Pallets_PWS Rev 1(2009 09 28).doc

HEADQUARTERS

WARNER ROBINS AIR LOGISTICS CENTER

ROBINS AIR FORCE BASE, WARNER ROBINS GEORGIA

AF CONTRACT NUMBER: TBD

PR NUMBER: TBD

DRAFT AS OF 27 Sep 2011

PERFORMANCE-BASED WORK STATEMENT (PWS)

TYPE WORK: Overhaul of Pallets

NSN: 1670-00-820-4896CT

Part Number: MIL-DTL-27443 TYPE I

SECTION I

DESCRIPTION OF SERVICES

1.1 Objective: This Performance-Based Work Statement (PWS) describes the repair/overhaul requirements for NSN 1670-00-820-4896CT (463L Pallet). All work shall be in accordance with (IAW) applicable documents listed in Section V, Appendix A. 463L pallets shall be restored to a safe and serviceable (new) condition, using the most cost effective way possible thereby avoiding the additional cost required to procure new pallets.

SECTION II.

SERVICES SUMMARY(SS)

Services Summary

SECTION III GOVERNMENT PROPERTY AND SERVICES

3.1 If first article testing is required, the following property will be furnished by the Government to be used in testing pallets. These items shall be furnished in as close to new condition as possible. Refer to Appendix B for the National Stock Number (NSN), Part Number, (P/N), Quantities, need dates and disposition instructions.

a. 6 each HCU-7/E side nets

b. 3 each HCU-15/C top nets

SECTION IV

GENERAL INFORMATION

4.1 Contractor furnished material or parts used for replacement shall equal or exceed the quality of the original material or parts. The material or parts shall be suitable for restoration of the end item for its intended purposes and shall be interchangeable without alterations to the parts or the end item.

4.2 The original design function of the item and parts shall not be changed, modified or altered unless authorized by the Procuring Contracting Officer (PCO).

4.3 Production problems. The contractor shall forward all production problems through the ACO and PCO to Contract Specialist at WR-ALC/GRVKBA, or Production Management Specialist at WR-ALC/GOUAD.

4.4 Data: For those standard parts which are obsolete and no longer available, contractor shall conduct research to identify a suitable substitute. Any parts or material supplied by the contractor shall equal or exceed the quality of the original parts or material. Such factors as function, environment, reliability, strength, safety economy and interchangeability shall be considered in the selection of substitute parts. The contractor shall submit a Nonstandard Part Approval Request (DD Form 2052) in accordance with DD Form 1423 (CDRL A009, DI-MISC-80071E/T) for approval of nonstandard parts which are form, fit, and function equivalents of the replaced parts. For part(s) replacements which require installation modification, an Engineering Change Proposal (ECP) shall be submitted.

4.4.1 CAVAF Reporting: The contractor shall report using the Commercial Asset Visibility (CAVAF). (CDRL A001, Data Item Description, DI-MGMT-81634B). The contractor shall provide data related to the tasks and efforts conducted for each repairable unit. Government contractors must use a valid Public Key Infrastructure (PKI) certificate to access/log into CAV AF. If CAVAF training is required, contact 586 CBSS/GBMCBA, Centralized Sellers Office (CSO), Robins AFB GA 31098, Phone (478) 327-6578, for additional information. The contractor shall conduct production reporting on a daily or as transactions occur basis.

4.4.2 Wide Area Work Flow. The contractor shall submit all requests for payment and acceptance in Wide Area Work Flow (WAWF).

4.4.3 Technical data: The removal, disassembly, inspection, repair adjustment, modification, test, assembly, and reinstallation of components and equipment will conform to the basic maintenance instructions manual and other applicable documents listed in Appendix A in Section V of this PWS.

