FY19_SETSS_PWS_19-WLSE-01.pdf

PWS 19-WLSE-01

PR: FD2060-19-30001 PWS Revision: 0

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Performance-Based Work Statement (PWS) 19-WLSE-01

For

FY19 C-5 Sustaining Engineering and Technical Support Services (SETSS)

Purchase Request #: FD2060-19-30001

Date: 21 September 2017

AFLCMC/WLS

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative or Operational Use) (12 July

2017). Other requests shall be referred to the C-5 Galaxy Contract Management Team, AFLCMC/WLS, 235 Byron Street, Suite 19A, Robins AFB, GA 31098-1670.

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Contents

1.0 DESCRIPTION OF ENGINEERING SERVICES

1.1 OBJECTIVES

1.2 BENEFIT TO UNITED STATES AIR FORCE (USAF)

2.0 SERVICES SUMMARY

2.1 OVERARCHING OBJECTIVES

2.2 ADDITIONAL PROGRAM-SPECIFIC OBJECTIVES

2.3 MSS

3.0 GOVERNMENT-FURNISHED PROPERTY (GFP), GOVERNMENT FURNISHED SERVICES AND

ACCESS TO GOVERNMENT SYSTEMS

3.1 FACILITIES AND AIRCRAFT

3.2 COMPONENTS AND SYSTEMS

3.3 MATERIALS AND EQUIPMENT

3.4 BASE SUPPORT

3.5 GOVERNMENT INFORMATION SYSTEMS ACCESS AND DATA

4.0 ENGINEERING AND TECHNICAL SERVICES

4.1 PERIOD AND PLACE OF PERFORMANCE

4.2 CONTRACT DATA REQUIREMENTS LIST(S) (CDRL)

4.3 ASIP

4.4 ASIP DATA INTEGRATION

4.5 ASIP MODERNIZATION

4.6 FSIP

4.7 CPCP

4.8 TDS SUPPORT

4.9 MSS

4.10 DIP TECHNICAL TASKINGS

4.11 CERTIFICATION SUPPORT

4.12 SYSTEM SAFETY PROGRAM

4.13 PROGRAM MANAGEMENT

4.14 TECHNICAL DATA

4.15 DRAWINGS AND MODELS

4.16 TRAVEL

4.17 HOLIDAYS AND FACILITY CLOSINGS

5.0 GENERAL INFORMATION

5.1 CONTINUATION OF MISSION ESSENTIAL SERVICES DURING CRISIS

5.2 SECURITY REQUIREMENTS

5.3 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

5.4 AFFIRMATIVE PROCUREMENT PROGRAMS (APP)

5.5 SAFETY REQUIREMENTS

5.6 INSPECTION OF SERVICES

5.7 CONTRACTOR MANPOWER REPORTING REQUIREMENTS

5.8 INVOICING/PAYMENT AND RECEIPT/ACCEPTANCE

5.9 TRAFFICKING IN PERSONS

6.0 APPENDICES

6.1 APPENDIX A: ACRONYMS

6.2 APPENDIX B: APPLICABLE DOCUMENTS

6.3 APPENDIX C: FATIGUE TEST ARTICLE COMPONENTS AND SECTIONS

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Revision Sheet

REV Date Pages Affected

Description

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FY19 C-5 Sustaining Engineering and Technical Support Services (SETSS)

1.0 DESCRIPTION OF ENGINEERING SERVICES

1.1 OBJECTIVES

This PWS describes services required to provide Sustaining Engineering and Technical Support services in support of the C-5 aircraft. These services include, but are not limited to, performing engineering investigations and analyses, formulating deficiency resolution concepts and designing proof of concepts. Areas to receive engineering support within this PWS include, but are not limited to: the Aircraft Structural Integrity Program (ASIP), the Functional Systems Integrity Program (FSIP), the Corrosion Prevention and Control Program (CPCP), the Deficiency Investigation Program (DIP), Technical Data Sustainment (TDS) Support, and Modernization Sustainment Services (MSS). MSS includes support of systems, components and analysis in support of C-5 major modifications. ASIP and CPCP are mandatory In Accordance With (IAW) and shall meet the intent of requirements established in MIL-STD-1530D, Aircraft Structural Integrity Program. FSIP is mandatory IAW and shall meet the intent of requirements established in MIL-STD-1798C, Mechanical Equipment and Subsystems Integrity Program.

1.2 BENEFIT TO UNITED STATES AIR FORCE (USAF)

These services will benefit the USAF by continuing to maintain the operational life cycle readiness and ensure the safety of the C-5 fleet. This will support keeping the C-5 fleet on time and on mission in accordance with the core USAF competencies of Rapid Global Mobility and Agile Combat Support.

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2.0 SERVICES SUMMARY

2.1 OVERARCHING OBJECTIVES

Performance Objective

Reference Paragraphs

Performance Threshold

Quality of Technical Data/Documents via CDRLs

4.2.2

There shall be no more than one (1) rejection of any deliverable.

The Government will reject a deliverable for technical error, including accuracy, completeness, and/or noncompliance with formatting requirements IAW the contract.

Receipt of Technical Data/Documents via CDRLs

4.2.1

There shall be no more than one (1) late submission of data/document(s) IAW the CDRLs per quarter and four (4) late submissions per year on a task order basis. The Contractor shall notify the PCO/COR if the delivery of any data/document will not meet the required delivery date and negotiate a revised date for delivery approved by the PCO/COR.

Contractor Manpower Reporting

5.7

Within 30 calendar days of contract/order award, the Contractor shall establish a record for the contract/order in eCMRA including Order Data, Contact Data and Location Data.

