HAL_OH_PWS.pdf

PR FD2060-13-30382 OVERHAUL

OVERHAUL (OH)

PERFORMANCE-BASED WORK STATEMENT (PWS)

for

HALVORSEN

NON-AIRCRAFT WEAPON SYSTEM PER AIR FORCE POLICY

DIRECTIVE (AFPD) 10-9

Rev: 4 Apr 2013

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 VEHICLE 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) (23 AUG 2012). 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 Halvorsen 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 overhaul 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. The Contractor shall accomplish the overhaul qualification effort as described in 4.1.7;

two years of low-rate overhaul will proceed before accomplishing full-rate overhaul. The overhaul functions include: vehicle receipt, incoming inspection, disassembly, repair, replacement, refurbishment, unique identification, finish coating, TCTO’s, in-process testing, assembly, post-overhaul inspection, post-overhaul test, storage and security, and packaging and shipping. Overhaul of the Halvorsens will preserve the Operational Safety, Suitability, and Effectiveness (OSS&E) baselines (section 3 of the Prime Item Development Specification (MP- SP-006, Rev 008)) so the Halvorsens will be available when needed, perform up to expectations, and perform safely.

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 20 loaders shall be in work at any one time.

3. GOVERNMENT FURNISHED PROPERTY, EQUIPMENT, MATERIAL, AND

SERVICES (GFP/GFE/GFM/GFS). The Government will provide two Halvorsens for the Overhaul Qualification. The Government will provide up to 50 Halvorsens annually for future low-rate and full-rate overhaul activities. The Government will provide historical Online Vehicle Interactive Management System (OLVIMS) data for the Halvorsens 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 Halvorsen overhaul in accordance with this PWS. Data in the Integrated Master Schedule (IMS), Earned Value Management System (EVMS), and Enterprise Resource Planning (ERP) 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. 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 20 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 Government 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 to the Government all changes to the Contract Work Breakdown Structure (CWBS) Dictionary and shall require Government approval. The Contractor shall provide its CWBS and CWBS Dictionary within 10 days after the award of the contract.

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 Halvorsen incoming inspection through overhaul and post-overhaul test, including as-maintained list, shall be captured in the Metric database.

4.1.4 Program quality assurance. The Contractor shall establish and maintain a Halvorsen quality program in accordance with International Standards Organization (ISO) 9001:2008 and the Halvorsen 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 Halvorsen program management reviews (PMRs) currently executed under the MM segment of this contract.

4.1.6 Status Reviews. The Contractor shall brief the Halvorsen 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 as often as necessary by mutual agreement, but not any less than monthly throughout the contract period of performance, and should not exceed 1 hour in duration. Status meetings may need to be held weekly in the beginning and reduce over time. 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. 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 Government Furnished Equipment (GFE) Halvorsens from the US Air Force; establish an overhaul line; develop an Overhaul Instructions Manual, successfully overhaul the two GFE loaders in accordance with 4.2 and 4.3, and obtain Government acceptance of both loaders within 23 months; 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.

The Contractor shall perform all tasks necessary to prepare for successful transfer of overhaul responsibility at 24 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 690 (+7) days (review start date) after contract award of the Contractor’s readiness to accept low-rate and full-rate overhaul responsibility 24 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, 365 (+7 days), and 540 (+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; the Contractor shall demonstrate implementation of processes to comply with the requirements; and, Contractor shall demonstrate establishment of employee training for the processes; 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- development of unique manufacturing instructions, 5- development of the Overhaul Instructions Manual from the manufacturing instructions, 6- preparation for low-rate overhaul start-up, 7- planning for full-rate overhaul, 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 and full-rate overhaul after 730 days (or 24 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 (Prime Item Development Specification (MP-SP-006. Rev 008), Halvorsen Finish Specification, Halvorsen OSS&E Execution Plan, Halvorsen CMP, and the Halvorsen Overhaul Instructions Manual). The Contractor shall be responsible for proactively identifying and resolving overhaul issues/deficiencies to support the overhaul line, support the Halvorsen performance requirements, and to maintain the OSS&E baselines (section 3 of the Prime Item Development Specification (MP-SP-006, Rev 008)). The Contractor shall change processes, equipment, etc. as necessary for continuous improvement, such as efficiency gains on the overhaul line resulting in reduced labor hours. The Contractor shall ensure performance of the Halvorsens will not be degraded by any actions taken.

