2 Basic overhaul process.

The Contractor shall overhaul the GFE Tunners in accordance with the latest approved revision of the OI Manual, 9032950-OI, excluding Chapter 21 Non-Technical Order (NTO) Field Repair.

NTOs are addressed in 4.2.4. The OI Manual details which parts/assemblies shall be reworked, scrapped and purchased new, or saved and re-used after being scuffed and re-painted. When the OI Manual requires a part to be replaced, the Contractor shall use a re-worked part if available.

If a re-worked part is not available, a new part may be used. All parts used “as is” shall be inspected/tested, serviced (when applicable), scuffed, and painted.

Parts identified as missing during incoming inspection shall be handled as follows:

a. Missing parts except structural components (4.2.4) are a part of the basic overhaul package and need no further consideration; and

b. Contractor shall compile a list of missing parts for each Tunner furnished, and store the list in the Metric database. The list shall be placed in electronic form (Microsoft Access database or Microsoft Excel spreadsheets) on the Contractor’s website for download by Tunner Program Office personnel for information only within 10 calendar days of completing each Tunner incoming inspection.

Parts identified as recent time-compliance technical orders (TCTO) installed parts shall be reused (when applicable) as part of the basic overhaul package.

Parts identified during incoming inspection as being damaged shall be handled as follows:

a. Damaged parts that are to be scrapped as part of overhaul are a part of the basic overhaul package and need no further consideration;

b. Damaged nonstructural parts intended to be reused shall be repaired under the basic overhaul package. If unable to repair, the parts shall be replaced under the basic overhaul package.

Contractor shall compile a list of damaged parts unabled to be repaired for each Tunner furnished, and store the list in the Metric database. The list shall be placed in electronic form (Microsoft Access database or Microsoft Excel spreadsheets) on the Contractor’s website for download by Tunner Program Office personnel for information only within 10 calendar days of completing each Tunner incoming inspection; and

c. Structural abnormalities shall be handled in accordance with 4.2.4.

The Contractor shall assess and document and repair corrosion-related damage, excluding structural abnormality damage from corrosion which is separately addressed in 4.2.4. Any Tunners not in compliance with the Tunner TCTOs shall be corrected using the GFE kit of material designated for that particular Tunner’s TCTO. If the kit is not available from GFE stores, upon Government approval, obtain the kit through the MM segment of the contract.

All Tunners overhauled shall be re-identified with the applicable 500 series dash numbers.

Additionally, the Contractor’s As-Maintained List (AML) for that particular Tunner shall be cleared after confirming the removed serialized parts match the contractor’s AML. Any differences shall be investigated to attempt a reconciliation of serial numbers on other fielded Tunners. The AML shall be maintained throughout the contract period and stored in the Metric database. The AML shall be placed in electronic form (Microsoft Access database or Microsoft Excel spreadsheets) on the Contractor’s website for download by Tunner Program Office personnel. The Contractor shall implement the Tunner UID marking per the Tunner UID plan (60K_UID_Plan). The Contractor shall report to the national registry the changes from virtual UID to physically marked UID and any other necessary information.

4.3.2.1 Receiving and handling. The Contractor shall receive, inspect, reconfigure, clean, and remove loose items from the Tunners, and perform all other tasks, per Chapter 3 of the OI Manual.

4.3.2.2 Chassis disassembly. The Contractor shall disassemble the chassis, reclaim all the fluids, remove the cab, deck, lift links, hydraulic cylinders, tanks, and miscellaneous items, and perform all other tasks, per Chapter 4 of the OI Manual.

4.3.2.3 Suspension disassembly. The Contractor shall remove the bogies, chassis hydraulics, electrical systems, and disassemble the suspension system, and perform all other tasks, per Chapter 5 of the OI Manual.

4.3.2.4 Chassis hydraulics, steering, powerpack, and miscellaneous disassembly. The Contractor shall disassemble the chassis hydraulics, chassis steering, chassis powerpack, and chassis miscellaneous items, and perform all other tasks, per Chapters 6 and 7 of the OI Manual.

4.3.2.5 Deck disassembly. The Contractor shall disassemble the deck, and perform all other tasks, per Chapter 8 of the OI Manual.

4.3.2.6 Cab disassembly. The Contractor shall disassemble the cab, and perform all other tasks, per Chapter 9 of the OI Manual.

4.3.2.7 Parts cleaning, corrosion prevention, and painting. The Contractor shall clean parts, apply corrosion prevention, and paint, and perform all other tasks, per Chapter 10 of the OI Manual.

4.3.2.8 Sub-assembly repair. The Contractor shall disassemble, rework, and reassemble, the air compressor, emergency pump, powerpack, fuel tank, radiator, heat exchanger, hydraulic manifolds and brackets, hydraulic tank, suspension bogies, bushings, and upper lift links, and perform all other tasks, per Chapter 11 of the OI Manual.

