SOW8Oct08.doc

8 OCT 2008

Statement of Work (SOW) for

72 kW / 90 kVA GENERATOR SET Prepared by

642d COMBAT SUSTAINMENT GROUP ENGINEERING DIVISION

460 RICHARD RAY BLVD STE 200

ROBINS AFB GA 31098-1813

DISTRIBUTION STATEMENT A. Approved for public release: Distribution is unlimited.

1 SCOPE

1.1 This document defines the tasks and support requirements for the procurement of a 72 kilowatt (kW) / 90 kilovoltampere (kVA) Generator Set as described by PD08WRGBGBEA04 and is to be used in conjunction with PD08WRGBGBEA04.

2 APPLICABLE DOCUMENTS

The following documents are applicable to the SOW to the extent defined herein.

2.1 Government documents.

2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this SOW to the extent specified herein.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-49506

Logistics Management Information

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-882D Standard Practice for System Safety

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-217F (2)

Reliability Prediction of Electronic Equipment

MIL-HDBK-470A

Designing and Developing Maintainable Products and Systems

MIL-HDBK-472

Maintainability Prediction

MIL-HDBK-1568

Material and Processes for Corrosion Prevention and Control in Aerospace Weapons Systems

MIL-HDBK-29612-3A

Development of Interactive Multimedia Instruction (IMI) (Parts 1-5)

2.1.2 Other Government documents, drawings, and publications.

PURCHASE DESCRIPTIONS

PD08WRGBGBEA04

72 kW / 90 kVA GENERATOR SET

DEPARTMENT OF DEFENSE MANUALS

TM 86-01M Air Force Technical Manual Contract Requirements DATA ITEM DESCRIPTIONS (DIDs)

DI-ADMN-81249A

Conference Agenda

DI-ADMN-81250A

Conference Minutes

DI-ALSS-81529 Logistics Management Information (LMI) Data

Product(s)

DI-ALSS-81557

Supplemental Data for Provisioning (SDFP)

DI-CMAN-80639C Engineering Change Proposal (ECP)

DI-CMAN-80640C

Request for Deviation (RFD)

DI-CMAN-80642C Notice of Revision (NOR)

DI-ILSS-80872

Training Materials

DI-ILSS-81335 Design Review Data Package

DI-MFFP-81403 Corrosion Prevention and Control Plan

DI-MGMT-80227 Contractor's Progress, Status and Management

Report DI-MISC-80508B Technical Report-Study/Services

DI-NDTI-80566A

Test Plan DI-NDTI-80603A Test Procedure

DI-NDTI-80809B Test / Inspection Report

DI-SAFT-80101B System Safety Hazard Analysis Report

DI-SAFT-81626 System Safety Program Plan (Copies of these documents, with the exception of PD08WRGBGBEA04, are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. Copies of PD08WRGBGBEA04 are available from the Procuring Contracting Officer (PCO).)

2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are Department of Defense (DOD) adopted are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents cited in the solicitation.

Reliability Information Analysis Center (RIAC)

NPRD-95

Nonelectronic Parts Reliability Data 1995

(Application for copies should be addressed to Reliability Information Analysis Center, 201 Mill Street, Rome NY 13440.)

2.3 Order of precedence. In the event of a conflict between the text of this document and PD08WRGBGBEA04 the matter shall be referred to the PCO for resolution. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. Additionally the terms "first article" and "preproduction" are to be used interchangeably in both this text (SOW) and PD08WRGBGBEA04, and the term "ARO" as used in PD08WRGBGBEA04, this text (SOW), and associated DD 1423s denotes "after the effective date of the contract/receipt of order".

3 REQUIREMENTS

3.1 Program management.

3.1.1 Program manager. The contractor shall identify to the Government and maintain a single point of contact (Program Manager) for all matters under this contract. The contractor shall also ensure that all program management personnel assigned to the program shall be available, as required, to meet program objectives.