4.2.1 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 technical order (TO) and non-TO (NTO) repair procedures are considered approved repair procedures. For the purposes of this PWS, structural abnormality is defined as any abnormal condition of the Halvorsen structure that affects the structural integrity, e.g., bent, twisted, cracked, broken, heavily corroded, or missing structural components. Structural components are: cab shells, deck main longitudinals and cross members, chassis longitudinal rails, chassis cross-members, and scissors; 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.

4.2.2 Overhaul instructions manual. The Contractor shall develop manufacturing instructions to overhaul the Halvorsen loader. The Contractor shall develop an Overhaul Instructions (OI) Manual derived from the manufacturing instructions; the OI Manual will be used for future competitive contracts. (MIL-PRF-32216, X012)

4.2.2.1 Approval and changes process. The OI Manual shall be submitted to the Government for approval, and any changes to the OI Manual must also be approved by the Government. The Contractor’s manufacturing instructions shall always track with the Government-approved OI Manual, and vice versa, i.e., the manufacturing instructions shall not violate the OI Manual.

Changes to the OI Manual can be submitted to the Government at any time for approval, and the changes can then be collected throughout the year and inserted in the next annual OI Manual revision. The Contractor shall change the manufacturing instructions and the OI Manual as necessary for continuous improvement. The Contractor shall utilize the system review board (SRB) and Configuration Management processes to accomplish and control changes to the OI Manual. At least once a year after the initial (first) submittal of the OI Manual is approved, the OI Manual shall be updated and published, and the revision designation (or date) changed. All requested changes to the OI Manual shall be submitted as Configuration Audit Summary Reports. (DI-CMAN-81022C/T, X001)

4.2.2.2 Development. The OI Manual is the overhaul material and labor content definition document describing how to comply with all overhaul requirements of 4.2, 4.3, and Appendix B, and shall be written so that any competent manufacturer can understand and perform overhaul of Halvorsen loaders; any processes referenced in the OI Manual shall be furnished and included in the OI Manual appendices. The OI Manual shall provide step-by-step procedures for performing all functions of the overhaul to return extensively-used fielded loaders to mission-capable condition. The functions of the overhaul shall include, as a minimum, the functions described in

4.3.1 through 4.3.15. The Table of Contents for the OI Manual shall be furnished to the Government prior to submitting the initial OI Manual for approval. Illustrations shall be used to enhance the communications of the overhaul instructions. (MIL-PRF-32216, X012)

4.2.2.3 Parts disposition. The OI Manual shall disposition all parts of the Halvorsen loader by detailing which parts/assemblies shall be reworked (or repaired or overhauled), scrapped and replaced, and saved and re-used. When the OI Manual requires a part to be scrapped and 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 saved and re-used shall be inspected/tested, serviced (when applicable), scuffed, and painted. Items/parts to be overhauled or repaired that are determined by the Contractor to be beyond economical repair may be replaced. Items/parts to be overhauled or repaired that cannot shall be replaced. All high value parts (see 4.2.3 and Appendix C) replaced in the field with new parts or overhauled parts within 12 months of arriving at the Contractor’s location for overhaul shall be saved and re-used as part of the basic overhaul package provided the high value parts pass a functional checkout by the Contractor.

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

a. Missing parts, except structural components (see 4.2.1), shall be replaced as part of the basic overhaul package and need no further consideration; and

b. Contractor shall compile a list of missing parts for each Halvorsen 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 the Halvorsen Program Office personnel for information only within 10 calendar days of completing each Halvorsen incoming inspection.

