StatementWork_0825855_00_1.doc - - 01-14-2009.doc

30 JUNE 2008

Statement of Work (SOW) for

250KW/312KVA 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 250 kilowatt (kW) Motor Generator (MG) as described by PD07WRGBZOENF7.

2 APPLICABLE DOCUMENTS

The following documents are applicable to the SOW to the extent specified 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

2.1.2 Other Government documents, drawings, and publications.

PURCHASE DESCRIPTIONS

PD07WRGBZOENF7

250KW MOTOR 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-81335 Design Review Data Package

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

(Copies of these documents, with the exception of PD07WRGBZOENF7, are available online at http://assist.daps.dla.mil/quicksearch/ or www.dodssp.daps.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. Copies of PD07WRGBZOENF7 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 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 PD07WRGBZOENF7 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 PD07WRGBZOENF7, and the term "ARO" as used in PD07WRGBZOENF7, this text (SOW), and associated DD 1423s denotes "after the effective date of the contract/order."

3.0 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 MG 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. All program schedules shall be completed in accordance with the applicable DD 1423. This 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 (T.O.) completion, 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 240 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 3.5.3 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 meeting and reviews are held at 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/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 Government 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. The contractor shall plan for and conduct two “hands-on” operation and maintenance orientation sessions for the using activities to familiarize the users with the MG. The orientation shall include but not be limited to: operational familiarization, ease of maintaining the unit for both corrective and preventative efforts, support/test equipment review, unit safety features, application of technical manual to modes and effects, troubleshooting/fault isolation, and theory of operation. This orientation shall be held at the Government facilities as part of the operational test (see 3.6.2 herein and 4.3 of PD07WRGBZOENF7 for additional details of the operational test). Orientation shall occur after successful installation and initial power-up/loading of the MG set at each operational test location. The contractor shall provide any required materials (i.e. handouts, foldouts, etc) for up to fifteen (15) Government personnel and one copy of the draft version of the technical manual/technical order at each test location.

3.5 System engineering.

3.5.1 System safety. The contractor shall perform a system safety analysis in accordance with 4.1 through 4.8 of MIL-STD-882D. The final MG 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-80101B)

3.5.2 Reliability.

3.5.2.1 Basic reliability model. The contractor shall develop and maintain a basic reliability model for the MG based on requirements of 3.9.8 of PD07WRGBZOENF7. 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 3.5.3 herein) and reviewed at the design reviews.

3.5.2.2 Basic reliability prediction. The contractor shall prepare and maintain a basic reliability prediction for the MG (see 3.9.8 of PD07WRGBZOENF7); it shall be based upon the associated basic reliability model (see 3.5.2.1 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-217F (2), NPRD-95, or otherwise approved by the procuring activity. The basic reliability prediction shall be documented in the design analysis (see 3.5.3 herein) and reviewed at the design reviews.

3.5.3 Design analysis. A design analysis of the MG and each subsystem shall be performed to verify compliance with this SOW and PD07WRGBZOENF7. The analysis shall include, but is not limited to, a system hazard analysis (see 3.6 and 4.6.6.1 of the PD); a basic reliability model (see 3.5.2.1.1 herein) and predictions (see 3.5.2.1.2 herein). An initial design analysis shall be provided at the PDR; updated versions of the analysis shall be provided at the CDR and with the first article test report. (DI-MISC-80508B)

3.6 Product qualification. Testing and verification of the MG set shall be performed in accordance with 4.0 of PD07WRGBZOENF7. Excluding any preliminary contractor testing, official first article inspection shall be completed within a 90 calendar day period. Operational testing shall be completed within a 120 calendar day period.

3.6.1 Test support kit. The contractor shall provide a kit of common repair parts is during the first article inspection and the aircraft compatibility/operational test and evaluation inspection so that minor breakdowns do not delay the test beyond repair time required to return the MG to serviceable condition.

3.6.2 Aircraft compatibility/operational test and evaluation (OT&E) inspection. After successful completion and Government approval of all first article/preproduction inspection, the MG unit shall be subjected to a combined aircraft compatibility and operational test and evaluation (OT&E) inspection. Additionally, after the first article MG unit is received at the specified Government location, on-site contractor support shall be made available for a minimum of 3 business days and a maximum of 7 business days during initial installation, power-up, and loading. After the initial set up period is completed on-site contractor support shall be available (if needed) within 5 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 at the first location shall be completed within sixty (60) calendar days (excluding shipping time to the location). Upon arrival at the second installation on-site contractor support shall be made available for a minimum of 3 business days and a maximum of 7 business days during initial installation, power-up, and loading. Air Force users will conduct all tests. After the initial set up period is completed on-site contractor support shall be available (if needed) within 5 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 at the second location shall be completed within sixty (60) 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 T.O. for the MG shall be available for Government use during the aircraft compatibility/operational test and evaluation inspection.

3.6.2.1 Test locations. After successful completion and Government approval of all first article inspection, one first article/preproduction MG shall be shipped to Tinker AFB, OK. Following completion of the test activities at Tinker the first article/preproduction unit shall be shipped to Offutt AFB, NE for test conclusion.

3.6.2.2 Scheduled shipping. The contractor shall be responsible for scheduling and coordinating shipment of the first article MG set from OT&E test location one to OT&E test location two. Shipment of the first article unit shall be completed within 30 calendar days of the approved conclusion of test activities at OT&E location one.

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 PD07WRGBZOENF7 and this SOW. After 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 occurs; after approval the contractor shall schedule the testing to be conducted. Twenty (20) calendar days prior to first article/preproduction inspection 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 thirty (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 OT&E. See section 4 of PD07WRGBZOENF7 for further details of these tests. (DI-NDTI-80566A/T, DI-NDTI-80603A/T, DI-NDTI-80809B)

3.6.4 Production acceptance test procedure and report. The contractor shall develop production acceptance test procedures based on the requirements specified in 4.4 of PD07WRGBZOENF7. The contractor shall test each unit in accordance with the approved production acceptance test procedures. The contractor shall enclose a test report for each MG with the unit pack up data. (DI-NDTI-80603A, DI-NDTI-80809B/T)

3.6.5 Transportation and shipping. The contractor's shipping responsibility associated with the first article, or preproduction unit, shall include all liability and costs to move the unit to, from, and between locations for aircraft compatibility/operational test and evaluation (OT&E) inspection and shipping back to the contractors facility upon test completion. This shall include the costs to transport the MG from operational test location one to operational test location two, and shall also include any transport of the MG to the contractor’s facility for repair purposes if such cannot be accomplished on-site.

3.7 Technical data.

3.7.1 Technical Order/Manual. The contractor shall submit Technical Manual(s) in accordance with TM-86-01M. Note: excluding the first article/preproduction MG's, no MG 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 the existing Government provisioning data system (D220). The following Data Item Descriptions (DID) apply: DI-ALSS-81529 Provisioning Technical Documentation: Short Form Provisioning Parts List (SFPPL), Design Change Notices (DCNs), DI-ALSS-81557 Supplement Data For Provisioning (SDFP).