PWS.pdf

Distribution Statement A: Approved for Public Release. Distribution is unlimited.

Performance Work Statement

Engineering Services and Technical Support for the

Munitions Handling Unit (MHU)-196 & MHU-204

PR Number: FD2060-17-30061

Date: 17 Nov 2016

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Table of Contents

1.0 Description of Services

1.1 Objective(s)

1.2 Benefit to United States Air Force (USAF)

1.3 Background

2.0 Services summary

3.0 Government property and services

3.1 Government property

3.2 Government systems

4.0 Technical requirements

4.1 Period and place of performance

4.1.1 Contractor/Order period of performance

4.1.2 Place of performance

4.2 Prototype/pre-production development, fabrication, test and evaluation

4.2.1 Prototype/Preproduction development

4.2.2 Fabrication and product integration requirements

4.2.3 Proof-of-concept test and evaluation

4.3 Field and depot technical support requests

4.3.1 Field-level engineering technical assistance requests (ETARs)

4.3.2 Depot-level technical support

4.3.3 MHU-196/204 damage inspection and report

4.3.4 Work instructions and test information/procedures report

4.3.5 Contractor oversight and final repair inspection

4.4 Reverse engineering

4.4.1 Producibility study

4.4.2 Prototype production and testing

4.4.3 Source qualificaiton

4.4.4 Technical Order (TO) review and updates

4.4.5 Product improvement(s)

4.4.6 Material analysis

4.5 Engineering Services

4.5.1 Analyses

4.5.1.1 Load analysis

4.5.2 Design stress/environment spectra development

4.5.2.1 Performance and function sizing analyses

4.5.2.2 Thermal/environmental analyses

4.5.2.3 Vibration/dynamics analyses

4.5.2.4 Design parameters and analyses

4.5.2.5 Finite element analysis (FEA)

4.5.2.6 Damage tolerance and repair report (DTARR)

4.5.3 Fatigue analysis

4.5.4 Technology insertion and systems integration due to obsolesce

4.5.5 Systems installation and integration

4.5.6 Test and evaluation

4.5.6.1 Contractor test activities

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4.5.7 Schedule inspection and maintenance requirements review

4.6 Configuration management

4.6.1 Engineering Change Proposals (ECPs)

4.6.2 Request for Variance (RFV)

4.6.3 Engineering data

4.7 Over and above

4.8 Technical Order (TO) and logistics support

4.8.1 TO requirements

4.8.2 Provisioning

4.8.3 Training/familiarization

4.9 Rapid manufacturing

4.10 Final report

4.11 Conferences, program, and technical reviews

4.11.1 Post award conference

4.11.2 Program Management Reviews (PMRs)

4.11.3 Technical reviews

4.11.3.1 Design reviews

4.11.3.2 TRR

4.12 Statement of work

4.13 CDRL

4.14 Travel

4.15 Counterfeit electronic parts

4.16 Program management

4.17 Program status reviews and Technical Interchange Meetings

4.18 Monthly status report

4.19 Conferences, program, and technical reviews

4.20 Integrated master schedule (IMS)

5.0 General information

5.1 Continuation of Mission-Essential Services during a Crisis

5.2 Security requirements

5.2.2 Security Clearance

5.2.3 Security Incident or Violation

5.2.4 Access to Government System(s)

5.2.5 A Access to Government Facility or Military Installation

5.3 Safety requirements

5.3.1 Mishap notification/investigation

5.3.2 Safety and Health Plan

5.4 Prime and subcontractors safety requirements

5.5 Contractor manpower reporting

6.0 Appendix

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1.0 Description of services. This Performance Work Statement (PWS) describes the requirements needed to support the Munitions Handling Unit (MHU)-196 and MHU-204 trailers (herein referred to as MHU-196/204) program. This includes contracted engineering services, testing, repair procedures and prototype support as related to software, hydraulics, structural, mechanical and electrical design, and engineering/technical sustainment.

Contractor responsibilities identified within this PWS shall include fulfilling work requirements of task assignments, designated by individual task orders issued, as required, by the Government.

Responsibility for meeting all requirements herein, and driven by task orders, resides with the Contractor.

Each task order will address specific task requirements, project scheduling, and other related performance criteria, as applicable. All task orders shall require delivery of a final report per paragraph 4.10. The Government shall own unlimited rights to all data generated as a result of this PWS; this requirement cannot be waived. All designs shall meet nuclear certification requirements per Air Force Instruction (AFI) 99-103 and Air Force Manual (AFMAN) 91-118.

1.1 Objective(s). This effort seeks to sustain equipment integrity and maintain mission capability as related to the aging MHU-196/204 and its associated support equipment. The Contractor shall, in response to Government issued task orders, furnish appropriate personnel, equipment, materials, and lab facilities necessary to perform any or all of the following:

- conceptual design(s) and review

- feasibility and interface design studies

- preliminary and detailed engineering design and services

- stress analysis

- fabrication/prototype support

- development, advancement and implementation of emerging technologies

- instrumentation and calibration

- testing

- inspections

- assembly/disassembly support

- installation and check-out, and

- packaging and transportation/shipment of hardware.