3.1.2 Plant access. The contractor shall arrange for full access to applicable contractor facilities and offices by Government representatives conducting any business, making observations, or performing inspections required by public law or by this contract.

3.1.3 Program schedule. The contractor shall prepare and update a monthly program schedule throughout the first article period of the contract and until the completion of the first full quarter of production 72 kW / 90 kVA Generator Set acceptance. At the end of this first quarter of full rate production the program schedule shall become quarterly and shall remain as such until the acceptance of the last deliverable item on the contract. The schedule shall identify the status of all portions of the contract and shall be identified in a contractor's milestone chart. This shall include but not be limited to: events such as reviews, meetings, percentage of Technical Order (TO) completion, provisioning data, tests, and identification/delivery of contract line items. (DI-MGMT-80227)

3.1.4 Conflict of requirements. In the event of any conflict of requirements specified herein, the conflict shall be referred to the PCO for resolution. If a difference in interpretation of contract requirements exists as specified herein between the contractor and any Government representative, the issue shall be referred to the PCO for resolution.

3.2 Program reviews.

3.2.1 Post Award Conference (PAC). The Government will convene the PAC with the contractor at WR-ALC, Robins AFB, GA. The PCO will coordinate the date and time of the conference with the contractor. The PAC shall be held within 60 calendar days of contract award.

3.2.2 Preliminary Design Review (PDR) and Critical Design Review (CDR). The contractor shall host a PDR within 60 calendar days ARO and a CDR within 180 calendar days ARO, or at any time proposed by the contractor and approved by the Government within 200 calendar days ARO. The PDR shall be held at Robins AFB, GA and the CDR shall be held at the Government approved, contractor proposed location. Both reviews will involve formal technical reviews of the proposed design and program risks will be reviewed on a technical and schedule basis. The PDR shall address at a minimum: design analysis as required in 3.5.4 of this document, equipment layout drawings, environmental concerns, mechanical design, packaging (layout), safety, dimensional data, producibility data, parts considerations, human engineering elements, corrosion aspects, reliability and maintainability aspects, and quality considerations. The CDR shall encompass at a minimum: all areas of the PDR, although at a much greater level of detail and completeness, and any mockups or assemblies shall be made available for Government review as well. (DI-ILSS-81335)

3.2.3 Conference room. When meetings and reviews are held the contractor or contractor proposed location, the contractor shall provide a conference room suitable for meetings of up to 15 Government representatives, plus contractor personnel in support of scheduled meetings.

3.2.4 Meeting agendas. The contractor shall publish an agenda for all meetings and conferences as specified herein (i.e., PDR, CDR, guidance conferences, etc). The contractor shall request from the Government any items or issues to be discussed or presented at the meetings and include as directed such items in the agenda. Agendas shall be submitted at least 10 calendar days prior to any meeting. (DI-ADMN-81249A/T)

3.2.5 Meeting minutes. The contractor shall provide a written record of the discussions, decisions, and action items identified at each meeting. The contractor shall submit meeting minutes no later than 10 calendar days after the meeting. (DI-ADMN-81250A)

3.3 Configuration management and control.

3.3.1 Configuration requirements. After first article acceptance, the contractor shall establish and maintain configuration control. The accepted first article units shall serve as the manufacturing standard. All further units shall be produced to the same design and using the same parts as the first article unit.

3.3.2 Engineering Change Proposals (ECP). Notwithstanding any other provisions in the contract, no contractor or subcontractor's change in design, fabrication, assembly, part, material, process, or source of supply shall be made after production release unless such change is approved in writing by ECP or request for deviation or waiver by the PCO. After first article/preproduction acceptance the contractor shall incorporate all changes via approved ECPs. Any request for change shall be accompanied by complete documentation supporting the need for change. A Notice of Revision (NOR) shall be submitted with each ECP. (DI-CMAN-80639C, DI-CMAN-80642C)

3.3.3 Production release. The contractor assumes all risks in initiating production before the PCO has determined that the first article has met all requirements and that the results of first article inspection have been delivered and accepted and that any deficiencies from the aircraft compatibility/operational test and evaluation inspection have been corrected and incorporated. Production release is acknowledgment by the Government that the contractor has satisfied all requisites to proceed with delivery of hardware to be furnished under the contract.

