PWS.doc

PERFORMANCE-BASED WORK STATEMENT (PWS)

for TH-1H Depot Level Maintenance On

TH-1H Helicopter

Special Operation Forces/Personnel Recovery (SOF/PR)

Date: 25 March 2013 Helicopter Integrated Product Team

AFLCMC/WIUBA

235 Byron Street, Suite 19A

Robins AFB GA 31098-1670

Purchase Request: FD2060-13-31131 DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors (Administrative or Operational Use; 11-03-28). Other requests for this document shall be referred to AFLCMC/WIUBA Robins AFB, GA 31098-1670.

1.0 DESCRIPTION OF SERVICES

This PWS establishes a standard Depot Level Maintenance (DLM) capability for the TH-1H model aircraft. The primary purpose for the DLM program is to accomplish aircraft structural inspections and repairs concurrent with zonal inspections at a depth and skill level greater than that available at Organizational and Intermediate (O&I) maintenance levels. All work performed under this PWS will be in accordance with the publications, technical manuals and specifications identified herein. All activities/services shall be under the guidance of Government personnel. The basic Period of Performance (PoP) is for one year with four annual options. The contractor shall furnish all necessary labor, supervision, equipment, tools, materiel, consumable supplies and facilities, except as otherwise noted herein. The DLM requirements shall also include scheduled/ unscheduled maintenance and the deployment of Contractor Field Teams (CFT). Emergent Drop-In maintenance will be considered an unscheduled requirement. Although drop-in maintenance is available on this contract, there is no guarantee that any drop-in maintenance will be performed. The contractor shall possess current, direct aircraft maintenance and extensive logistics and program management knowledge and experience of the TH-1H helicopter. The Services Summary highlights the following tasks: develop and provide presentation materials, provide studies/logistics services accurately, provide status reports promptly, mishap notification and reporting when necessary, accomplish inspection, correction, and repair of drop in maintenance, and accomplish reassembly and inspection to certify airworthiness and to prepare aircraft for delivery. This requirement is to be accomplished at the Contractor’s facility. This effort will benefit the war fighter by providing a safe and structurally sound helicopter to facilitate Student Utility Pilot Training. This task is considered mandatory for the efficient operation of AFLCMC/WIUBA, WIUB, and WIUBA.

2.0 SERVICES SUMMARY (SS)

3.0. GOVERNMENT FURNISHED PROPERTY, EQUIPMENT, MATERIAL, and SERVICES (GFP/GFE/GFM/GFS)

3.1. Government Furnished Property/Facilities – Except as identified in Appendix B the contractor shall furnish all repair parts, materiel, and supplies required for performing the work of this PWS. The USAF will provide salvage aircraft hulks to the Contractor as Government Furnished Property (GFP). These aircraft will be cannibalized as a source of supply for customer aircraft undergoing DLM. Disposition of GFP will be provided at contract completion.

3.1.1 Government Furnished Material (GFM): Control procedures for GFM at the contractor’s facility shall include, as a minimum; inspection for completeness, proper type, and damage occurring during shipment, identification and protection from improper use or disposition. Report to the CFA/CFR any damaged equipment or material malfunctioning, or otherwise unsuitable for its intended use.

3.2. Government Furnished Information – Throughout the duration of this contract, the contractor will be provided access to USAF engineering and technical data. The Government will provide, as necessary, access to maintenance information systems that will allow the contractor to input information on completed tasks. Access to appropriate Government legacy sustainment related computer systems will be provided for the Contractor upon obtaining a Common Access Card (CAC). See PWS paragraph 3.4 for procedures for obtaining a CAC. The Government will retain ownership of all data after contract completion.

3.3. Reporting Loss of Government Property (FEB 2011)

a. Definitions. As used in this clause— “Government property” is defined in the clause at FAR 52.245-1(a), Government Property. “Loss of Government property” means unintended, unforeseen, or accidental loss, damage, or destruction of Government property that reduces the Government’s expected economic benefits of the property. Loss of Government property does not include purposeful destructive testing, obsolescence, normal wear and tear, or manufacturing defects. Loss of Government property includes, but is not limited to—

(1) Items that cannot be found after a reasonable search;

(2) Theft;

(3) Damage resulting in unexpected harm to property requiring repair to restore the item to usable condition; or

(4) Destruction resulting from incidents that render the item useless for its intended purpose or beyond economical repair.