4.2.2.3.2 TCTO parts. Parts identified as being time-compliance technical order (TCTO) parts installed within 12 months of arriving at the Contractor’s facility for overhaul shall be saved and reused as part of the basic overhaul package.

4.2.2.3.3 Damaged parts. 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 Halvorsen 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 Halvorsen Program Office personnel for information only within 10 calendar days of completing each Halvorsen incoming inspection; and

c. Structural abnormalities shall be handled in accordance with 4.2.1.

d. Damaged parts from corrosion shall be repaired under the basic overhaul package, excluding structural abnormality damage from corrosion which is separately addressed in 4.2.1.

4.2.2.4 Identification. All overhauled Halvorsens shall be re-identified per the Contractor’s configuration management plan developed in 4.2.4 of the PES PWS. The Contractor shall maintain IUID marking requirements during overhaul per the Contractor’s IUID plan developed in 4.2.5 of the PES PWS. The Contractor shall report to the national registry as required.

4.2.2.5 As-maintained list. The Contractor shall maintain the as-maintained list (AML) for each Halvorsen during overhaul. The AML shall be placed in electronic form (Microsoft Access database or Microsoft Excel spreadsheets) on the Contractor’s website for download by Halvorsen Program Office personnel.

4.2.3 High value parts. The high value parts are defined as the parts list in Appendix C.

4.3 Basic overhaul. The Contractor shall overhaul the GFE Halvorsens in accordance with the latest approved revision of the OI Manual (see 4.2.2). 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. The requirements by function are stated below:

4.3.1 Vehicle receipt. The Contractor shall arrange for receipt of inbound shipments, including off-loading the Halvorsens upon arrival. The Government will deliver the GFP Halvorsens to the Contractor’s location. The Contractor shall clean the vehicles and remove loose items as appropriate.

4.3.2 Incoming inspection. The Contractor shall perform a receiving (incoming) inspection and functional test for each loader delivered to them from the Government for overhaul to record the general state of the vehicles, and specifically any damage to the vehicles and any missing parts of the vehicles. Any suspected shipping damage should be addressed with the shipping company. The Contractor shall identify to the Government any issues, or concerns that affect the Contractor’s ability to complete the tasks of this PWS. The incoming inspection and functional test shall be conducted with the Government quality assurance representative (QAR) present.

The Contractor shall develop an incoming inspection and functional test checklist template to document the state of the vehicles. Contractor shall store the completed incoming inspection and functional test checklist for each loader overhauled 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 Halvorsen Program Office personnel for information only within 10 calendar days of completing each Halvorsen incoming inspection and functional test.

4.3.3 Disassembly. The Contractor shall disassemble the loaders per Appendix B, and reclaim all fluids.

4.3.4 Repair. The Contractor shall perform all necessary repairs per Appendix B.

4.3.5 Replacement. The Contractor shall replace parts as necessary per Appendix B.

4.3.6 Refurbishment. The Contractor shall refurbish and overhaul parts as necessary per Appendix B.

4.3.7 Unique identification. The loader and any of its components for which the Government’s unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. UID information shall be included as both a bar code and human readable markings.

4.3.8 Finish coating. The entire loader shall be finished such that when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the loader, shall not deteriorate to the extent that prevents the loader from performing its mission (see 3.6 of Appendix B).

4.3.9 TCTOs. Any Halvorsen provided for overhaul by the Government not in full compliance with Halvorsen TCTOs shall be corrected to be in full compliance; service bulletins are excluded.

4.3.10 In-process testing. Any testing required during the overhaul process to ensure that a good quality output is achieved shall be accomplished.