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1.2 Benefit to United States Air Force (USAF). Maintaining nuclear munitions handling equipment supports the following USAF Concepts of Operational Needs (CONOPS): Global Strike, Global Persistent Attack, and Nuclear Response. Each of the three CONOPS links the effects and capabilities and the USAF role in contributing to joint-service war and conflicts.

1.3 Background. The MHU-196/204s are auxiliary, electrically powered towed vehicles used to transport, position, and upload/download B-1B, B-2 and B-52 conventional and nuclear munitions.

MHU-196/204s are critical equipment used with the Support Equipment and Vehicles Division that underpins part of the United States nuclear deterrent program.

This equipment is defined as a Critical Safety Item per joint publication SECNAVINST 4140.2;

AFI 20-106; DA Pam 95-9; DLAI 3200.4; DCMA INST CSA (AV) “Management of Aviation Critical Safety Items.” That is, per paragraph 1E therein, states the following: “An item shall be identified as CSI when failure of that item could result in loss or substantial damage to the air vehicle or weapons system, or death or serious injury to personnel.”

2.0 Services summary

Table I. Services Summary

Performance Objective PWS Reference

Performance Threshold

Quality of Contract Data Requirements List (CDRL) deliverable

4.2 - 4.12, 4.16, 4.18, 4.20

There shall be no more than one (1) rejection of each deliverable. There shall be no more than two (2) total rejection(s) of deliverables per quarter. The Government will reject a deliverable if one or more technical errors or one or more minor errors are found within the deliverable. A technical error is defined as the format not being in accordance with the CDRL or the content not being accurate and complete in accordance with the CDRL, PWS or contract. A minor error is defined as a typographical or grammatical error. The rejected deliverable shall be corrected and resubmitted within 10-calendar days of notification of Government rejection.

Receipt of CDRL deliverable

4.2 - 4.12, 4.16, 4.18, 4.20

There shall be no more than one late submission(s) of deliverables per quarter. The Contractor shall notify the Government if the delivery of any data/document will not meet the scheduled delivery date and negotiate a revised delivery date. The data/document shall be delivered by the revised delivery date acceptable to the Government.

Request for assistance 4.2 - 4.11 The Contractor shall initially respond to a request for assistance within 12 business hours.

Follow-up assistance, if required, shall be

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Performance Objective PWS Reference

Performance Threshold provided by the suspense date acceptable to the Government.

Quality of support requests

4.3 At a minimum, 75% of repaired assets shall pass

initial test and inspection. Remaining 25% (or less) of failed assets shall pass on the second attempt. This metric will be calculated per contract year.

There shall be no more than one Quality Deficiency Report/Product Quality Deficiency Report (QDR/PQDR) of total repaired assets in a single contract year, with a goal of zero.

Technical Data Package

(TDP)

4.6 The Contractor shall submit the TDP in

accordance with this PWS and all CDRL requirements. One Government directed revision per drawing is allowed. The Contractor’s final product shall be 100% accurate and comply with the applicable CDRL requirements.

Delivery of final reports 4.10 The Contractor shall provide a final report in accordance with 4.10. The Government shall reject the submitted report if one or more technical flaws or one or more minor flaws are found within the report. A technical flaw is defined as the format not being in accordance with the PWS, CDRL, or contract or the content not being complete in accordance with the PWS, CDRL, or contract. A minor flaw is defined as a typographical or grammatical error. There shall be no more than one rejection of each report.

There shall be no more than one total rejection(s) of reports per quarter.

Contractor manpower reporting

5.5 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 an annual count of Contractor/subcontractor personnel performing services and report all Contractor/subcontractor labor hours required for performance of services for each fiscal year (FY). All data shall be reported no later than October 31 of the following FY.

3.0 Government property and services.

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3.1 Government property. Government property will not be provided.

3.1.1 All data and material developed and generated under the contract/order becomes the property of the Government and shall be provided to the Government upon completion of the contract/order. All Department of Defense (DD) Form 1423-1 CDRL deliverables, the data and information therein, become the property of the Government upon receipt.

3.2 Government system(s). Access to Government system(s) will not be required to perform tasks under the contract/order.

4.0 TECHNICAL REQUIREMENTS

4.1 Period and place of performance.

4.1.1 Contract/Order period of performance. The period of performance for the contract/order will extend one year beyond the date of the final order, unless otherwise specified.

4.1.2 Place of performance. These services shall be performed at the Contractor’s facility, at the subcontractor’s facility, or at Government installations (in particular, but not limited to, Hill

AFB, UT).

4.2 Prototype/pre-production development, fabrication, test and evaluation. When required, the Contractor shall accomplish the following: design, develop and build prototype/pre-production units, or one-time production units (six or less); conduct tests; evaluate potential solutions or items as related to MHU-196/204 equipment use.

The Contractor shall supply drawings to the Government per paragraph and subparagraphs of 4.6, with unlimited/unrestricted data and documentation rights. The Contractor shall supply the Government with all solid models used for design and analysis purposes, along with all associated data necessary to fully replicate all presented results.