4.4.4 Repairable Item Inspection Report: The contractor shall provide a monthly lot sample size test report of the inspected pallets in accordance with DD Form 1423 (CDRL A010, DI-ILSS-80386). The report shall be formatted and contain information in accordance with the following table or another table pre-approved by the government:

Monthly Totals

2nd

3rd

Total

4.5 Security: Unclassified.

4.6 Quality: The contractor’s quality program shall be established and maintained IAW FAR 52-246-11. The contractor’s quality program shall meet the requirements of ISO 9001:2000, and is to be approved by the cognizant government representatives.

4.6.1 Defects reported: When requested, the contractor shall assist the cognizant ACO in evaluating product quality deficiency reports and exhibits for defects reported on items repaired under this contract to determine the root cause for deficiencies. These defects may be reported from field or depot organizations. Corrective action to prevent repeat discrepancies shall be an integral part of the contractor’s quality program at no additional cost to the Government. The contractor shall establish and maintain a program, approved by the cognizant representative, to assist the cognizant government representative to accomplish the requirements set forth in Air Force T.O 00-35D-54 and Joint Regulation DLAR 4155.24.

4.6.2 Inspection: The DCMA QAR shall conduct inspections in accordance with ANSI/ASQC Z1.4, general inspection Level II, single sampling plans for normal inspection (see 4.10.3.2). The Government may recheck any point of measurement at no additional cost to the contract IAW the Inspection of Services Clause, 52.246-4.

4.6.3 Inspection of Service Clause: The U.S. Governement reserves the right to witness any contractor efforts to accomplish the requirements of contract. Additionally, the Inspection of Service clause – as incorporated in Part 1, Section E, “Inspection and Acceptance,” of the contract – establishes Governement access to contractor records as well as rights to inspection and tests, and recourse for failure to provide services which meet contract requirements.

4.6.4 Condemnation/overhaul limitation: The contractor shall not overhaul any item where the total cost of parts and labor exceed 75% of the government replacement cost of the item unless authorized through the ACO to the PCO at WR-ALC/GRVKBA.

4.7 Accessory and component reuse, repair and replacement: The reuse, repair, and replacement of accessories and components shall equal or exceed the quality of the original material or parts.

4.7.1 Expense parts of an end item determined unserviceable or missing shall be replaced with equivalent serviceable parts at no additional cost. Material/parts used for replacement shall be selected in accordance with the applicable illustrated parts breakdown T.O.s and Air Force drawings. Only those part numbers identified within these documents will be used. Subassemblies shall be repaired as a part of the next higher assembly.

4.8 Receipt of Pallets at Facility:

4.8.1 Handling: Care shall be exercised to prevent damage to the items, including shipping materials. The contractor shall immediately notify the ACO when assets are received in improper conditions.

4.8.2 Inventory inspection: The pallet shall be inspected with inspection results recorded on a form listing all required repairs. This form shall be identified to the pallet by an identification number and shall be located in the same area of each pallet. The receiving inspection form shall include a place to verify that all required repairs have been satisfactorily completed and accepted.

4.8.3 Preservation: The contractor shall handle and store pallets IAW chapter 2 of TO 25D33-2-2-2 to adequately provide protection against rust, corrosion, theft and other damage.

4.9 Specific Work Requirements:

4.9.1 General: Inspection, disassembly, cleaning, repair, assembly, and corrosion treatment shall be in accordance with TO 35D33-2-2-2, 7031843M, MIL-DTL-27443 and this PWS. Any pallet repair beyond replacement of rings and corner brackets shall require disassembly of the pallet and replacement of the core with a new balsa core.

4.9.2 Reserved 4.9.3 Materials: All materials (e.g. balsa wood, adhesive, skins, corner straps, side rails, rivets, and rings) for repair of pallets shall be as specified in AF Drawing 7031843M, TO 35D33-2-2-2, and MIL-DTL-27443.

4.9.4 Aluminum skins: Aluminum skin shall be either new or reclaimed. If the bottom skin of a HCU-6/E pallet is determined to be damaged beyond repair (holes other than rivet holes, edge damage, corrosion, skins coated with black or yellowish-white ambient-cured adhesive, etc.), it shall be replaced in accordance with 7031843M. Corner damage is allowed providing not more than one inch must be removed from each edge to remove the damage. Only one(1) damaged corner is allowed per skin. If the bottom skin is not damaged beyond repair and it is in accordance with 7031843M, it shall be reused.