3.3.4 Request for Deviation (RFD). The contractor shall prepare an RFD whenever a departure from the contractually-specified baseline is proposed for a specific number of units or for a specific time. (DI-CMAN-80640C)

3.4 Orientation.

3.4.1 Operation and maintenance orientation. The contractor shall plan for and conduct a one-time classroom and “hands-on” operation and maintenance orientation for the using activities to familiarize the users with the 72 kW / 90 kVA Generator Set. The orientation shall include but not be limited to: operational familiarization, ease of maintaining the unit for both corrective and preventative efforts, support and test equipment review, unit safety features, application of technical manual to modes and effects, troubleshooting, fault isolation, and theory of operation. This orientation shall take place at the contractor facility (within CONUS) within 90 calendar days prior to shipment of the 72 kW / 90 kVA Generator Set to the operational test and evaluation inspection locations. The contractor shall provide all required reference material in accordance with paragraph 3.4.2 herein for up to 15 United States Air Force (USAF) personnel. Copies of the latest draft effort in developing the TO for the 72 kW / 90 kVA Generator Set shall also be available. The contractor is not required to provide transportation to and from the site, lodging, or meals for the approximately 15 USAF personnel during the orientation. (DI-ILSS-80872/T)

3.4.2 Operation and maintenance familiarization/orientation material. The contractor shall develop an interactive multimedia system (program media) on CD ROM or DVD to be used during the operation and maintenance orientation and for use in the field for familiarization of operational and maintenance personnel at the organizational level. MIL-HDBK-29612-3A shall be used as a general guide, although contractor format is acceptable. This program media shall be in sufficient detail to provide the technician adequate skills to operate and provide general maintenance for the up-keep of the 72 kW / 90 kVA Generator Set in the field. The program media shall also be in sufficient detail to allow the Air Education and Training Command (AETC) to formulate a training course for future use. The program media shall be compatible with existing USAF personal computers (Microsoft Windows based operating systems) and consist of all materials (e.g., software, firmware) necessary to execute the material. Approximately 15 copies of the draft version program media shall be available for use at the operation and maintenance orientation for USAF personnel. Feedback from the USAF personnel attending the operation and maintenance orientation shall be gathered and used to develop the final version of the program media to be used for organizational level familiarization. The program media shall be subject to final Government approval before final delivery. Final delivery of two copies of the program media shall be made to WR-ALC. One copy of the program media shall be sent with each 72 kW / 90 kVA Generator Set as pack up data. Note: excluding the first article/preproduction 72 kW / 90 kVA Generator Sets, no 72 kW / 90 kVA Generator Set delivery acceptance will occur without completed and Government accepted orientation material. (DI-ILSS-80872/T and MIL-HDBK-29612-3A)

3.4.3 Government rights. The contractor shall extend to the Government unlimited usage rights for the duplication and distribution of the operation and maintenance familiarization/orientation material (program media) identified in 3.4.2 herein.

3.5 System engineering.

3.5.1 System safety. The contractor shall establish, conduct, document, and maintain a system safety program in accordance with 4.1 through 4.8 of MIL-STD-882. The final 72 kW / 90 kVA Generator Set design shall be based on the safety analysis results such that the associated risk is reduced to a level acceptable to the Government. (DI-SAFT-81626, DI-SAFT-80101B)