4.2.1 Prototype/Preproduction development. As directed by task order, the Contractor shall perform and/or be responsible for prototype/preproduction developmental tasks that include, but are not limited to, the following (A001, DI-MISC-80508B, Technical Report – Study/Services):

a. Design and integrate mechanical and electrical/electronic packages and subsystems, using state-of-the-art technology, to replace antiquated equipment.

b. Provide conceptual layouts, feasibility studies, preliminary design drawings and analysis, detailed drawings, engineering analyses and appropriate computer output files which shall allow for the fabrication of mechanical hardware from a variety of materials options such as metals, fiberglass, carbon fibers, ceramics, polycarbonate, etc.

c. Provide rapid access to initial one-time production runs for modified piece parts, sub-system components, or systems, which were developed or improved as a result of a specific task order.

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d. Design printed circuit boards, electrical/electronic hardware components and subsystems.

e. Design the integration of electrical/electronic hardware into final assemblies; developing interface, installation and operation specifications, and providing mounting, power, wiring and circuit protection.

f. Deliver a technical documentation package (see paragraph and subparagraphs of 4.6) for long-term manufacturing purposes, with unlimited data rights. Delivery shall include a documentation package, which shall include documentation for manufacturing (necessary jigs, tables, special tooling, relevant/associated instruction(s), order of assembly and manufacturing, etc.).

g. Conduct engineering services (see paragraph and subparagraphs of 4.5) as appropriate and/or as requested by the Government.

4.2.2 Fabrication and product integration requirements. As directed by task order, the Contractor shall perform and/or be responsible for fabrication and product integration tasks that include, but are not limited to, the following (A002, DI-MISC-80508B, Technical Report – Study/Services):

a. Fabricate, assemble and integrate mechanical and electrical/electronic packages and subsystems, using state-of-the-art technology, to replace antiquated equipment.

b. Fabricate and integrate mechanical hardware from a variety of materials such as metals, fiberglass, carbon fibers, wood, ceramics, polycarbonate, moldable or formable materials, etc., or any combination of these materials.

c. Fabricate initial one-time production runs (six or less) of piece parts, sub-system components, or systems, which were evaluated, developed or improved as a result of a specific task order.

d. Fabricate and integrate printed circuit boards, electrical/electronic hardware components and subsystems.

e. Fabricate and/or integrate mechanical and electrical/electronic hardware into final assemblies; create and validate installation and operation specifications, while providing mounting, power, wiring and circuit protection.

f. Deliver all equipment and manuals necessary to manufacture the items post Contractor fabrication (jigs, special tooling, special test equipment, etc.).

4.2.3 Proof-of-concept test and evaluation. When requested by the Government, the Contractor shall test and evaluate proof-of-concept and conduct functional demonstrations of equipment resulting from this effort. Functional demonstrations shall test and evaluate the following: design alternatives and preferences, test and validate theories, refine and/or validate mechanistic idealization and assumptions, validate performance(s), interfaces, and evaluate operational safety, suitability and effectiveness. Testing and evaluation shall be in accordance with paragraph and subparagraphs of 4.5.6 (A003, DI-MISC-80508B, Technical Report – Study/Services)

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4.3 Field and depot technical support requests. For any MHU-196/204 repair or overhaul support need, the Contractor shall review and provide comprehensive engineering assistance and technical resolution in writing, to AFLCMC/WNZEA, within 40-calendar days from Contractor date of receipt. Unless otherwise agreed upon by the Contractor, maximum Government-to- Contractor submittal of field and/or depot-specific repair support, or equivalent, shall not exceed one submittal per every 41-calendar days. Upon request, the Contractor shall coordinate and be available at the location of need within 96 hours of Government notification.

Ongoing operations may warrant Contractor support at various operational bases, repair depots, or other locations to support multiple technical discrepancies. In such instances, the Contractor may be required to physically observe, monitor, and evaluate system performance, collect data, and/or provide on-site technical assistance to resolve operational, repair and/or depot problems.

Contractor personnel selected to provide assistance to field or depot related activities shall be fully qualified individuals who have a specific knowledge of the systems and processes related to a given task order. The Contractor shall be available to support any USAF, Air National Guard, or USAF Reserve location with the continental United States within 96 hours of notification via the Government. (A004, DI-MISC-80508B, Technical Report – Study/Services);

This need is related to novel issues, as well as Government-related and established technical documentation shortfalls, misunderstandings, missing related technical documentation, etc.

For this task, the Contactor shall develop and provide comprehensive technical instruction(s), guidance and/or oversight to Government personnel during the following activities: inspection, disassembling and associated procedures, cleaning, repairing, replacing of parts, major assemblies, sub-assemblies, structures or components, reassembly and procedures, and testing of items. That is, the Contractor shall provide the Government with the technical guidance necessary to complete any repair required to restore the MHU-196/204 to a serviceable equivalent “like new” condition while retaining the structural, functional and configuration integrity.

Repairs requiring more than 40 hours of Government-related maintenance activity to complete shall require AFLCMC/WNZEA direction.

The Government reserves the right to publish any delivered information in applicable Technical Orders, without limitation.