The Contractor shall provide a count of contractor/subcontractor personnel performing services for each fiscal year and report all contractor/subcontractor labor hours required for performance of services for each fiscal year. All data shall be reported no later than October 31 of the following fiscal year.

2.2 ADDITIONAL PROGRAM-SPECIFIC OBJECTIVES

2.2.1 FSIP

Performance Objective

Reference Paragraphs

Performance Threshold

Engineering solution(s) for Rapid Response Taskings

4.6.6.2.1

Initial plan for assessing the task shall be submitted within 24 hours of PCO phone or email tasking and contractor acknowledgement.

Final plan for assessing the task shall be submitted within 48 hours of PCO formal written tasking. The Contractor’s final assessment plan shall be submitted and accepted by COR with no more than one revision per submission.

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2.2.2 MSS

Performance Objective

Reference Paragraphs

Performance Threshold

Deficiency Report (DR) investigations 4.9.1

For investigations conducted under section 4.9.1 during the period of performance, identify root cause IAW TO 00-35D-54.

Provide initial response to DR investigations as an interim report within the following time periods after Contractor is assigned DR and is notified by JDRS:

CAT I: 20 clock hours CAT II: 7 calendar days

Provide final resolution response or resolution plan, including new Estimated Completion Date (ECD), as an interim report with a notification to the COR within the following time periods:

CAT I: 45 calendar days CAT II: 100 calendar days COR requested corrective action to interim report shall be completed within 48 hours.

DRs in open status which have been referred to the Contractor shall be updated with an interim report every 80 calendar days with a notification to the COR, with the exception of DRs in open awaiting funds status. COR requested corrective action to interim report shall be completed within 48 hours. DRs in open awaiting funds status shall be updated every 350 calendar days.

Responses for all categories shall meet the requirement 100% of the time.

3.0 GOVERNMENT-FURNISHED PROPERTY (GFP), GOVERNMENT FURNISHED

SERVICES AND ACCESS TO GOVERNMENT SYSTEMS

3.1 FACILITIES AND AIRCRAFT

Warner Robins Air Logistics Complex (WR-ALC), C-5 Galaxy Division (AFLCMC/WLS) will provide access to Government facilities and aircraft as required in order for the Contractor to perform various tasks. Aircraft will be made available based on fleet requirements and with the approval of Air Mobility Command (AMC), Air Force Reserve Command (AFRC) and AFLCMC/WLSE.

3.2 COMPONENTS AND SYSTEMS

AFLCMC/WLS will provide access to off aircraft components as required in order to support activities outlined in this PWS to include reasonable access on a noninterference basis to discuss issues with repair technicians. Availability of parts shall be subject to C-5 fleet requirements and the approval of the responsible organization at WR-ALC, Oklahoma City Air Logistics Complex (OC-ALC), Ogden Air Logistics Complex (OO-ALC) and any other Government agency. Any aircraft components or

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other materials within the supply chain that are provided outside of a Government facility for activities outlined in this PWS shall utilize shipping containers which meet the requirements of the AFMC Form 158, Packaging Requirements, and which shall be in accordance with MIL-STD-2073-1E, Standard Practice for Military Packaging, and/or MIL-STD-129R, Military Marking for Shipment and Storage.

Shipping containers which meet the requirements of the AFMC Form 158 and are suitable for return of serviceable assets shall be reclaimed and stored for reuse. Unsuitable shipping containers shall be disposed of and replaced with new containers that meet the requirements of the AFMC Form 158.

3.3 MATERIALS AND EQUIPMENT

3.3.1 All Government property, including equipment, furnished during the life span of this effort will be documented upon receipt and upon turn-in to the appropriate Government representative(s), except for items consumed during the performance of this PWS. The Government will retain ownership of all provided property, including equipment. The Contractor may be required to purchase/lease materials and equipment for successful completion of this task. The Contractor shall obtain prior approval from the AFLCMC/WLSK Procuring Contracting Officer (PCO) for purchasing/leasing materials and equipment.

3.3.2 A listing of all special tooling bought or made by the Contractor and charged to the Government under this contract shall be provided to the Government. GFP shall be accounted for in the Consolidated Government Furnished Property (CGFP) listing attached to contract in accordance with FAR and applicable supplements. At the conclusion of the task order/contract or as directed by the PCO, GFP and Government Furnished Equipment (GFE) shall be returned to the Government in the condition provided unless previously approved by the PCO less normal wear and tear.

3.3.3 Reporting Loss of Government Property: The Contractor shall use the Defense Contract Management Agency (DCMA) eTools software application to report loss of Government property at the site below IAW and applicable supplements and shall be in compliance with all applicable guidance and clauses listed in the contract. DFARS 252.245-7002 defines “Loss of Government property” as “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.” The reporting requirement does not change any liability provisions or other reporting requirements that may exist under the contract/order. http://www.dcma.mil/aboutetools.cfm

3.3.4 All property provided by the Government remains the property of the Government and shall be returned to the Government upon completion of the contract/order unless the PCO directs the Contractor to retain the property for continued use under a successor contract. Retention of the property by the Contractor will require modification of both losing and gaining contracts in accordance with the FAR and applicable supplements and shall be in compliance with all applicable guidance and clauses listed in the contract. All Government property shall be returned to the http://farsite.hill.af.mil/vfdfara.htmhttp:/farsite.hill.af.mil/reghtml/regs/far2afmcfars/fardfars/dfars/dfars252_237.htm#P1507_110585 http://www.dcma.mil/aboutetools.cfm

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Government in the condition provided unless approved in advance by the PCO.