4.3.2.9 Cab assembly. The Contractor shall assemble the cab, and perform all other tasks, per Chapter 12 of the OI Manual.

4.3.2.10 Deck assembly. The Contractor shall install the deck fasteners, hydraulics, electrical, top side bolt-ons and catwalks, and perform all other tasks, per Chapter 13 of the OI Manual.

4.3.2.11 Chassis assembly. The Contractor shall install the pneumatics, brackets, plates, supports, electrical boxes, bulkheads, manifolds, engine, and steering, and perform all other tasks, per Chapter 14 of the OI Manual.

4.3.2.12 Chassis hydraulics installation. The Contractor shall install the hydraulic manifolds, tubes, heat exchanger, clamps, spiral wraps, and tube guards, and perform all other tasks, per Chapter 15 of the OI Manual.

4.3.2.13 Chassis assembly station four. The Contractor shall install the suspension, lift links, lift cylinders, encoders, maintenance stands, radiator tubes, and adjust the lift links, and perform all other tasks, per Chapter 16 of the OI Manual.

4.3.2.14 Chassis integration. The Contractor shall install the cab and deck, integrate the power pack, and perform all other tasks, per Chapter 17 of the OI Manual.

4.3.2.15 Initial startup, and final test. The Contractor shall start the engine and checkout the Tunner, and perform a final test, and perform all other tasks, per Chapters 18 and 19 of the OI Manual.

4.3.2.16 Overhaul packaging. The Contractor shall package some Tunner parts to ready the Tunner for shipment, and perform all other tasks, per Chapter 20 of the OI Manual.

4.3.3 Post overhaul test/final outgoing inspection. The Contractor shall conduct 150 hours of post overhaul testing in accordance with Chapter 19 of the OI Manual for overhaul qualification.

The test shall be reduced to 75 hours for low-rate overhaul. And, the test shall be further reduced to 50 hours for full-rate overhaul. Per the OI Manual, the Contractor shall document and correct all failures occurring during the post overhaul test. The Contractor shall perform a final outgoing inspection using a Contractor-generated, Government-approved checklist for the DCMA resident QAR. The Contractor shall document and correct all non-conformance reports (NCRs) found during the inspection; minor cosmetic conditions such as dents, gouges, cuts, and dimples that do not affect operation of the vehicle, shall be acceptable. (DI-NDTI-80809B/T, X005)

4.3.4 Storage, packaging, and shipping. The Contractor shall provide storage and security for all Tunners while in the Contractor’s possession. The Tunners shall be placed in storage after Tunner receipt/incoming inspections are completed. The Contractor shall have storage capability for up to ten Tunners at the Contractor’s facility, during pre- and post-overhaul periods. The Contractor shall pack and prepare each Tunner for return shipment to the Government, to include reconfiguring the Tunner to Air Transport Mode (bogies in), and preparation of required shipping documents. The Contractor shall install active radio-frequency identification (RFID) tags for tracking purposes for outside continental United States (OCONUS) shipments. The Contractor shall arrange for loading of each Tunner onto Government provided transportation after all overhaul related activities are completed.

4.4 Green procurement program (GPP). GPP is a mandatory federal acquisition program that focuses on the purchase and use of environmentally preferable products and services. GPP requirements apply to all acquisitions using appropriated funds, including services, and new requirements. FAR 23.404(b) applies and states the GPP requires 100% of Environmental Protection Agency (EPA) designated product purchases that are included in the Comprehensive Procurement Guidelines (CPG) list that contains recovered materials, unless the item cannot be acquired:

a. competitively with a reasonable timeframe,

b. meet appropriate performance standards, or

c. at a reasonable price.

The prime contractor is responsible for ensuring that all subcontractors comply with this requirement.

4.5 Performance of service during crisis. The Functional Commander/Functional Director (FC/FD) has determined that this requirement is not Mission Essential (M-E) in accordance with DoDI 1100.22.

5. APPENDICES.

Appendix A. Applicable Documents The following documents of the exact revision listed below form a part of this PWS to the extent specified herein.

Name of Pub Sections that Apply Date of Pub/Rev Title of Pub

MISC1‐9032950P Entire doc 23 Sep 04 Corrosion Control Plan

ISO 9001:2008 Entire doc 2008 Quality Management System

9032950‐OI All chapters except 21 29 Apr 11 Overhaul Instructions Manual

OSSE 60_EP Entire doc 10 Feb 03 OSS&E Execution Plan

T.O. 36M2‐3‐35‐

Entire doc 28 Jan 11 Change 7

Operation and Operator Maintenance Instructions

SP1‐9032950D Entire doc 13 Feb 07 Performance Spec for 60K Loader Vehicle

EVMS Entire doc 2007 Earned Value Management System

60K_UID_Plan Entire doc Rev B, 16 Dec 08 Individual Unique Identification Plan

Appendix B. Reparable parts/assemblies (36 high value part dispositions)

High Cost Repai r-ables

Part No.