3.5.2 Reliability and maintainability.

3.5.2.1 Reliability.

3.5.2.1.1 Basic reliability model. The contractor shall develop and maintain a basic reliability model for the 72 kW / 90 kVA Generator Set based on requirements in 3.10.10 of PD08WRGBGBEA04. All equipment and associated quantities comprising these parts shall be included in the model. All equipment, including those intended solely for item redundancy and alternate modes of operation, shall be modeled in series. A basic reliability block diagram shall be developed and maintained for the items with associated allocations and predictions in each reliability block. The basic reliability block diagram shall be keyed and traceable to functional block diagrams, drawings, and schematics, and shall provide the basis for accurate mathematical representation of basic reliability. Nomenclature of elements of the item used in the basic reliability block diagrams shall be consistent with that used in functional block diagrams, drawings, schematics, weight statements, power budgets, and specifications. The basic reliability model shall be documented in the design analysis (see 3.5.4 herein) and reviewed at the design reviews.

3.5.2.1.2 Basic reliability prediction. The contractor shall prepare and maintain a basic reliability prediction for the 72 kW / 90 VA Generator Set (see 3.10.10 of PD08WRGBGBEA04); it shall be based upon the associated basic reliability model (see 3.5.2.1.1 herein). All equipment and associated quantities comprising these parts shall be included in the model except for documented exclusions approved by the procuring activity. Failure rate data (or equivalent reliability parameters) shall be consistent with the level of detail of the basic reliability model and availability of procuring activity approved relevant data sources for a comprehensive prediction (for example, software reliability, human reliability, storage reliability, etc.). The prediction shall be based upon the worst-case service use profile. All data sources for failure rates, failure distribution, and failure rate adjustment factors (for example, stress factors, duty cycle, etc.) shall be identified for each reliability block. Data sources shall be MIL-HDBK-217, NPRD-95, or otherwise approved by the procuring activity. The basic reliability prediction shall be documented in the design analysis (see 3.5.4 herein) and reviewed at the design reviews.

3.5.2.2. Maintainability. The contractor shall prepare and maintain a maintainability prediction for mean time to repair (MTTR) using MIL-HDBK-470, Appendix D, and MIL-HDBK-472 for guidance. The model and failure rate data shall be consistent with that of the basic reliability prediction (see 3.5.2.1.2 herein). The maintainability prediction shall be documented in the design analysis (see 3.5.4 herein) and reviewed at the design reviews.

3.5.3 Corrosion control. The contractor shall establish, conduct, document, and maintain a corrosion prevention control program using MIL-HDBK-1568 for guidance. A corrosion prevention and control plan shall be developed. (DI-MFFP-81403)

3.5.4 Design analysis. A design analysis of the 72 kW / 90 kVA Generator Set and each subsystem shall be performed to verify compliance with this SOW and PD08WRGBGBEA04. The analysis shall include, but is not limited to, a system hazard analysis (see 3.7 and 4.6.7.1 of the PD); a basic reliability model (see 3.5.2.1.1 herein) and predictions (see 3.5.2.1.2 herein); and an air transportability analysis for C-130 transport (see 3.9.7.2 and 4.6.9.10.2 of the PD). An initial design analysis shall be provided at the PDR; updated versions of the analysis shall be provided at the CDR and with the preliminary and final first article test reports. (DI-MISC-80508B)

3.6 Product qualification, shipping and support. Testing and verification of the 72 kW / 90 kVA Generator Set shall be performed in accordance with section 4.0 of PD08WRGBGBEA04. Excluding any preliminary contractor testing, official first article phase one inspection shall be completed within a 90 calendar day period. Phase two first article inspection (aircraft compatibility) shall be completed within a 60 calendar day period. Operational test and evaluation inspection shall also be completed within a 90 calendar day period. The contractor's shipping responsibility shall be as specified in the contract and shall include at a minimum: all liability and costs incurred to move all equipment to and from locations for testing and/or demonstration purposes. Each first article/preproduction 72 kW / 90 kVA Generator Set shall be furnished with one 115 VAC cable part number JB8817-60 (with RVS) CAGE 0SMN2, or JB8816-60NJ (without RVS) CAGE 0SMN2, or equivalent (depending upon contractors line drop compensation design); one 28VDC cable part number MS90347-22, CAGE 96906 or equivalent; and one 270 VDC cable part number 5PTV6002-101, CAGE 81861 for use during test activities. One first article/preproduction 72 kW / 90 kVA Generator Set shall also be fitted with a 230 VAC cable part number MS21378-15 CAGE 96906 or equivalent in addition to the 115 VAC cable. Additionally, the contractor shall ensure that a kit of common repair parts is available during the first article inspection and the operational test and evaluation inspection so that minor breakdowns do not delay the test beyond repair time required to return the 72 kW / 90 kVA Generator Set to serviceable condition.