3.4 BASE SUPPORT

For the Contractor’s personnel to complete some tasks, AFLCMC/WLSE will provide facilities to support up to eight (8) Contractor personnel (to include subcontractors) required to be collocated at Robins Air Force Base (RAFB) at any one time. AFLCMC/WLSE will provide office space, desks, chairs, telephones and access to copying machines at RAFB. Computers and monitors will be provided by AFLCMC/WLSE; however, shredders, fax and any other office supplies will not be provided by the Government.

3.5 GOVERNMENT INFORMATION SYSTEMS ACCESS AND DATA

3.5.1 The Government will provide Contractor personnel access to systems required to perform tasks under the contract/order subject to approval of Department of Defense (DD) Forms 2875, System Authorization Access Request (SAAR). Upon completion of the contract/order or transfer/termination of Contractor personnel, applicable system accounts will be closed.

3.5.2 AFLCMC/WLSE will provide applicable engineering reports, technical orders, historical data, and engineering drawings. The Government shall provide access to data collected by Government Data Systems and archived in the C-5. Any data collected by the Contractor under this contract is the sole property of the Government. As necessary, the Contractor shall utilize and collect and collate data from the following systems, including but not limited to:

• 107 Database (Field Initiated Engineering Assistance Request)

• 202 Database (PDM Initiated Engineering Assistance Request)

• A400 (Joint-Reliability Availability Management System (J-RAMS))

• AFIRM (Aging Fleet Integrity and Reliability Management)

• AIDE (Aircraft Integrated Data Environment)

• CAVAF (Commercial Asset Visibility Air Force) Reporting system

• DART (Data Analysis and Redistribution Tool

• EDS (Embedded Diagnostics System)

• G081 (Core Automated Maintenance System (CAMS)for Mobility)

• G099 (Reliability and Maintainability Information System(REMIS))

• GCSS-AF (Global Combat Support System-Air Force)

• GDSS 2 (Global Decision Support System 2)

• GIDEP (Government – Industry Data Exchange Program)

• JDRS (Joint Deficiency Reporting System)

• JEDMICS (Joint Engineering Data Management Information and Control System)

• LIMS-EV (Logistics Installations and Mission Support – Enterprise View)

• MEARS (Multi-user Engineering Change Proposal (ECP) Automated Review System)

• PDMSS (Program Depot Maintenance Support System)

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• SBSS (Standard Base Supply System)

• Team Center (C-5 Workflow)

• WAWF (Wide Area Work Flow)

• Wholesale and Retail Supply Systems

3.5.3 Secure Internet Protocol Router Network (SIPRNET)

Access to SIPRNet is authorized. The Contractor shall be responsible for setting up the enclave, securing facilities, equipment and qualified/cleared personnel to host, obtain certification and accreditation, and sustain Government provided SIPRNet interface/access at no cost to the Government. The Government is responsible for providing the circuit subscription and circuit Computer Network Defense Service Provider (CNDSP) monitoring services. The Contractor shall use the Defense Information System Agency (DISA) Defense Information System Network (DISN) Connection Process Guide (CPG), Version 5.1, dated September 2016, or most current version, to obtain certification and accreditation of SIPRNet capabilities and follow DISA IA standards to maintain accreditation. Contractor provided sustainment shall include providing continuous oversight, managing software and hardware systems (to include topology updates) and achieving required accreditation/reaccreditation requirements.

4.0 ENGINEERING AND TECHNICAL SERVICES

4.1 PERIOD AND PLACE OF PERFORMANCE

4.1.1 Contract Period of Performance

The ordering period for this contract will extend over 5 years and 6 months. The basic ordering period will be 12 months after receipt of order. There will be four optional ordering periods which are 12 months each following the basic ordering period and a 6 month option to extend services.

4.1.2 Place of Performance

These services shall be performed at a combination of U.S. Government installations, as necessary (including RAFB), and at the Contractor’s facility.

4.2 CONTRACT DATA REQUIREMENTS LIST(S) (CDRL)

Data Item # DID Title Program Data A001 DI-MGMT-80368A/T Status Report A002 DI-ADMN-81249B Conference Agenda A003 DI-ADMN-81250B Conference Minutes A004 DI-MGMT-81605 Briefing Material A005 DI-ADMN-81401B Contract Change Proposals (CCPs) A006 DI-MISC-80748/T Engineering Services Memorandum (ESM) A007 DI-MGMT-81797/T Program Management Plan Drawings and Models

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B001 DI-SESS-81000E/T Product Drawings/Models and Associated Lists B002 DI-SESS-81000E/T Product Drawings/Models and Associated Lists B003 DI-GDRQ-81256B Mathematical Model Finite Element Structure Report B004 DI-GDRQ-81257A/T Mathematical Model Finite Element Analysis Report B005 DI-GDRQ-80650 Design Data and Calculations Technical C001 DI-MISC-80711A Scientific and Technical Reports C002 DI-MISC-80711A/T Scientific and Technical Reports - ASIP Master Plan C003 DI-MISC-80711A/T Scientific and Technical Reports - Final Report C004 DI-IPSC-81756 Software Documentation C005 DI-MISC-80711A/T Scientific and Technical Reports - Historical C006 DI-NDTI-80566A Test Plan C007 DI-NDTI-80603A Test Procedures C008 DI-NDTI-80809B Test/Inspection Report C009 DI-MGMT-81453B Data Accession List C00A DI-PSSS-81656B Bill of Materials (BOM) for Logistics and Supply Chain

Risk Management C00B DI-TMSS-81354 Technical Manual Research and Analysis Source Data C00C DI-MISC-81241 Airworthiness Directives/Service Bulletins/Advisory Data Safety D001 DI-SAFT-80101C System Safety Hazard Analysis Report (SSHAR) D002 DI-SAFT-80102C Safety Assessment Report (SAR)

4.2.1 There shall be no more than one (1) late submission of data/document(s) IAW the CDRLs per quarter and four (4) late submissions per year on a task order basis. The Contractor shall notify the PCO/Contracting Officer’s Representative (COR) if the delivery of any data/document will not meet the required delivery date and negotiate a revised date for delivery approved by the PCO/COR.