4.3.11 Assembly. The Contractor shall assemble the loader as necessary per Appendix B.

4.3.12 Post-overhaul inspection. All overhauled loaders shall be inspected per Appendix B (paragraph 4.7.1) using a post-overhaul inspection checklist. During post-overhaul test and post-overhaul inspection, deficiencies or failures shall be recorded as Test Discrepancy Reports (TDRs). Any TDRs recorded during post-overhaul inspection shall be corrected prior to accomplishment of post-overhaul test. (DI-NDTI-80809B/T, X005)

4.3.13 Post-overhaul test and adhesion tape test. All overhauled loaders shall be tested per Appendix B (Sections 4 and 5), and a test report provided for each loader. The burn-in verification for each loader requires approximately 150 hours of operation for overhaul qualification, approximately 75 hours for low-rate overhauls, and approximately 50 hours for full-rate overhauls. Any TDRs recorded during post-overhaul test shall be corrected prior to acceptance of loader; minor cosmetic conditions such as dents (less than 0.5 inches at it widest point and less than 0.125 inches deep and no signs of tearing or creased metal) and scratches (less than 1 inch in length and the base material is not exposed) that do not affect the operation or safety of the vehicle, shall be acceptable. (DI-NDTI-80809B/T, X005)

4.3.14 Storage and security. The Contractor shall store the loaders at the Contractor’s facility during pre- and post-overhaul periods. Loaders shall be stored in such a manner as to give reasonable protection against rust, corrosion, other damage, and theft while at the Contractor’s facility.

4.3.15 Packaging and shipping. The Contractor shall pack and prepare each loader for return shipment to the Government to include reconfiguration to air or surface transport mode, if necessary, preparation of required shipping documents, and installation of active radio-frequency identification (RFID) tags for tracking purposes for outside continental United States (OCONUS) shipments. Loaders shall be prepared for shipment in accordance with TO 36-1-191 and the applicable Halvorsen TOs. The Contractor shall load each overhauled Halvorsen onto Government-provided transportation after all overhaul related activities are completed and approved by the Government.

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, Policy and Procedures for Determining Workforce Mix and DFARS 237.76, Continuation of Essential Contractor Services.

4.6 Inspection of services clause. The Federal Acquisition Regulation (FAR) 52.246-4, Inspection of Supplies—Fixed-Price, gives the Government the right to inspect Contractor Performance.

4.7 Safety requirements.

4.7.1 Contractor compliance. Contractors shall comply with Occupational Safety and Health Act (OSHA) Public Law 91-596, OSHA Standard 29 CFR 1910, and OSHA Standard 29 CFR 1926 for the protection of their employees. To ensure the protection of Air Force personnel, assets and interests, the Contractor shall be solely responsible for compliance with all federal, state and local laws, codes, ordinances, regulations, the Occupational, Safety and Health Act (Public Law 91-596) and the resulting OSHA Standards 29 CFR 1910 and OSHA Standards 29 CFR 1926, all Air Force Occupational Safety and Health (AFOSH) Standards, and any applicable local guidance. The Contractor shall establish and maintain a safety and health program detailed in a written Contractor’s Safety and Health Plan. The Air Force is part of the OSHA Voluntary Protection Program (VPP). All shall familiarize themselves with the requirements of VPP.

Information on the VPP can be accessed at http://www.osha.gov/dcsp/vpp/index.html.

Additionally, the Contractor is responsible for the safety and health of all subcontractor employees.

4.7.2 Mishap notification. The Contractor shall telephonically notify the Safety office within four (4) hours of all mishaps or incidents to DoD property entrusted by this contract operation.

No more than one instance of late mishap notification per calendar year is acceptable. Follow all other reporting requirements as identified on the DD1423, X015, for Accident/Incident Report (Mishap Notification & Reporting). (DI-SAFT-81563, X015)

4.7.3 Mishap investigation. If requested by the Government Procuring Contracting Officer (PCO) or Administrative Contracting Officer (ACO), the Contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenances and training records until released by the investigating safety office. If the government investigates the mishap, the Contractor and the subcontractors shall cooperate fully and assist the government personnel until the investigation is completed.