4.3.1 Field-level engineering technical assistance requests (ETARs). Contractor provided guidance and instruction(s) shall include comprehensive, step-by-step written instructions, associated figures (to include modeling/analysis information, as appropriate or as requested by the Government) and technical guidance, to allow Government field-level organic replacement or repair. (A005, DI-MISC-80508B, Technical Report – Study/Services)

Tasks shall relate to structural, electrical, and hydraulic component or MHU-196/204 system deficiencies; to include equipment damage(s), lack of organic engineering/technical information or instruction, and equipment degradation or malfunction related to the following:

a. Equipment age and usage (corrosion, obsolescence, fatigue, etc.).

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b. Government maintenance, inspections, operations, and/or mishap induced damage or neglect.

The Contractor shall provide engineering services (see paragraph and subparagraphs of 4.5) as related to performing risk assessments, engineering studies, analysis, evaluations, Engineering Change Proposals, and TO-related modifications, or similar technical services, as required by AFLCMC/WNZEA to support ETAR or similar requests.

Reference paragraphs 4.3.3-4.3.5 for additional requirements resulting from this effort.

4.3.2 Depot-level technical support. Upon Government request, the Contractor shall support depot maintenance at Hill AFB, UT, as related to specific task order requirements. Support shall include providing technical analysis and technical documentation and instructions to support the following, as related to the MHU-196/204 (A006, DI-MISC-80508B, Technical Report – Study/Services; A007, DI-SESS-81705, Depot Level Repair Instructions):

a. repair

b. fabrication and manufacturing

c. rebuilding and subsystem overhaul support

d. equipment repair and/or modification(s)

e. equipment refurbishment

f. equipment disassembly and assembly

g. subsystem testing and analysis

h. repair processes and procedures

i. engineering services (see paragraph and subparagraphs of 4.5)

j. upgrades and modifications

k. drawing changes

l. de-painting, painting and disposal of parts

m. part substitutions

n. inspections

Such support shall involve structural, electrical, mechanical, software and/or hydraulic component or system deficiencies, to include damage(s) and equipment degradation related to the following:

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a. equipment age and usage (corrosion, obsolescence, fatigue, etc.); and,

b. Government maintenance, inspections, operations, and/or mishap induced damage or neglect.

Reference paragraphs 4.3.3-4.3.5 for additional requirements resulting from this effort.

4.3.3 MHU-196/204 damage inspection and report. Upon Government request, the Contractor shall review and assess any damage found to exist within fielded or depot MHU-196/204 units.

Post equipment inspection, a Contractor shall provide an assessment report to the Government.

This report shall, at a minimum, include the following information:

a. Date(s) and time(s) of inspection.

b. Name(s) of inspector(s) and local USAF point of contact information.

c. Identification of the end-item by serial number (if applicable), part number, stock number, contract number, and physical location

d. List of all components or parts affected, requiring repair, replacement, overhaul, etc.

e. Digitally colored photographs of the asset and affected area(s) or systems.

f. Preliminary rationale for repair, replacement, overhaul, etc., requirement and need (to include detailed description of problems experienced, troubleshooting methods required for diagnosis, etc.)

g. Comments, if any, pertaining to any unusual observations during inspection and disassembly, in regards to the end item or subcomponents.

h. Configuration/upgrade recommendations, if any, and estimated associated costs.

i. Inspection data sheets describing manner and methods of inspection(s), all deficiencies found and proposed corrective actions and alternatives due to such findings.

j. Inspection noting and describing all items outside allowable dimensional, performance, damage, etc., tolerance(s), as applicable.

k. Associated engineering or technical information.

l. Total repair, replacement, overhaul, etc., estimate which shall include all material, parts, test equipment, special tools (if applicable), and any other costs for any projected work to be accomplished by the Government

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The Contractor shall provide the Government with this report no later than 10-calendar days post Government request for support by the Government Primary Contractong Officer (PCO). (A008, DI-MISC-80508B, Technical Report – Study/Services)

4.3.4 Work instructions and test information/procedures report. Post Government approval of paragraph 4.3.3, the Contractor shall generate a comprehensive repair, depot, overhaul, etc., Statement of Work (SOW) (see paragraph 4.14) instruction for WNZEA and USAF maintainers for planned execution.

The SOW report shall allow affected equipment to be returned to a “like new” condition, post rework and/or repair implementation. Aside from including relevant repair information within the report, in process and post repair inspection(s) and test information/procedures shall be included.

At a minimum, the report shall include the following:

a. The necessary organic procedures and guidance to completely repair, overhaul, trouble shoot, etc., the damaged asset(s), returning damaged assets to a “like new” condition,

b. Test and inspection procedures, which shall include the following:

o output test data meaning and interpretation guidance with necessary to pass or fail criteria o troubleshooting procedures o full disclosure of any test equipment, setup and calibration requirements

c. Supporting technical data and accompanying rationale, limitations, and any necessary assumptions, as relating to sustained service for any repairs that are not returned to the Technical Order baseline

d. Step-by-step instructions, with associated figures and photos, for any procedure not included within 11N series Technical Orders.