4.2.2 There shall be no more than one (1) rejection of any deliverable. The Government will reject a deliverable for technical error, including accuracy, completeness, and/or noncompliance with formatting requirements IAW the contract.

4.2.3 The Contractor shall electronically submit all CDRL deliverables through MEARS, with exceptions as noted in CDRLs or as directed by the PCO/COR. The Contractor shall utilize MEARS to set up, prepare, maintain, and track contract data status and ensure timely data deliveries. The Contractor shall work with the government to ensure that an adequate number of Contractor personnel obtain and possess Public Key Infrastructure (PKI) certification from an accepted Government source. MEARS classroom training will be made available to Contractor personnel upon request.

4.3 ASIP

The Contractor shall perform ASIP to maintain the structural integrity of the C-5 aircraft and manage the economic life cycle costs. These efforts shall meet the intent of the most recent revision of MIL- STD-1530D, Aircraft Structural Integrity Program, and JSSG-2006, Aircraft Structure. Tasks

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involved include, but are not limited to, structural analysis, maintaining and updating the Force Structural Maintenance Plan (FSMP) and Durability and Damage Tolerance Analysis (DADTA). To accomplish these functions requires the Contractor to perform static, fail-safe, linear and non-linear finite element, residual strength, probabilistic risk, and DADTA.

4.3.1 FSMP

4.3.1.1 The Contractor shall maintain the currency of the FSMP for the C-5 fleet. The updated plan shall be in accordance with the guidance in MIL-STD-1530D, and JSSG-2006. The FSMP shall provide a comprehensive evaluation of the structural requirements versus existing/ongoing inspections, procedures and operational usage. Additional analysis may be required to ensure optimal inspection intervals.

4.3.1.2 The Contractor shall maintain the FSMP to identify inspection, repair and modification requirements including criteria, schedules and procedures for use at field or depot levels. The FSMP shall contain recommendations concerning the life of critical parts, inspection methods and procedures required to maintain safety, inspection intervals and the rationale behind them and recommended modifications or replacements. The FSMP shall be updated by the contractor no later than 30 calendar days, or a mutually agreed completion date, after a proposed change is approved by

COR.

4.3.1.3 As structural issues arise, the Contractor shall support the ASIP manager by performing detailed linear and non-linear finite element analysis, and performing static, fail-safe, risk and damage tolerance analyses to determine their safety and economic impact on the fleet and suggested fleet management actions to mitigate risks. This analysis is the basis for updates to the FSMP.

Analysis shall be in accordance with MIL-STD-1530D and JSSG-2006. The FSMP shall be updated by the contractor no later than 30 calendar days, or a mutually agreed completion date, after a proposed change is approved by COR.

4.3.1.4 The Contractor shall support programs such as the C-5 Non-Destructive Inspection (NDI) program as directed by the ASIP Manager.

4.3.1.5 The Contractor shall support the ASIP Manager as required for customized composite repairs of primary structure, including use of finite element modeling.

4.3.1.6 The Contractor shall deliver updates and changes to FSMP in a format that is exportable to the AFIRM website as new analysis is completed.

4.3.1.7 The Contractor shall submit FSMP documentation as part of the ASIP report. The FSMP shall be updated by the contractor no later than 30 calendar days, or a mutually agreed completion date, after a proposed change is approved by COR.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports; CDRL C00B, DI-TMSS-81354, Technical Manual Research and Analysis Source Data; C006, DI-NDTI-80566A, Test Plan; C007, DI- NDTI-80603A, Test Procedure; CDRL C008, DI-NDTI-80809B, Test/Inspection Report)

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4.3.2 ASIP Master Plan

4.3.2.1 The C-5 ASIP Master Plan shall be reviewed and updated, at a minimum, annually throughout the service life of the aircraft as required per MIL-STD-1530D, paragraph 5.1.1. The C-5 Master Plan shall incorporate all C-5 Mission Design Series into subject document and shall be exportable to AFIRM. The ASIP master plan shall, at a minimum, consist of the followings sections:

• Introduction (e.g. General Information, Aircraft Background, Aircraft Description, Weight and Operating Limitations)

• Summary (e.g. General Information, Analysis, Testing, Data Recording Programs, Data Recording Systems, Tracking Programs)

• ASIP Tasks A. Design Information (Task I) B. Design Analysis and Development Testing (Task II) C. Full Scale Testing (Task III) D. Certification and Force Management Development (Task IV) E. Force Management Execution (Task V)

4.3.2.2 The ASIP Master Plan shall maintain a revision history and clearly identify any changes in current documentation with past releases of the subject document. The Contractor shall submit the ASIP Master Plan (Appendices included) annually.

(CDRL C002, DI-MISC-80711A/T, Scientific and Technical Reports)

4.3.3 ASIP Scientific and Technical Reports

The Contractor shall submit individual ASIP engineering reports as requested by C-5 ASIP Manager.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.3.4 Final ASIP Report

The Contractor shall submit a final ASIP engineering report annually. Report shall document the results of all significant analyses and studies conducted during ordering period, including those conducted under ASIP Data Integration (Section 4.4), and any technical drawings generated, and contain as appendices IAT, L/ESS, FSMP and MDCS. (CDRL C003, DI-MISC-80711A/T, Scientific and Technical Reports)

4.4 ASIP DATA INTEGRATION

The Contractor shall perform ASIP to maintain the structural integrity of the C-5 aircraft and manage the economic life cycle costs. These efforts shall meet the intent of the most recent revision of MIL- STD-1530D, Aircraft Structural Integrity Program, and JSSG-2006, Aircraft Structure. Tasks involved include, but are not limited to, Individual Aircraft Tracking (IAT), Loads/Environmental Spectra Survey (L/ESS), Structural Audits and Maintenance Data Collection System (MDCS).