4.8 Item unique identification (IUID). The Contractor shall develop an IUID marking plan detailing the strategy to execute the marking requirements. The loader and any of its components for which the Government’s unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. IUID information shall be included as both a bar code and human readable markings. The Contractor shall change the IUID marking plan and associated processes as necessary for continuous improvement. (DI-MGMT- 81803/T, X013)

4.9 Procedure for invoicing/payment/acceptance. The multi-functional team (MFT) can request that data items be attached to acceptance forms through Wide Area Work Flow (WAWF) or submitted to government personnel as spelled out in the data Contract Data Requirements List (CDRL). To allow for payment of separately priced data items, the MFT must use WAWF for acceptance. Data CDRL will determine submittal requirements; however, both separately priced and non-separately priced items must be accepted in WAWF in order for the line item to be closed out in the contract. Information regarding Wide Area Work Flow-Receipt and Acceptance is available on the Internet at https://wawf.ef.mil.

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

PUBLICATION

SECTIONS

APPLY

DATE OF

PUBS

TITLE OF PUBLICATION

MIL‐STD‐130N All 17 Dec 07 Identification Marking of U.S. Military Property

MP‐SP‐006, Rev 008 All 30 Nov 2011 Prime Item Development Specification (PIDS) Halvorsen

Appendix B: HALVORSEN OVERHAUL TASKS

1 GENERAL

1.1 Information:

1.1.1 Maintenance requirements shall include the following: Operation, disassembly, inspection, cleaning, adjustments, repair/overhaul, part(s) replacement, fabrication of part(s), and test, as applicable, of Halvorsen loaders authorized for overhaul.

1.1.2 Original design or functional capabilities of the Halvorsen loaders and parts thereof shall not be changed unless such changes are authorized by the Government Procuring Contracting Officer (PCO) or directed by the requirements of this document.

1.1.3 Parts repaired, replaced, or reused and all work performed shall be subject to Government inspection and approval.

1.1.4 Visits: Assistance visits will be made by the ACO and/or WR-ALC contracting, engineering, or program management personnel when such visits are considered necessary, particularly in relation to production schedules. Observation visits may be made by user MAJCOM personnel occasionally with prior notice to Contractor.

1.1.5 Materials: Materials used shall be free from defects which would adversely affect the performance or maintainability of individual components or of the overall assembly.

Materials not specified herein shall be of the same quality used for the intended purpose in commercial practice. Unless otherwise specified herein, all equipment, material, and articles incorporated in the work covered by this document are to be new and fabricated using materials produced from recovered materials to the maximum extent possible without jeopardizing the intended use. The term "recovered materials" means materials which have been collected or recovered from solid waste and reprocessed to become a source of raw materials as opposed to virgin raw materials.

1.1.5.1 Dissimilar Metals: During re-assembly, no metals shall be assembled in direct contact with dissimilar metals unless suitable protection against galvanic corrosion is applied. Dissimilar metals are defined by MIL-STD-889, Dissimilar Metals.

1.1.6 Nondestructive Inspections: Nondestructive inspections shall be performed by personnel certified to NAS 410, Certification and Qualification of Nondestructive Test Personnel.

Magnetic particle inspection of magnetizable parts shall be performed in accordance with TO 33B-1-1, Nondestructive Inspection Methods, Basic Theory. Fluorescent penetrant inspection of nonmagnetizable parts shall be performed in accordance with TO 33B-1-1.

1.1.7 General guidance for corrosion prevention and control can be found in TO 36-1-191.

1.2 Terms Explained:

For the purpose of this document, the terms used herein are defined as follows:

1.2.1 Administrative Contracting Officer (ACO): The individual responsible for overall administration of the contract.

1.2.2 End Item: A recoverable article of equipment used by the Government. In the context of this document, usually refers to the Halvorsen Loader.