If repair or overhaul is not a feasible option due to structural integrity, the Contractor shall present analysis (to the Government) detailing applicable rationale.

The Contractor shall provide work instructions supporting this effort to the Government no later than 40-calendar days following Government receipt of data resulting from paragraph 4.3.3.

The Government reserves the right to reject Contractor repair procedures, and require Contractor re-work, provided adequate technical information/data is not available and presented by the Contractor. (A009, DI-MISC-80508B, Technical Report – Study/Services)

4.3.5 Contractor oversight and final repair inspection. If required by the Government, each asset shall be organically repaired, reworked, overhauled, etc., and tested with direct Contractor oversite. The Contractor shall be responsible for determining and providing written instruction (to the Government) in regards to any trouble shooting required during this process.

For this activity, the Contactor shall detail data generated per 4.3.4. Additionally, a report shall be compiled and submitted to the Government that shall include the following information:

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a. Date(s) of acceptance test(s) and/or inspection(s).

b. Inspection and testing authority points of contact.

c. Identification of asset by serial number (if applicable), part number, and stock number.

d. Comments, if any, pertaining to any unusual observations during repair/overhaul and/or testing.

e. A chronological list of all tests and checks performed with the resultant values/readings including pass/fail criteria information.

f. A dimensional report with all final clearances and tolerances (dimensional, load, etc.)

included.

The Contractor shall provide a report supporting this effort, and detailing findings, to the Government no later than 10-calendar days following the organic repair or overhaul activity origination date. (A010, DI-MISC-80508B, Technical Report – Study/Services)

4.3.6 Quality of support requests. At a minimum, 75% of repaired assets shall pass initial test and inspection. The remaining 25% (or less) of failed assets shall pass on the second attempt. There shall be no more than one QDR/PQDR of total repaired assets in a single contract year, with a goal of zero.

4.4 Reverse engineering. Upon request, the Contractor shall reverse engineer an item, items or subsystems, duplicating the equipment both functionally and dimensionally, by physically examining and measuring existing MHU-196/204 parts. The Contractor shall develop comprehensive technical data (physical, mechanical, material characteristics, etc.) for the purposes of Government competitive procurement. The Government shall own the data delivered or data/equipment resulting from this effort (unlimited data rights). Drawings shall be delivered with Government Commercial and Government Entity (CAGE) and title block, shall be delivered in Government approved format (see paragraph and subparagraphs of 4.6) and shall contain the documented parameters necessary to reproduce the item independent of external sources or information. The final configuration shall meet or exceed the operational requirements of the original design. (A011, DI-MISC-80508B, Technical Report – Study/Services; A012, DI-MGMT- 80894A, Source/Vendor List)

4.4.1 Producibility study. The Contractor shall conduct a producibility study, that shall at a minimum, accomplish and deliver the following (A013, DI-MGMT-80797, Producibility Analysis Report):

a. Order of product assembly and disassembly drawings, instructions, special tools required, and inspection procedures.

b. The materials specified shall be reviewed for impact on availability, cost, producibility, and long-term function of the part. A range of materials equivalent in strength and

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weatherability to the listed material(s) in the prototype or design shall be specified to permit bidders to estimate manufacturing costs based on their best in-house process, and materials available.

c. Heat treatment requirements, lead-times, and industry standards (SAE-AMS-H-6088, SAE-AMS-H-6875, etc.).

d. The impact of finishes on function and cost; the most economical finishes that will satisfy the lifetime (fatigue) and functional requirements shall be specified. That is, if machine finishes are required, the highest roughness acceptable shall be specified for the designed function.

e. Where applicable, the drawings shall list the appropriate data concerning acceptance of detail parts or assemblies, as follows:

o dynamic tests, defining pertinent cycling, torsional deflection limitations under specified loading, gear backlash, and machine testing set up and requirements o electrical parameters and characteristics, continuity checks, dielectric data, and durability o circuit parameters and characteristics, circuit path checks, input/output parameters, any special functions, wave form analysis, and layering and bonding requirements o enclosure requirements, such as pressure and leakage allowances, heat limitations and dissipation requirements o min and max fluid fill levels o fastener torque values o shop-level practices and requirements o liquid penetrant, magnetic particle, and radiographic inspections and required personnel certifications, and o a review of interchangeable, moving and mating parts to ensure proper dimensions and functioning of close fitted items and/or tolerance stack.

The Contractor shall report findings to the Government following completion of this effort.

4.4.2 Prototype production and testing. The Contractor shall manufacture and test a prototype production of the reverse engineered item (see paragraph 4.5.6).

4.4.3 Source qualification. The Contractor shall identify an approved source post successful prototype production and testing.

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4.4.4 Technical Order (TO) review and updates. TOs shall be reviewed and changes resulting from the creation of the technical data package shall be incorporated, as applicable, in accordance with paragraph and subparagraphs of 4.8.

4.4.5 Product improvement(s). As a result of the reverse engineering effort, product improvement and manufacturing-based changes shall be recommended, as applicable. Such alternatives may be considered during the reverse engineering process and may be incorporated prior to completion of the process upon Government approval.