(Dash No. Shown is Typical Field Configuration)

Item Description Qty/

Loade r

Weibull Threshol d (Bx)

ETI

(Hours)

Bx

Use d

Specific Disposition Information

1 9435273-305 ENGINE 1 2000 B20 See Note 1 2 9434838-4 MANIFOLD, SUPPLY-M1 1 5000 B10 See Note 2 3 9434857-3 CYLINDER, SUSPENSION 10 2500* B10 See Note 3 4 9034441-1 HUB, PAINTED 6 >>10000* B10 See Note 4 5 9034439-1 HUB, PAINTED 4 >10000* B10 See Note 4 6 9034108-2 CYLINDER, LIFT 4 5000* B10 See Note 3 7 9034437 MOTOR HYDRAULIC/ MV1 -MV4 4 9500 B10 See Note 2 8 9581240-317 PUMP ASSY,PAINTED,SS-PV1 1 4000 B15 See Note 2 9 9581240-319 PUMP ASSY,PAINTED,CS-PV2 1 4000 B20 See Note 2

10 9627489 HYD. MOTOR 9 <1500* B10

Return all to

Vendor 11 9035490 MANIFOLD ,CONV.MTR. 9 >10000* B10 See Note 4 12 9034194 CYLINDER, CONVEYOR 9 5000 B10 See Note 2 13 9034416-301 ASSY, ROLL CYLINDER 8 >10000* B10 See Note 4 14 9434839-1 MANIFOLD, LIFT-M2 1 5500 B10 See Note 2 15 9581520 MAN, FLOW DIVIDER 3 >10000* B10 See Note 4 16 9034432-1 MANIFOLD, DRIVE CONT. M5-6 2 6500 B10 See Note 2 17 9034382 CYLINDER, STEERING 2 8000 B20 See Note 2 18 9434837-1 MANIFOLD, SUSPENSION, M4 1 3700 B10 See Note 2 19 9627550-301 WHEEL, CONVEYOR 18 <3000* B10 See Note 5 20 9916218-1 HYD. FILTER (CF-080-0057) 1 >10000* B10 See note 6 21 9034417-1 CYLINDER, SIDE SHIFT 2 5000* B10 Re-pack only 22 9033260-1 MANIFOLD, DECK ROLL 1 6500* B10 See Note 4

KSC24M-BC-

550YNP

CHAMBER, AIR BRAKE 10 <3500* B10 Replace All at O/H

24 9916220-1

FILTER, PAINTED (CF-080-0035) FL1-

FL2

2 <4000* B10 See Note 7

25 9035332-1 GEAR BOX-PAINTED 1 <3000* B10 See Note 5 26 9033261-2 MANIFOLD, SIDE SHIFT 1 6500* B10 See Note 4 27 9034962 ENCODER, OPTICAL 2 3000 B10 See Note 2 28 200225289-301 PUMP ASSY, STANDBY 1 >10000* B10 See Note 4 29 9434855 MANIFOLD, RETURN, HYD. 1 >10000* B10 See Note 4 30 9034273 CYLINDER, BOOST 1 3000* B10 Repack (Only) All 31 9035495-3 MANIFOLD, CONV.SUPLY. 1 7500* B10 See Note 4 32 9627380 MANIFOLD, CONVEYOR 1 9000* B10 See Note 4 33 200225310-1 Motor, Hyd., Fan Drive MF11-13 3 5500* B10 Replace All at O/H 34 9916219-1 HYD. FILTER (CF-080-0037) 1 5500* B10 See Note 6 35 9916248-1 PIN, SUSPNSN CYLINDER 20 5000* B10 See Note 5 36 9034128-1 SFT, SUSP PVT 10 >10000* B10 See Note 5

Note 1: If ETI Hours are <500 = Low Level Repair, 500 to 2000 = Mid Level Repair, >2000 = Full Repair.

Note 2: Use Weibull Analysis threshold as scrap or re-use criteria. If below the threshold, Clean and re-paint only.

Note 3: Replace seals and repack all cylinders. Inspect rods for damage or corrosion and replace if required.

Note 4: Clean and Re-paint (only) all units.

Note 5: Refurbish per the Overhaul Instructions Manual (9032950-OI) Note 6: Replace all Filter Elements, Seals and O Rings (only) and clean and re-paint.

Note 7: Replace all Filter Elements, Seals, O Rings, and Pressure Indicators (only) and clean and re-paint.

* Further analysis of the field usage data, beyond the Weibull Analysis Threshold, indicated that other criteria were more appropriate in determining the disposition for these specific repairable parts. Therefore, the "Weibull Threshold ETI" will not be used as the disposition decision for these parts.