1.2.3 Major Assembly: An assembly of component parts essential to the operation of the end item; for example, engine, rear axle assembly, transmission.

1.2.4 Component: 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 that end item.

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

1.2.6 Overhaul: The disassembly, cleaning, inspection, repair or replacement of parts or components, reassembly, and test of an item or accessory IAW applicable technical orders, directives, or authorized manufacturer's publication to provide an operationally safe, serviceable, and reliable item.

1.2.7 Repair: The restoration or replacement of parts or components of material as necessitated by wear and tear, damage, or failure of parts, in order to maintain the specific item of material in efficient operating condition.

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

1.2.9 Test: Operation of an item to determine its capability to perform the function for which it was designed as stated in applicable technical order.

1.2.10 Serviceable: An item capable of meeting the requirement and performing the function for which designed or modified and meets all test requirements established by this document.

1.2.11 Excessively Worn: Worn beyond serviceable limits and therefore subject to parts failure.

Excessive wear of mating parts or linkage connections is usually evidenced by too much play (lash or lost motion).

1.2.12 Technical Publication: Means the Government Technical Order or Commercial Publication, as applicable, containing detailed information on technical procedures, including instructions on the operations, and information on Government vehicles including mounted equipment.

1.2.13 Deteriorated: The degeneration or decline in the condition, appearance, performance, or serviceability of any item from that required, as to render that item unfit for further use.

1.2.14 Sub-Assembly: A portion of an assembly consisting of two or more parts assembled together to form a sub-assembly, e.g., an end frame of a generator consisting of multiple parts, brushes, springs and bearing assembled on the end frame would be a sub-assembly.

1.2.15 Engine: The complete basic engine as listed in the applicable TOs in section 6.

1.2.16 Engine Accessories: All external items contained in the fuel, ignition, starting, battery charging, air compressor, and control systems that are normally removed for rework or replaced without disassembly of the engine.

1.2.17 Engine Accessory Parts: All assemblies, sub-assemblies or components, and detail parts pertinent to engine accessories.

1.2.18 Defective: The absence of any characteristic essential to the complete function, appearance, performance, or serviceability of any item, as to render that item unfit for its intended purpose.

1.2.19 Procuring Contracting Officer (PCO): The individual authorized to enter into contracts for supplies and services on behalf of the Government.

1.2.20 Structural Abnormality: Any structural condition, except normal wear, weld defects/cracks, and missing/displaced parts, that departs from the technical order configuration as established by the engineering drawings, e.g., structural failures, deformation, parent metal cracks, or repair. Corrosion damage is not considered to be structural abnormality unless the structure is damaged beyond 15% of the depth of the metal. Structure: The frame members associated with the chassis, scissors, and deck that are used as the support for the other items.

1.2.21 Commercial: A manufacturer's standard (product), having been marketed, in production and sold in substantial quantities to the general public for a minimum of one year prior to the date of invitation for bid or request for proposal.

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

1.2.23 Parts: Essential elements, components, or sub-assemblies of an item.

1.2.24 Essential Repair: The accomplishment of the corrective maintenance necessary to restore the items to a serviceable condition.

1.2.25 In-Process Inspection: An inspection performed during the assembly of an end item or its components at those stages when further assembly would prevent inspection for compliance with applicable T.O.s.

1.2.26 Item Identification: The means by which, with the use of the USAF Technical Orders, Federal Supply Catalogs, manufacturer's drawings, or Air Force Specifications, or other applicable drawings, specifications, or parts of catalogs, an item may be recognized and associated with its next major assembly.

1.2.27 Like New: A used part or accessory which by inspection and/or test can be expected to provide performance essentially equal to a new like item.

1.2.28 Nondestructive Inspection (NDI): Methods for investigating the quality, integrity, properties, and dimensions of material and components without damaging or impairing their serviceability.

1.2.29 Operational Check: A functional test of an accessory or component accomplished in a condition similar to its installed environment to ensure its designed operation.