4.9.5 Rail assemblies: Damaged rail assemblies (e.g. dents and gouges) shall be repaired in accordance with TO 35D33-2-2-2 and 7031843M. Dents or gouges on the outside vertical surface of a rail in excess of one-eighth (1/8) inch deep shall be cause for rejection. Dents or gouges on either horizontal bonding surface (where skins bond to rails) shall be cause for rejection.

4.9.6 Ring assemblies: Damaged or excessively corroded ring assemblies shall be replaced according to the requirements of 5.2.3.6 of TO 35D33-2-2-2. Cleaned rings shall be coated with preservative type primer MIL-PRF-26915D. Each ring shall be designed to sustain a 7,500 pound tension load along any line in this plane within the angular limits. Each ring shall also be designed to sustain a 7,500 pound load along any line originating at the attachment point in a vertical plane extending above the pallet and parallel to the edge without permanent deformation.

4.9.7 Pallet defects: The pallets shall have no critical defects. The pallets shall have no major defects. The pallets may have a minimal number of minor defects. The number of minor defects in a given delivery order shall be less than 6.5% of the total number of units.

4.9.8 Performance: The repaired pallets shall meet all performance as requirements of TO 35D33-2-2-2, 7031843M, MIL-DTL-27443 and this PWS.

4.9.8.1 Ring movement. The pivot point of the ring shall be outside the usable surface edge. Each ring shall be capable of at least 225º of free movement in a vertical plane that intersects the pallet edge at right angles.

4.9.8.2 Lifting capabilities: The pallet shall be capable of the following lifting requirments.

4.9.8.2.1 Corner lifting: When uniformly loaded with 18,000 pounds, the pallet shall be capable of withstanding, without permanent deformation or component separation, 10 lifting cycles by means of four cables attached to the four tiedown rings adjacent to the four corners. Corner lifting shall be IAW 3.4.4.1 and 4.5.5.1 of MIL-DTL-27443.

4.9.8.2.2 Forklift lifting: When uniformly loaded to rated capacity (10,000 pounds), the pallet shall withstand 10 lifting cycles, without deformation, by a forklift truck having 72-inch long by six (6) to eight (8)-inch wide tines spaced 42 inches center-to-center. Forklift lifting shall be IAW 3.4.4.2 and 4.5.5.2 of MIL-DTL-27443.

4.9.8.2.3 Forklift “wedge” lifting: When uniformly loaded to rated capacity (10,000 pounds), a pallet shall withstand 5 lifting cycles from a smooth, dry, concrete surface without deformation. The tines shall be wedged under the pallet perpendicular to a pallet rail. A forklift truck having 72 inch long by 6 to 8 inch wide tines spaced 42 inches center-to-center shall lift the pallets. Forklift truck tines shall have an end radius of not less than 0.250 inch. Forklift “wedge” lifting shall be IAW 3.4.4.3 and 4.5.5.3 of MIL-DTL-27443.

4.9.8.2.4 Surface pressure: The pallet shall be able to withstand a one-inch square steel mandrel supporting a 900-pound load to the top surface. The corners of the mandrel may be slightly rounded. Permanent deformation of the test panel in the load area shall not exceed 0.005 inch in depth. Deflection while under load shall not exceed 0.015 inch.

4.9.9 Identification:

4.9.9.1 The maintenance facility shall furnish and affix an aluminum data plate or decal to each repaired pallet. The data plate or decal shall identify the maintenance facility's name, Air Force Contract Number and date of repair. When an aluminum data plate is used, letters and numerals shall be applied by etching, engraving or metal stamping. If a decal is used, the decal shall be weather and fade resistant.