(CDRL C003, DI-MISC-80711A/T, Scientific and Technical Reports)

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4.4.1 Fleet Usage IAT

4.4.1.1 The Air Force will provide the Contractor all data required for IAT runs on a monthly basis.

After receipt of data, the Contractor shall perform IAT monthly for each C-5 aircraft to track aircraft usage for the purpose of establishing and adjusting inspection, maintenance and repair intervals for each critical airframe location. IAT fleet or individual aircraft data shall be in a format that is exportable to the AFIRM website. Monthly IAT runs are completed within 30 days of receipt of data.

4.4.1.2 The C-5 IAT system currently resides on the Air Force computer facility system at OC-ALC.

OC-ALC personnel are routinely operating the system. The Contractor shall provide support to OC- ALC in the operation of the IAT system as needed.

4.4.1.3 The Contractor shall utilize existing and modified IAT programs to produce coordinated output of IAT usage.

4.4.1.4 The Contractor shall review usage annually to identify and quantify fleet flying trends which may impact recommended structural inspections and fleet service life. The Contractor shall notify the ASIP manager via the most convenient means of these changes. Review shall be completed no later than 5 weeks after receipt of data for each annual period.

4.4.1.5 The Contractor shall monitor and process flight-by-flight usage data provided by the Government for completeness and accuracy and shall inform the ASIP manager and OC-ALC of erroneous data or other problems via the most convenient means. Data corrections are the responsibility of the Government. Processing of the flight-by-flight data shall consist principally of assimilating the data into representative mission profiles and determination of usage statistics by individual aircraft, force average (all Mission Design Series) and operator (AMC and AFRC).

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.4.2 L/ESS

4.4.2.1 The Contractor shall support the C-5 ASIP manager in maintaining an effective L/ESS program. L/ESS data resides in parallel at OC–ALC and at the Contractor. The Contractor shall provide engineering support to OC-ALC when needed to support L/ESS.

4.4.2.2 The Contractor shall perform L/ESS evaluations, analysis, and support to provide time history data and statistical and data trend information for other C-5 ASIP tasks (IAT, DADTA, etc.).

4.4.2.3 The Contractor shall provide information related to the L/ESS system, data, and analysis results to AFLCMC/WLSE.

4.4.2.4 The Contractor shall process the extracted L/ESS data provided by OC–ALC, perform error corrections and review of the data for reasonability, edit extracted L/ESS data, and correlate the edited data with combined usage data.

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4.4.2.5 The Contractor shall reduce processed L/ESS data, review the reduced data, and generate the final product, accumulated measured spectrum data, for engineering evaluations. The Contractor shall evaluate and interpret the analyzed data to support the ASIP program.

4.4.2.6 The Contractor shall perform monthly L/ESS processing of data provided by OC-ALC.

Processing shall be completed within 30 days after receipt of data for each month. The Contractor shall ensure that monthly L/ESS data processing actions are completed within 30 days of receipt of data.

4.4.2.7 The Contractor shall perform quarterly L/ESS data reviews to determine its quality and summarize discrepant parameters for the purpose of supporting OC-ALC maintenance analysis operations. Reviews shall be completed within 45 days after receipt of data for each quarter. The Contractor shall notify the ASIP Manager via the most convenient means of L/ESS problems encountered as part of the quarterly review. The Contractor shall ensure that quarterly L/ESS data quality reviews are completed within 45 days of receipt of data.

4.4.2.8 The Contractor shall also provide technical support to the using organizations in the diagnosis and repair of the on-board instrumentation. This support will consist of telephone consultation with maintenance personnel and, if necessary, on-site assistance in the repair of the instrumentation.

4.4.2.9 The Contractor shall update stored media information of usable L/ESS flights as additional data is available. This file is to be maintained for use in studies and evaluations which are to be conducted to support the C-5 FSMP.

4.4.2.10 The Contractor shall maintain the flight-by-flight usage data inventory on media approved by the ASIP manager. The entire inventory shall be maintained such that it may be rapidly queried and selectively extracted.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.4.3 Structural Audits

4.4.3.1 The Contractor shall perform structural audits to collect maintenance data on aircraft identified by the ASIP manager at PDM or other field level locations. These inspections shall focus only on structures. The Contractor shall perform these audits on-site at the maintenance facility. All structurally significant findings shall be recorded in a Fleet Repairs database exportable to the AFIRM website. Updates shall be provided within 60 days of completion of structural audit.

4.4.3.2 The Contractor shall maintain the database program that identifies aircraft structure locations requiring inspections based on IAT usage as an aircraft enters Home Station Check (HSC), Major or Minor Isochronal (ISO) or PDM level scheduled maintenance. The Contractor shall review inspection requirements/intervals and update changes into the databases as needed. These databases shall be exportable to AFIRM.

4.4.3.3 Fleet Repairs database shall allow for initial and reoccurring inspection intervals to be added to the findings when needed and tracking of the repairs and time of next inspection by damage hours.

Fleet Repairs database shall have search capability, allow for trending, and forecasting of

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maintenance problems. The Fleet Repairs database shall reside in parallel on the Government’s and the Contractor’s servers.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.4.4 Fleet Data

4.4.4.1 The Contractor shall review MDCS database annually to determine if any items based on complexity require further study either through DIP or as a separate task orders.