1.2.30 Product Audit: An inspection and evaluation of a repaired item for the purpose of Government verification that all work directed fully complies with contractual requirements.

1.2.31 Quality Control Deficiency (QCD): A deficiency attributable to sub-standard workmanship, errors, or non-conformance to technical requirements.

1.2.32 Reclamation: The process of disassembly of end items to recover serviceable or economically repairable spare parts.

1.2.33 Usual and Customary: Those parts and/or services which are normally provided by firms accomplishing overhauls primarily for commercial customers.

1.2.34 Non-Standard Part: A part which is not listed in the vehicle specification/data package or is not an approved alternate part.

1.2.35 Standard General Practice: A Contractor's established common, routine business practice.

1.2.36 Reliability:

(1) The duration of failure-free performance under stated conditions.

(2) The probability that an item can perform its intended function for a specified interval under stated conditions.

1.3 Data:

1.3.1 Maintenance Records: No special forms are required to be maintained by the maintenance facility except for those directed by this document.

1.3.2 Reporting Requirements: Reports shall be submitted as listed on DD Form 1423.

1.3.3 Production Management System: The Contractor shall establish, implement, and maintain a production management system. In addition, the Contractor shall maintain an effective, timely, and responsive manufacturing surveillance system. This system shall permit determination and documentation of manufacturing milestones and time phase of components and assemblies (in house and subcontracted) required to meet program milestones, contractual performance, and delivery schedule.

1.3.4 Technical Data:

1.3.4.1 The removal, disassembly, inspection, cleaning, repair, part(s) replacement, fabrication of part(s), reinstallation of components and equipment, adjustments, and tests shall conform to the basic maintenance instruction manual and other applicable T.O.s listed in Section 6 of this document.

NOTE: The standard for efficient, proper, non-defective, normal, correct and otherwise satisfactory condition and functioning required after overhaul is that specified explicitly either in the text of this document and/or in applicable TO's and other data referenced in Section 6. Whenever detailed criteria are not provided in this document or in references of Section 6, performance shall be IAW standard commercial practices.

1.3.4.2 Torque, wear, fits, tolerances, pressures, and adjustments shall be within the limits specified in the applicable publications listed in Section 6. No parts or assemblies shall be used in this overhaul that will result in downgrading the capability of the item being overhauled.

1.4 Security: Unclassified.

1.5 Quality:

1.5.1 The Contractor's inspection system shall be established and maintained in accordance with contract terms and conditions. This system shall be developed and available for cognizant Government Quality Assurance Representative (QAR) review prior to beginning production.

1.5.2 The inspection system shall include a clear and complete set of work documents (workbook logs) for all maintenance required which shall assure specific and uniform step-by-step directions for accomplishing work accurately, economically, and safely.

Documents shall specify component removals, inspections, and reinstallations which affect quality and shall include caution and warning notes where failure to follow prescribed notes could result in damage to Air Force property or injury to personnel.

Removal and reinstallation of items (including lines, fittings, components) when required to gain access to another component shall be listed as separate entries on the work document. Quantitative criteria (dimensions and tolerances) shall be included in the work document. The document shall also include criteria essential for determining the acceptability of work performed. Work documents shall be maintained and reviewed regularly for accuracy, completeness and compliance. Revisions shall be written when necessary to prevent recurring deficiencies. Corrective/preventative actions shall extend to the performance of all supplies and shall be responsive to deficiency reports forwarded from the users through the ACO.

1.5.3 Fastener Quality Assurance: Contractor shall comply with the Fastener Quality Assurance Requirements of Air Force Drawing 8838302 for all Fasteners used in the course of this contract.

1.6 Disposal:

1.6.1 Disposal of scrap material, including irreparable tires, shall be in accordance with the Plant Clearance Officer.

2 GENERAL WORK REQUIREMENTS

2.1 Instructions

2.1.1 All work shall be IAW technical orders listed in Section 6 and instructions outlined in this document.