4.9.9.2 The maintenance facility shall furnish and affix (2) bar codes to each pallet. One bar code shall be located on one corner of the pallet above the locking lips on a long rail; the other shall be located above the locking lips on the short rail located diagonal to the first bar code. The bar codes shall be an aluminum plate or a weather and fade resistant decal. The bar codes shall use code 39 format, shall be at least 0.625” tall, and shall have no less than six characters. At time of contract award, supplier shall furnish sequential serial numbers to equal quantities in releases against contract. These sequential serial numbers will be different for each pallet. Also, the supplier shall assign lot numbers.

4.10 Verification:

4.10.1 Inspection, testing, and verification: Unless otherwise specified in the contract or purchase order, the contractor is responsible for the performance of all inspection, test, and verification requirements as specified in this PWS.

4.10.2 First production testing: If first article testing is required then first production testing shall be witnessed by WR-ALC/GRVEB Engineer. The contractor shall submit test procedures and test report IAW DD Form 1423, DI-NDTI-80603A and DI-NDTI-80809B respectively. DCMA QAR will be asked to be present with the Engineer. Three first production test units shall be repaired using at least one new rail, new top and bottom skins, and new core. The three test units shall be labled A, B, and C. First production testing shall be accomplished in accordance with the following paragraphs of MIL-DTL-27443:

4.10.3 Conformance inspection: Conformance inspection shall be accomplished in accordance with the following:

4.10.3.1 Individual test. Each pallet shall be subjected to the test specified in paragraphs 4.5.1 and 4.5.2 of MIL-DTL-27443.

4.10.3.2 Sampling Test. Sample pallets from each lot shall be selected in accordance with ANSI/ASQC Z1.4 general inspection level II, single sampling plan for normal inspection (see 4.6.2). A lot shall consist of pallets manufactured under the same conditions and submitted for inspection at the same time. The acceptable quality level (AQL) shall be 0 percent defective for critical defects, 0 percent defective for major defects and 6.5 percent defective for minor defects per delivery order. Selected sample pallets shall be examined for defects as specified in 4.4.2.5 of MIL-DTL-27443 and tested as specified in 4.5.5.1 of MIL-DTL-27443.

4.10.4 Rejection criteria: Throughout all tests, the pallet shall be closely observed for the following conditions, which shall be cause for rejection:

a. Failure to conform to performance requirements specified herein.

b. Structural failure of any component, including permanent deformation, or evidence of impending failure.

c. Evidence of excessive wear or delamination.

d. Misalignment of components.

e. Conditions which present a safety hazard to personnel during operation, service or maintenance.

4.11 Performance of services in Crisis. The Functional Director (FD) has reviewed service of the contract and has been determined not mission essential during a crisis situation IAW DODI 3020.37.

4.12 Safety:

4.12.1 Occupational Safety and Health Act: The contractor shall comply with Occupational Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards; OSHA standards 29 CFR 1910, 1926, for the protection of their employees. Robins AFB is part of the OSHA Voluntary Protection Program (VPP). All contractors are required to familiarize themselves with the requirements of VPP. Infromation on the VPP can be accessed at http://www.osha.gov/dcsp/vpp/index.html. It is the contractor’s sole responsibility to ensure that all safety requirements are met. The contractor is also responsible for the safety and health of all subcontractor employees.

4.13 Green Procurement Statement: None of the products specified for this contract are listed on a mandatory environmental purchasing list. See attached Green Procurement Form.

4.14 Packaging: When shipping containers are received that meet the requirements of the AFMC Form 158 and/or the packaging clauses cited in the contract, and are suitable for return shipment of serviceable assets, they shall be reclaimed, stored, and protected for reuse. Unserviceable containers shall be disposed of and replaced with new containers that meet the requirements of the AFMC Form 158 and/or the packaging clauses cited in the contract.

SECTION V

APPENDIX

APPENDIX A Technical Documents

The sections that apply are sited in the specific paragraphs in this PWS.