4.4.4.2 The Contractor shall integrate all relevant aircraft structures and systems data from C-5 Automated AFMC Form 202, Non-Conforming Technical Assistance Request and Reply, and TO 00-25-107, Maintenance Assistance, JDRS, AIDE, G081 CAMS for Mobility, G099 REMIS and GCSS-AF into relational databases exportable to AFIRM. Structural discrepancies shall be reviewed by the Contractor for structurally significant findings. All structurally significant findings shall be recorded in a Fleet Repairs database exportable to the AFIRM website. Updates shall be provided within 60 days of completion of structural audit.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.5 ASIP MODERNIZATION

4.5.1 The Contractor shall deliver an IAT report, computer programs and documentation on an annual basis if changes are made to the IAT programming. (Scientific and Technical Reports; CDRL C004, DI-IPSC-81756, Software Documentation)

4.5.2 The Contractor shall deliver a L/ESS report, computer programs and documentation on an annual basis if changes are made to the L/ESS programming. (CDRL C004, DI-IPSC-81756, Software Documentation)

4.5.3 The Contractor shall accomplish a Major ASIP update. The Major update shall include:

4.5.3.1 Updates to the C-5M Operational Mission Profiles;

4.5.3.2 Update C-5M environmental criteria;

4.5.3.3 Update C-5M DADTA; and

4.5.3.4 Update C-5M FSMP.

4.5.4 Service Life Assessment Plan (SLAP)

The Contractor shall complete SLAP for the C-5M to determine requirements for the aircraft to reach 65,000 Equivalent Flight Hours (EFH). AF Engineering Structures Bulletin EZ-SB-16-001 shall be used as guidance for the assessment. SLAP to include, but not limited to, the following:

4.5.4.1 Damage Tolerance Analysis of Major structural joints;

4.5.4.2 Conduct a Widespread Fatigue Damage (WFD) assessment of the C-5 fleet;

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4.5.4.3 Determine if increased number of tracking zones is warranted;

4.5.4.4 Revalidate Strain Gage correlations;

4.5.4.5 Revisit Stress Corrosion Cracking (SCC) locations;

4.5.4.6 Conduct preliminary planning and document generation/update required to accomplish a complete teardown of a C-5A (based on teardown of aircraft 69-0004) and given the following assumptions:

a) AMARG will accomplish aircraft disassembly and component sectional cuts as specified in documents generated above, and

b) Documents shall be general in nature to allow the Government to perform detailed parts teardown and inspection and shall be delivered with unlimited data rights (Distribution Statement: D).

4.5.4.7 Accomplish teardown and engineering analysis of the Fatigue Test Article components/sections referenced in PWS Appendix C and located at LMA Marietta.

4.5.4.8 Compile/Revisit Test & In-Service Cracking History; and

4.5.4.9 Revisit Certified Service Life Calculations.

4.5.5 The Contractor shall update, and verify/validate as necessary, C-5 Air Vehicle Level (AVL) Finite Element Models (FEMs) as follows:

4.5.5.1 The Contractor shall create a separate AVL FEM (N9467) baselined from AVL FEM N9466 to represent the C-5 Space Cargo Modified (SCM) aircraft configuration. The Contractor shall ensure that all updates made to either FEM N9466 or FEM N9467 are reflected in the other FEM, where appropriate. The Contractor shall ensure that all updates made to either FEM N9466 or FEM N9467 shall be reviewed for impacts to the integrated pylon-wing detail FEM (N9498) and that updates are reflected in FEM N9498 where appropriate.

4.5.5.2 The Contractor shall update models to ensure the fuselage active Degree of Freedoms (DOFs) is accurate.

4.5.5.3 The Contractor shall create a C-5 SCM (C-5C) Load System for FEM N9467.

4.5.5.4 The Contractor shall model all Main Landing Gear (MLG) fairings, Nose Landing Gear (NLG) fairings and wing-to-fuselage fairing structure.

4.5.5.5 The Contractor shall incorporate fastener level models into the C-5 AVL FEMs in support of Major Joint Analysis. By mutual agreement between the Contractor and the Government, the below locations may be substituted with alternate C-5 Major Joint locations requiring a similar Level of Effort (LOE) as dictated by C-5 fleet requirements.

a) Wing Station (W.S.) 120 inner wing-center wing-fuselage attach joints, including Fuselage Station (F.S.) 1106, 1303, 1383 mainframe-to-wing attach points

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b) Horizontal Stabilizer Pitch Trim Attach point

c) Aft Fuselage to Empennage Attach structure

d) W.S. 577 Inner Wing to Outer Wing Attach Joint

e) F.S. 1303, 1383, 1523 and 1603 BL 0.0 splice joints

f) Flap Torque Box to Rear Beam Attachment joint

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports; CDRL B003, DI-GDRQ-81256B, Mathematical Model Finite Element Structure Report; CDRL B004, DI-GDRQ-81257A/T, Mathematical Model Finite Element Analysis Report; CDRL B005, DI-GDRQ-80650, Design Data and Calculations)

4.6 FSIP

4.6.1 Mechanical Subsystems Integrity Program (MECSIP)

4.6.1.1 Maintenance Significant Items (MSI)

The Contractor shall perform a specific preview of a mechanical component with high time maintenance hours and perform statistical analyses of component scheduled analysis for identified MSI as directed by the C-5 FSIP Manager.

4.6.1.2 Critical Safety Items (CSI)

The Contractor shall perform a specific preview of a mechanical component with a Catastrophic severity for identified CSI as directed by the C-5 FSIP Manager.