4.4.6 Material analysis. Material analysis, including chemical and metallurgical analysis, shall be performed to determine the exact composition, surface treatments, finishes, hardness, and heat treatments pertinent to each piece-part/component being reverse engineered.

4.5 Engineering services. The Contractor shall perform engineering services as specified in assigned task orders. These services may include but are not limited to:

a. analytical engineering

b. system integration and technology insertion engineering

c. independent lab and/or field tests

d. development of engineering concepts and design packages

e. accident investigations and/or failure analysis

f. damage analysis and tolerance assessments, and

g. rapid design to support temporary and/or permanent repairs.

Additionally, such engineering services shall include, but are not limited to, the elements detailed in the subparagraphs that follow:

4.5.1 Analyses. Analyses shall include, but are not limited to, the elements detailed in the subparagraphs that follow. The Contractor shall provide empirical data and/or hand calculations (Government discretion) to verify damage tolerance and engineering reports.

4.5.1.1 Load analysis. The Contractor shall define the magnitude and distribution of static, dynamic, and repeated loads, which the equipment encounters while being operated within the envelope established by 11N series TOs. This analysis shall involve identifying the internal and external operating load sources, as well as inertial effects imposed by accelerations, decelerations, angular velocities, hydraulics and design. Where applicable, the loads analysis shall include the effects of temperature and system installation (e.g., dynamic response and deformation of the support structure). Repeated load sources imposed during operation shall be included, as applicable. When applicable, these analyses shall address ground operation, as well as maintenance, storage, and transportation. (A014, DI-MISC-80508B, Technical Report – Study/Services)

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4.5.2 Design stress/environment spectra development. The Contractor shall conduct analysis and document the design stress/environment spectra for system and individual system elements typical of operational use. The design stress/environment spectra shall characterize the repeated operating loads, pressures, thermal cycles, vibration, acoustics, and chemicals in a format which accounts for the primary functional duty cycle and usage of the equipment. The intent of this effort is to develop a spectrum that characterizes the significant usage events, which may affect primary failure modes (e.g., fatigue, cracking, stress, corrosion, cracking, wear, etc.), which the system elements will experience based on the design service life and usage. This data shall be in a format that allows AFLCMC/WNZEA engineers to apply findings to individual pieces of field-level equipment, as necessary. Spectras developed and delivered to the Government shall be suitable to assist in replacement or repair material selection(s), component sizing, and performance/life assessments and verification. (A015, DI-MISC-80508B, Technical Report – Study/Services)

4.5.2.1 Performance and function sizing analyses. The Contractor shall conduct analysis to support component sizing, configuration development, and to identify or verify specific performance requirements. (A016, DI-MISC-80508B, Technical Report – Study/Services)

4.5.2.2 Thermal/environmental analyses. Thermal and/or environmental analyses shall be conducted to determine the steady state and transient thermal and/or chemical environments for individual elements of the system (and their effects), as necessary. Thermal and chemical environments shall be used in the redesign, analyses, and testing (e.g., strength, durability, damage tolerance, vibration/dynamics, etc.) of the individual components and/or systems. (A017, DI- MISC-80508B, Technical Report – Study/Services)

4.5.2.3 Vibration/dynamics analyses. Dynamic analyses shall be conducted to establish component vibration mode shapes and frequencies. An analytical dynamic model of the system and/or critical components shall be developed to identify critical system modes, potential forcing functions, and resonance conditions/concerns. The analyses shall determine if the vibration levels are acceptable for the reliable performance of equipment throughout service life requirements. If vibratory levels are deemed unacceptable, the Contractor shall provide mitigation methods necessary to enable reliable performance throughout the equipment service life. (A018, DI-MISC- 80508B, Technical Report – Study/Services)

4.5.2.4 Design parameters and analyses. The Contractor shall determine the stresses, deformations, and factors of safety, which result from the applications of design conditions, loads, and environments of MHU-196/204 operation. (A019, DI-MISC-80508B, Technical Report – Study/Services)

4.5.2.5 Finite element analysis (FEA). The Contractor shall evaluate the equipment using a non-linear FEA program, and provide a report to the Government for review. The FEA program shall be identified to the Government and referenced within the report. All assumptions, materials selected, analysis/verification techniques [for example, element type(s), mesh types, size(s) and plots, loads, boundary conditions, and real world results/data, etc.] shall be presented and identified within the report for each item analyzed. Empirical or hand calculations shall be presented to verify computer model and analysis output. The Government will identify, with support by the Contractor, items requiring FEA. (A020, DI-MISC-80508B, Technical Report – Study/Services, PR: FD2060-17-30061 PWS REVISION: 0 17

A021, DI-GDRQ-81256B, Mathematical Model Finite Element Structure Report; A022, DI- GDRQ-81257A, Mathematical Model Finite Element Analysis Report)

4.5.2.6 Damage tolerance and repair report (DTARR). The Contractor shall generate and deliver a DTARR to the Government. The Contractor shall propose to the Government and coordinate any items recommended for DTARR evaluation. This report shall include, but not be limited to, the following (A023, DI-SESS-81485A, Durability and Damage Tolerance (DADT) Test Report):

a. account for maximum allowable limits in regards to corrosion, material deformation, surface scratches, cracking, gouges, missing material, misdrills, holes, fastener hole elongation, etc., for each structural member experiencing critical loading during travel and operation, and,

b. incorporate comprehensive instruction(s) of repair procedures for the types and locations of damage typical of use.