3.6.1 First article phase two (aircraft compatibility) inspection. After successful completion and Government approval of all first article phase one inspection the two FA units shall be subjected to phase two (aircraft compatibility) inspection. This testing shall be comprised of two phases. Phase one will consist of shipping one first article/preproduction 72 kW / 90 kVA Generator Set to perform F-22 aircraft simulator testing at the Vehicle Systems Simulator (VSS) and F-35 aircraft simulator testing at the Vehicle Systems Integration Facility (VSIF) at Lockheed Martin, Ft. Worth, Texas. USAF and Lockheed Martin personnel will conduct all tests but on-site contractor support shall be required for a minimum of 2 business days and a maximum of 10 business days. After successful completion and Government approval of the aircraft simulator testing the 72 kW / 90 kVA Generator Set shall be shipped to the phase two test location. Phase two will commence upon arrival of both 72 kW / 90 kVA Generator Sets at the phase two test location. USAF personnel will conduct all tests but on-site contractor support shall be required for a minimum of 5 business days and a maximum of 10 business days. All inspection shall be completed within 60 calendar days of leaving the contractor facility (includes shipping time). All first article phase two (aircraft compatibility) inspection shall be satisfactorily completed and approved by the Government prior to first article acceptance or commencement of operational test and evaluation inspection. Copies of the latest draft effort in developing the Technical Order (TO) for the 72 kW / 90 kVA Generator Set shall be available for Government use during the first article phase two (aircraft compatibility) inspection.

3.6.1.1 Test locations. After successful completion and Government approval of all first article phase one inspection, one first article/preproduction 72 kW / 90 kVA Generator Set shall be shipped to the Lockheed Martin facility in Ft. Worth, TX. Concurrent with this shipment, the remaining first article/preproduction 72 kW / 90 kVA Generator Set shall be shipped to Edwards AFB, CA. Upon successful completion and Government approval of the tests performed at the Lockheed Martin facility in Ft. Worth, TX the 72 kW / 90 kVA Generator Set shall be shipped to Edwards AFB, CA to join the other first article/preproduction unit.

3.6.2 Operational test and evaluation inspection. Following successful completion and Government approval of all first article/preproduction inspection the first article 72 kW / 90 kVA Generator Set(s) shall be subjected to an operational test and evaluation inspection (OT&E). USAF personnel will conduct all tests but on-site contractor support shall be available (if needed) within five business days of notification for the duration of the testing period. On-site support shall only be used after exhaustion of electronic support via telephone, fax, email, etc. All OT&E shall be completed within 90 calendar days (excluding shipping time to the location). Down time due to breakage or parts failure will not count towards the total test time at either location. Copies of the latest draft effort in developing the TO for the 72 kW / 90 kVA Generator Set shall be available for Government use during the operational test and evaluation inspection. All tests shall be satisfactorily completed and approved prior to first article acceptance.

3.6.2.1 Test locations. After successful completion and Government approval of all first article inspection, one first article/preproduction 72 kW / 90 kVA Generator Set shall be shipped to Dyess AFB, TX and the other first article/preproduction 72 kW / 90 kVA Generator Set shall be shipped to Charleston AFB, SC. Shipment from the final first article phase two (aircraft compatibility) inspection location (Edwards AFB, CA) to the OT&E locations shall occur within 30 calendar days of first article inspection completion and Government approval.