4.6.1.3 Component Analyses

The Contractor shall perform specific preview and in depth failures analysis for all mechanical Work Unit Codes (WUCs) that are identified as poor performers by AFLCMC/WLSE. Preview analysis is to determine the cause of reliability degradation. In depth analysis is to determine the root cause for the decrease in reliability of the component.

4.6.1.4 Component Teardown Inspection

The Contractor shall provide specific engineering support to analyze current and historical performance as required to define a plan for teardown analysis of some mission critical mechanical components.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports; C006, DI-NDTI-80566A, Test Plan;

C007, DI-NDTI-80603A, Test Procedure; CDRL C008, DI-NDTI-80809B, Test/Inspection Report)

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4.6.2 Avionics Integrity Program (AVIP)

4.6.2.1 MSI

The Contractor shall perform a specific preview of an avionics/electrical component with high time maintenance hours and perform statistical analyses of component scheduled analysis for identified MSI as directed by the C-5 FSIP Manager.

4.6.2.2 CSI

The Contractor shall perform a specific preview of an avionics/electrical component with a Catastrophic severity for identified CSI as directed by the C-5 FSIP Manager.

4.6.2.3 Component Analyses

The Contractor shall perform specific preview and in depth failures analysis for all avionics WUCs that are identified as poor performers by AFLCMC/WLSE. Preview analysis is to determine the cause of reliability degradation. In depth analysis is to determine the root cause for the decrease in reliability of the component.

4.6.2.4 Component Teardown Inspection

The Contractor shall provide specific engineering support to analyze current and historical performance as required to define a plan for teardown analysis of some mission critical mechanical components.

4.6.2.5 Wiring Integrity Program (WIP)

The Contractor shall provide wiring support to the C-5 WIP Manager as required. Support shall include, at a minimum, providing wiring numbers and information on various Electrical Wiring Interconnect System (EWIS) components.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports; C006, DI-NDTI-80566A, Test Plan;

C007, DI-NDTI-80603A, Test Procedure; CDRL C008, DI-NDTI-80809B, Test/Inspection Report)

4.6.3 FSIP Data Integration

4.6.3.1 The Contractor shall integrate all relevant aircraft systems data from CAMS (G081), REMIS (G099) and GCSS into relational databases exportable to AFIRM. This shall include ISO/HSC inspection data, daily reports, aircraft status, Not Mission Capable statistics, Enroute Reliability, Air Aborts, component reliability matrix, etc. The Contractor shall accomplish this monthly.

4.6.3.2 The Contractor shall maintain all Preview/In-Depth analyses, WUC Alerts, En-route Reliability analyses, component tracking of critical items and Air Aborts in a format exportable to the AFIRM website. The Contractor shall accomplish this monthly.

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4.6.3.3 The Contractor shall collect component failure data from CAMS (G081), REMIS (G099) and GCSS. The reliability data shall be Type-1 MTBF or inherent failures. This data shall be maintained in a format exportable to AFIRM. The Contractor shall accomplish this monthly.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.6.4 FSIP Scientific and Technical Reports

The Contractor shall submit up to five (5) individual FSIP engineering reports as requested by the C-5 FSIP Manager. (CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.6.5 Final FSIP Report

The Contractor shall submit a final FSIP engineering report. Report shall document the results of all significant analyses and studies conducted during ordering period and contain as appendices MECSIP and AVIP data. (CDRL C003, DI-MISC-80711A/T, Scientific and Technical Reports)

4.6.6 Rapid Response

The Contractor shall provide Rapid Response engineering services and related materials upon receiving telephone taskings from an AFLCMC/WLSK PCO. The Contractor shall commence work immediately. Each telephone task for Rapid Response engineering services shall fall under the ceiling price of the order, which the Contractor shall not exceed except at his own risk. Each telephone tasking will include the place of performance, the period of performance, category of task and the description of the engineering services to be performed. The PCO will confirm each telephone tasking in writing within 48 hours of issuance. At a minimum, each tasking shall require a Final Scientific and Technical Report. (CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.6.6.1 Rapid Response Categories

Rapid Response tasking shall fall into one or more of the seven categories outlined below.

4.6.6.1.1 Mishaps

The Contractor shall analyze and propose corrective action or procedure changes related to any damage whether structural, mechanical or electrical which caused the aircraft to be involved in an accident, whether it was the aircraft’s or some other instrument’s fault.

4.6.6.1.2 Safety Hazards

The Contractor shall analyze and propose corrective action or procedure changes related to any system or structure in the aircraft which could/did lead to an unserviceable/grounded condition for which there is no existing data or obvious reason for hazard.

4.6.6.1.3 Structural Damage

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The Contractor shall analyze and propose corrective action or procedure changes related to any damage found in the structure of the aircraft which causes the aircraft to be unserviceable/grounded for which there is no existing data (loads, stress, etc.).

4.6.6.1.4 Mechanical Damage

The Contractor shall analyze and propose corrective action or procedure changes related to any damage/malfunction found in mechanical/hydraulic systems on the aircraft which causes the aircraft to be unserviceable/grounded and for which there is no existing data or obvious reason for damage/malfunction.

4.6.6.1.5 Electrical Damage

The Contractor shall analyze and propose corrective action or procedure changes related to any damage/malfunction found in electrical/avionic systems on the aircraft which causes the aircraft to be unserviceable/grounded and for which there is no existing data or obvious reason for damage/malfunction.

4.6.6.1.6 Material Failures

The Contractor shall analyze and propose corrective action or procedure changes related to any failure of materials found on the aircraft which causes the aircraft to be unserviceable/grounded and for which there is no existing data or obvious reason for damage/malfunction.