Individual FEA-generated von Mises stress plots, as well as associated displacements and strains, shall be presented for each structural component detailed within the report. Load distribution and loading applied to each member, along with associated rationale, shall be provided for each scenario within the report.

These requirements shall be accomplished using a non-linear FEA program. This program shall be identified to the Government and included within the report. All simplifications and assumptions (and associated rationale), materials and mechanical properties selected, and analysis/verification techniques [for example, element type(s), mesh types, size(s) and plots, loads, boundary conditions, and real world results/data, etc.] shall be presented and identified within the report for each item analyzed. Empirical or classical stress analysis shall be presented within the appendix of the report to verify the FEA data output. The Contractor shall generate subsequent data on damage tolerance and repair in response to any field and depot technical support requests (see paragraph 4.5.2.6), as required by the Government.

4.5.3 Fatigue analysis. The Contractor shall conduct fatigue analysis of critical components subject to cyclic loading in order to estimate equipment failure timeframes, order of failure within the equipment, etc. Material endurance limits shall account for effects such as, but not limited to the following (A024, DI-MISC-80508B, Technical Report – Study/Services):

a. size effect

b. loading effects

c. surface finish

d. surface treatments

e. temperature

f. environment

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S-N curves or constant life fatigue data for the applicable materials shall be used to drive fatigue life expectancy. Stress concentration factors, S-N curves, or constant life fatigue data used shall be obtained from Government-accepted publications (for example, Metallic Material Properties Development and Standardization Handbook). To prevent premature failure caused by repeated loads, the design and manufacturing methods of all parts and the techniques by which they are assembled and installed shall be such that applied or residual tensile stresses and stress concentrations are minimized.

4.5.4 Technology insertion and systems integration due to obsolescence. Upon Government request, the Contractor shall integrate new technologies into current system architectures as specified by individual task orders. The Contractor shall apply a systems design approach to ensure that mission objectives and system criteria requirements are sustained. Emphasis shall be on open systems architecture and the demonstration of clear and definable improvements in the performance, logistics supportability, reliability, and maintainability of the item. All efforts shall employ the latest technology in consonance with economic considerations. (A025, DI-MISC- 80508B, Technical Report – Study/Services)

If applicable, design concepts shall include provisions for continuous technological upgrade to maximize opportunities for product improvement available from emerging technological advances in the commercial marketplace. Commercial-off-the-shelf (COTS) equipment and software meeting the requirements of individual task orders shall be used whenever possible.

If directed by individual task orders, the Contractor shall evaluate unproven technology applications, identify potential risks and/or provide software support and development.

The Contractor shall submit all technical data to the Government for engineering review and approval prior to implementation. The Government shall own data rights to all documentation and data generated by the individual task orders. Limited rights to data not generated by individual task orders may be negotiated and acquired; provided the Government concurs and prior to beginning any work. The rights of any computer software to be delivered under any specific task order will be specified in the task orders and negotiated prior to award of the task order. Failure to negotiate limited rights prior to award of the task order shall constitute an agreement by the Contractor that the data shall be delivered to the Government complete and with unlimited rights.

4.5.5 Systems installation and integration. The Contractor shall install and integrate equipment or software into systems or modify existing systems as specified by individual task orders. If required, the Contractor shall fabricate integration hardware and installation kits, and acquire or develop associated software in order to support this PWS. Upon request, the Contractor shall assist the Government in identifying all equipment and utilities required for installation at the Government-determined installation site. The Contractor shall assist the Government in ensuring that the required equipment, utilities, and resources are identified and available at the installation site. Such support is related to and shall include the following (A026, DI-MISC-80508B, Technical Report – Study/Services):

a. sustainment and design improvement studies

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b. mechanical systems

c. electrical systems

d. hardware and software

e. systems and controls

The Contractor shall manufacture, acquire, and assemble hardware and software as required to accomplish task order objectives through either manufacture or procurement.

At the conclusion of all testing efforts (unless prior approval is provided by the Government), test assets shall be returned by the Contractor to a “like new” condition. The Contractor shall receive Government approval prior to start of any destructive testing.

4.5.6 Test and evaluation. The Contractor shall, as required by individual task order, define and develop test programs, plans, and procedures, witness and support or conduct testing, evaluate and/or document the results of testing and evaluation for MHU-196/204 items, components, subsystems and/or systems. Types of testing may include, but will not be limited to the following (A027, DI-MISC-80508B, Technical Report – Study/Services):

a. software testing

b. hardware testing

c. hardware and software component testing

d. subsystem and system level development testing

e. fatigue testing,

f. system compatibility testing

g. acceptance testing

h. functional testing

i. integration testing

j. qualification testing

k. nuclear certification testing (or equivalent such as Aircraft Structural Integrity Program, Mechanical Equipment and Subsystem Integrity Program, etc.)

l. operational testing

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If a phased approach is employed to support product testing, the Contractor may be required (by the Government) to implement corrective actions discovered in previous testing before retesting occurs.