3.6.3 First Article/Preproduction test plan, procedures and report. The contractor shall develop a detailed first article/preproduction inspection test plan. The test plan shall address all requirements identified in PD08WRGBGBEA04 and this SOW. Upon Government approval of the test plan the contractor shall develop a test procedure. The test procedure shall include at a minimum: top level test instructions, simple block style diagrams of test instrumentation connections, and identification of test instruments by manufacturer and model number. All test procedures shall be approved by the Government before initiation of testing; after approval the contractor shall schedule the testing to be conducted. Not later than 20 calendar days prior to first article/preproduction inspection phase one testing, the contractor shall notify the Government of the date, time, and location of the testing. The contractor shall submit a preliminary first article/preproduction test report within 30 calendar days of completion of the testing. No further testing (such as OT&E) will occur until the preliminary test results are submitted and approved. Completed analysis, certification, inspection, and demonstration results shall be presented with the test data requirement. The contractor shall submit a final first article/preproduction inspection test report upon completion of the OT&E. The final copy shall include all data submitted in the preliminary version plus identify any issues and corrections that occurred during the aircraft compatibility and OT&E inspection. See 4.0 of PD08WRGBGBEA04 for further details of these tests. (DI-NDTI-80566A/T, DI-NDTI-80603A/T, DI-NDTI-80809B)

3.6.4 Refurbishing. After completion of all inspection and testing the first article/preproduction 72 kW / 90 kVA Generator Sets shall be shipped back to the contractor facility for refurbishment. The first article/preproduction 72 kW / 90 kVA Generator Sets shall be retained at the contractor facility until the last shipment on the last delivery order and shall serve as the manufacturing standard(s). The contractor shall be responsible for any repairs that may be necessary to restore the unit to a serviceable condition while retaining configuration integrity. The contractor shall be responsible for all costs associated with delivery of the first article/preproduction 72 kW / 90 kVA Generator Sets to the contractor's facility for refurbishment.

3.6.5 Production acceptance test procedure and report. The contractor shall develop production acceptance test procedures based on the requirements specified in 4.4 of PD08WRGBGBEA04. The contractor shall test each unit in accordance with the approved production acceptance test procedures. The contractor shall enclose a test report for each 72 kW / 90 kVA Generator Set with the unit pack up data. (DI-NDTI-80603A, DI-NDTI-80809B/T)

3.7 Technical data.

3.7.1 Technical order. The contractor shall develop and submit technical orders for the 72 kW / 90 kVA generator set. The manuals’ technical accuracy and content shall be verified before final acceptance by the Government. Note: excluding the first article/preproduction 72 kW / 90 kVA Generator Sets, no 72 kW / 90 kVA Generator Set delivery acceptance will occur without completed and Government accepted technical manuals. (TM-86-01M)

3.7.2 Provisioning. The contractor shall identify and recommend logical spare/repair parts sufficient to meet system/equipment operation and supportability in accordance with the Air Force Initial Provisioning Performance Specification (IPPS). MIL-PRF-49506 shall be used as a guide. Format shall be consistent with existing Government Provisioning data system (D220). The following Data Item Descriptions (DID) apply:

DI-ALSS-81529 Provisioning Technical Documentation (PTD); specific PTD to be submitted is Provisioning Parts List (PPL), Design Change Notices (DCNs).

DI-ALSS-81557 Supplement Data For Provisioning (SDFP).

DI-ALSS-81350/T LMI Summary worksheet for Hand Tools List; Standard Modified Hand Tools List.

3.7.3 Aircraft transportability certifications. The contractor is responsible for providing all required data to the procuring activity in order to obtain all necessary aircraft transportability certifications. This data shall be provided with the preliminary first article test data.