Document Number

Technical Orders (TO)

Change 1 USAF Materiel Deficiency Reporting and Investigating System

Government Specifications

MIL-PRF-6915D

MIL-STD-129P

MIL-STD-130L

MIL-STD-2073-1D

Joint Regulation DLAR 4155.24

Entire

Government Drawings

Non Government Specifications

APPENDIX B Terms Explained

1. Administrative contracting officer(ACO): That individual having overall administrative responsibility for the contract.

2. Calibration: A comparison between two instruments, one of which is a standard of known accuracy, to detect and correlate or adjust any variation in the accuracy of the instrument being compared.

3. Components: A separate identifiable part of an end item which performs a function within the system or subsystem and is necessary for the proper operation of the end item.

4. Data: All management, engineering and logistic information, reports and documentation required.

5. Depot facility: An industrial type facility established to perform overhaul functions in support of field and using organization. This includes AFMC assigned installations and commercial contractors who are engaged in performing depot level work on weapon systems or equipment under a contract issued and managed by AFMC.

6. End item: A recoverable piece of equipment listed as a line item on a government contract.

7. Expense items: These are consumable items with an Expendability-Recoverability-Reparability-Category (ERRC) Designator of XB3 and XF3. (ERRC codes N and P are consumable items). The ERRC code is identified by the last letter of the Source Maintainability Recoverability (SMR) code listed in the systems Illustrated Parts Breakdown (IPB) Technical Order.

8. Inspect or check: An examination of an item to determine identity, condition and proper installation.

9. Investment items: These are non-consumable items with an ERRC Designator of XD1, XD2, ND2 or NF2 (ERRC codes C, T, S, and U are non-consumable items). The ERRC code for an item is identified by the last letter of the SMR code listed in the system IPB Technical Order.

10. Nondestructive inspection: Methods of investigating the quality, integrity, properties and dimensions of material and components without damaging or impairing their serviceability.

11. Operational check: A functional test of an accessory, component, or system accomplished in its installed environment to assure proper installation and operation.

12. Procuring contracting officer (PCO): The individual authorized to enter into contracts for supplies and services on behalf of the Government and who is responsible for overall acquisition process.

13. Quality assurance representative (QAR): The Government representative responsible for administration of the Quality Assurance function for this solicitation/contract.

14. Recoverable: Another name for investment items.

15. Repair: The restoration or replacement of parts or components of an end item as necessitated by wear and tear, or damage, in order to return the end item to serviceable condition.

16. Reparable: An unserviceable item that can be repaired and restored to a serviceable condition.

17. Serviceable: An item capable of meeting the requirement and performing the function for which designed or modified and meets all test requirements of the end item Technical Orders (T.O.), or as established by this work specification.

18. Critical defects: The following items will be classified as critical defects. (1) Length, width, and lip dimensions out of tolerance (2) Skin not bonded/delamination (3) Pallet not processed in accordance with approved process specification (4) Failed lift test (5) Exceeds shear tie gap test (6) Flatness out of tolerance.

19. Major defects: The following items will be classified as major defects. (1) Lock notches out of tolerance (2) Tiedown ring and corner bracket fastening device not coated with wet primer when installed (3) Tiedown ring missing (4) Tiedown ring mounting hardware loose (5) Rivet missing (6) Wrong rivets (7) Wrong skin material (8) Parts not plated in accordance with drawing (9) Part not marked in accordance with MIL-STD-130L (10) Thickness exceeds tolerance (11) Tiedown ring and corner bracket fastening devices not coated as specified after installation.

20. Minor defects: The following items will be classified as minor defects. (1) Corner gap exceeds tolerances (2) Skin to rail gap exceeds tolerance (3) Adhesive flash not cleaned off (4) Rivet too close to edge of skin (5) Cocked rivet (6) Weight exceeds maximum.

21. Lifting cycle: A lifting cycle shall be considered starting with a pallet at rest on the ground, hoisted into the air, held in place for one minute, and lowered back to rest on the ground.

DRAFT

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