4.5.6.1 Contractor test activities. Upon Government request, the Contractor shall perform all activities associated with conducting tests or provide technical support to Government personnel, such as, but not limited to, the following:

a. Test mechanical and electrical/electronic packages, equipment, components, subsystems and integrated assemblies.

b. Install, test, and calibrate instrumentation such as pressure, temperature, and flow sensing devices, force measuring equipment, strain gages, and specialized data acquisition equipment as required in the task order.

For each test, the Contractor shall provide the Government with the comprehensive documentation to permit re-accomplishment and creation of all tasks independent of Contractor support.

4.5.7 Schedule inspection and maintenance requirements review. The Contractor shall develop and propose changes to the scheduled inspection and maintenance requirements TO (11N series), as applicable. The Contractor shall propose modifications based on the operational/use profile, safety, analysis or mission critical failures experienced by Government. Upon Government request, the Contractor shall review available maintenance data, support maintenance and depot review meetings and provide recommendations, with supporting documentation and analysis, for change consideration to the maintenance programs. (A028, DI-MISC-80508B, Technical Report

– Study/Services)

4.6 Configuration management.

4.6.1 Engineering Change Proposals (ECPs). Notwithstanding any other provision in the basic contract or task orders, no Contractor or subcontractor's change in design, fabrication, assembly, part, material, process, or source of supply shall be made to the allocated or product baselines unless such change is submitted in writing by ECP and approved by the procuring activity. Any request for change shall be accompanied by complete documentation supporting the need for the change. A system safety impact statement shall be provided as part of the submittal; it shall quantify and qualify the system safety risk identified and how it impacts the system safety risk already identified for the system. A Notice of Revision (NOR) shall be submitted with each ECP.

Should the Government approve an ECP, the Contractor shall be responsible for submitting updated Tos to reflect the changes made in the ECP. (A029, DI-SESS-80639D, Engineering Change Proposal (ECP); A030, DI-SESS-80642D, Notice of Revision (NOR))

4.6.2 Request for Variance (RFV). The Contractor shall prepare a RFV whenever a departure from the contractually-specified base line is proposed for a specific number of units or for a specific time. (A031, DI-SESS-80640D, Request for Variance (RFV))

4.6.3 Engineering data. When a TDP is required by a task order, the Contractor shall develop/produce/maintain and deliver a Technical Data Package (TDP) that accurately depicts the

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final product. The Contractor shall submit the TDP in accordance with this PWS and all CDRL requirements. The TDP shall represent the approved, tested, and accepted configuration of the defined delivered item(s). TDP data includes, but is not limited to, Computer Aided Design (CAD) data, CAD models, model based definition data sets, Gerber data and Master Bill of Materials (BOM). The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement or manufacture of an interchangeable item that duplicates the physical and performance characteristics of the original product without additional design engineering effort or recourse to the original design activity or any third party. Vendor Item Control Drawings shall be used to specify the requirements for purchased items when such items have been approved for use in the design and are used without alteration, selection or source qualification (testing of an item prior to procurement action to ensure that it satisfies the specified requirements). All engineering product definition data created using Government funding as a result of this contract shall be considered a part of the TDP and shall be delivered to the Government with unlimited rights. The TDP shall be delivered in accordance with Air Force Product Data Specification drawing 9579776 Revision M (CAGE 98752), reference attached DD Form 1423 Block 16. (A032, DI-SESS-81000E/T, Product Drawings/Models and Associated Lists)

a. Engineering Data Guidance Conference. The Contractor shall support and cochair a Guidance Conference with AFLCMC/LZPEM for engineering data within 60 calendar days after contract award. The Conference shall be convened at a site and on a date agreed upon by the Government contracting officer and the Contractor. The Contractor shall prepare an agenda and record the minutes of the Guidance Conference. The Contractor shall address, discuss, and provide status on the following:

(1) Understanding of all CDRL requirements, applicable Data Item Descriptions

(DIDs), specifications, and standards.

(2) TDP review requirements and schedules.

(3) TDP delivery requirements and schedules.

(4) Contractor’s drafting practices/procedures Digital TDP drawing formats/CAD programs.

(5) The Contractor’s quality assurance procedures relating to TDP documents, including quality control of subcontractor and vendor data.

(6) The role of subcontractors and vendors who may deliver TDP documents under this contract.

(7) The Contractor’s configuration management system, including methods for releasing documents, approving documents, and incorporating changes into documents.

(8) Digital TDP deliverables.

Note: The Guidance Conference may be held in conjunction with other meetings or conferences. (A033, DI-ADMN-81249B, Conference Agenda; A034, DI-ADMN-81250B Conference Minutes)

b. In-process review (IPR) of the TDP. The Contractor shall host, support, and co-chair an

IPR of the engineering drawings and associated lists and other documentation to be included in the TDP. The IPR shall be conducted only after the Contractor's quality

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