4.6.6.1.7 Mission Critical

The Contractor shall provide engineering services for any damage or failure which could prove detrimental to the execution of needed military logistical support or military action.

4.6.6.2 Data

4.6.6.2.1 The Contractor shall submit a Rapid Response Tasking report that documents the results of all significant analyses and studies conducted under the tasking. Initial plan for assessing the task shall be submitted within 24 hours of PCO phone or email tasking and Contractor acknowledgement. Final plan for assessing the task shall be submitted within 48 hours of PCO formal written tasking. (CDRL C001, DI-MISC-80711A, Scientific and Technical Reports)

4.6.6.2.2 The Contractor shall submit any drawings, computer models or other data generated during Rapid Response Taskings. (CDRL B001, DI-SESS-81000E/T, Product Drawing/Models and Associated Lists; CDRL C009, DI-MGMT-81453B, Data Accession List)

4.6.6.3 Shipping

The Contractor’s response may involve shipment of materials required to perform repair or replacement due to damage or failure to any worldwide location.

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4.7 CPCP

The Contractor shall provide engineering analysis and corrective action for the prevention, control, and resolution of corrosion related issues on the C-5 aircraft. This includes, but is not limited to, the following:

4.7.1 The Contractor shall survey as necessary the Air Force Corrosion Office, other Department of Defense Weapon Systems, commercial airline aging aircraft and industry for advances in prevention and control materials and methods.

4.7.2 The Contractor shall recommend implementation of advanced materials and methods for improving C-5 corrosion prevention and control as appropriate. Recommendations must consider Environmental Protection Agency (EPA) restrictions and logistics infrastructure support requirements for shipment, storage, application, containment and clean-up of materials and implementation of methods.

4.7.3 The Contractor shall review adequacy of existing corrosion prevention and control tasks contained in C-5 technical data. The Contractor shall recommend improvements.

4.7.4 The Contractor shall identify additional or emerging corrosion-prone areas not currently addressed in C-5 technical data. The Contractor shall identify associated corrosion types and recommend methods for prevention and correction.

4.7.5 The Contractor shall provide updates to the C-5 FSMP as a result of corrosion prevention and control activities in accordance with this PWS. The Contractor shall provide support documentation for updating all other affected C-5 technical documentation, including technical orders and work cards through the Engineering Requirement Review process as a result of changes in corrosion prevention and control methods and materials.

4.7.6 The Contractor shall review new corrosion findings as a result of field and depot maintenance.

Findings shall be evaluated with regard to the effectiveness of the prevention procedures and coating systems used. Findings shall be evaluated for any observed trends and recommendations made for improved maintenance procedures and/or adjustments to corrosion inspection requirements in the

FSMP.

4.7.7 The Contractor shall submit evaluation or analysis report within 45 days of completion of evaluation or analysis.

4.7.8 The Contractor shall, at the request of the CPCP Manager, support PDM/Field activities as necessary in relation to C-5 related corrosion issues for all Mission Design Series.

4.7.9 The Contractor shall submit individual CPCP engineering reports as requested by C-5 CPCP Manager.

(CDRL C001, DI-MISC-80711A, Scientific and Technical Reports; CDRL C00B, DI-TMSS-81354, Technical Manual Research and Analysis Source Data)

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4.8 TDS SUPPORT

Technical data necessary to support spares, repairs and maintenance of C-5 shall be provided as specified below. Data requests will be accomplished by contractual correspondence or email request from the PCO and will be contingent upon availability of sufficient funds. Disputes as to the intent of data requests shall be resolved by the Government and Contractor Chief Engineers through their respective contracting officers.

4.8.1 The Contractor shall submit copies of non-dimensioned drawings (Envelope or Mylars) as requested. The drawings shall be delivered with the digital media format used in their creation if existing for example Computer Augmented Design and Manufacturing (CADAM) and Computer Aided Three-dimensional Interactive Application (CATIA), with CATIA as the preferred media.

4.8.2 The Contractor shall submit copies of existing dimensioned drawings as requested. The drawings shall be delivered in the digital media format used in their creation, if existing; for example, CADAM and CATIA with CATIA as the preferred media.

4.8.3 The Contractor shall submit copies of individual engineering reports as requested to replace previously submitted reports that are missing from the C-5 Engineering Library. (CDRL C005, DI- MISC-80711A/T, Scientific and Technical Reports)

4.8.4 The Contractor shall submit applicable sections of the Original Equipment Manufacturer (OEM) Specification Manuals (Design Specifications, OEM Standard Shapes, OEM Standard Process Specifications, OEM Standard Material Specifications, OEM Preferred Parts Handbook, and OEM Engineering Purchasing Specifications) as requested to support spares, repairs and maintenance of the C-5. Contractor shall make available applicable data called out on OEM drawings as requested to aid C-5 Engineering in analysis.

4.8.5 The Contractor shall generate and submit Digital Loft Data (DLD) for various contoured aircraft parts necessary to fabricate parts for the C-5 aircraft as required per the Master Prioritized Aircraft Parts List (MPAPL) provided by the Government per each order. The Contractor shall retain the same rights as on the original Master Dimensions Data (MDD) used in its creation. DLD shall have no higher distribution statement than the original MDD used in its creation. The data shall be sufficient to determine the original contour of the part in question and shall be delivered in CATIA.

The Contractor shall deliver DLDs of aircraft parts and any revised data (drawings, Master Dimensions Data, etc.). Each DLD and revised data shall be delivered to the Government no later than 7 days after completion of the DLD. Government review comments will be provided no later than 7 days after submittal. Revised DLD and data is due 7 days after receipt of Government comments.

(CDRL B002, DI-SESS-81000E/T, Product Drawings/Models and…