“Unit acquisition cost” means—

(1) For Government-furnished property, the dollar value assigned by the Government and identified in the contract; and

(2) For Contractor-acquired property, the cost derived from the Contractor’s records that reflect consistently applied, generally acceptable accounting principles.

b. Reporting loss of Government property.

(1) The Contractor shall use the Defense Contract Management Agency (DCMA) eTools software application for reporting loss of Government property. Reporting value shall be at unit acquisition cost. The eTools “LTDD of Government Property” toolset can be accessed from the DCMA home page External Web Access Management application at http://www.dcma.mil/aboutetools.cfm.

(2) Unless otherwise provided for in this contract, the requirements of paragraph (b)(1) of this clause do not apply to normal and reasonable inventory adjustments, i.e., losses of low-risk consumable material such as common hardware, as agreed to by the Contractor and the Government Property Administrator. Such losses are typically a product of normal process variation. The Contractor shall ensure that its property management system provides adequate management control measures, e.g., statistical process controls, as a means of managing such variation.

(3) The Contractor shall report losses of Government property outside normal process variation, e.g., losses due to Theft; Inadequate storage; Lack of physical security; or “Acts of God.”

(4) This reporting requirement does not change any liability provisions or other reporting requirements that may exist under this contract.

3.4 Common Access Card (CAC) Requirements: The employee's Contracting Company's Security Point of Contact shall forward a CAC request to the appropriate Government Contracting Officer. The Government Contracting Officer will sign and submit letter to the Government Contracting Officer Representative (COR) requesting concurrence for the issuance of a CAC. The COR will forward the CAC request to the Government Trusted Agent (TA) for processing. Email notification will be provided by the TA to contract employee once information is loaded in Trusted Associate Sponsorship System (TASS). Contractor has 30 calendar days to complete application process. User ID and Temporary Password will be provided - contractor has seven days to initially log into TSS system.

4.0 GENERAL INFORMATION – If the contractor fails to meet any minimum performance requirements, the Government will provide increased surveillance until the contractor meets all minimum performance requirements for six consecutive months. (During this time, all monthly reports required under the Services Summary section of this PWS will be required bi-weekly instead of monthly).

4.0.1 Use of AF Technical Data - Use of AF Technical Orders to perform depot maintenance tasks is mandatory with the following exceptions: If an AF approved Bell Work Instruction exists for the maintenance task, it is acceptable to utilize the existing work instruction. If no work instruction exists, the AF T.O. or equivalent Bell Helicopter Maintenance Manual is to be used. A work instruction shall be developed and approved by the AF prior to use. If no equivalent Bell Maintenance Manual task or work instruction exists, the AF T.O. shall be used. All revisions to AF T.O.s and/or Bell Maintenance Manuals that occur during this work effort shall be reviewed and included as part of the DLM work process. The applicable Bell Work Instruction shall be updated to reflect the revision. A separate Work Instruction will be developed to show 100% compliance with AF 6WC-1 &-2 work cards.

4.1 Meetings, Briefings, and Presentations – The Contractor shall coordinate and support logistics and production working group meetings as required. The Contractor shall provide agendas, briefing materials, minutes, and other supporting documentation to all meeting participants. As a minimum, the Contractor shall be proficient in the Microsoft (MS) Office Suite, to include MS Word, MS Excel, MS PowerPoint, and MS Project. The Contractor provides draft presentation materials seven working days prior to scheduled presentation at least 90% of the time. After Government comments and Contractor has made corrections, final presentation materials shall be submitted NLT two working days before conference, meeting or review. Conference minutes shall be submitted within seven working days after the conference, meeting or review. Government Program Manager will review and approve/disapprove within five working days. Contractor shall have five working days to incorporate comments and resubmit.

The Contractor shall provide directed deliverables on schedule with no more than two typographical or editorial errors. (DI-ADMN-81249A), DI-ADMN-81250A, DI-ADMN-81373) (CDRLs A001, A002, A003)

4.1.1 Technical Report-Studies/Services – The Contractor shall provide requested technical reports-studies-services as required in support of the TH-1H helicopter DLM. The Contractor shall provide data deliverables five working days after completion of review, study, analysis, etc. Final copies shall be delivered within 10 days after receipt of corrections from the Government. Government Program Manager will approve/disapprove within 15 working days. Contractor shall incorporate comments and resubmit within five working days. (DI-MISC-80508B) (CDRL A004)

4.2. Reports – The Contractor shall submit monthly status reports to the Government. These reports shall cover services provided by the Contractor during the last monthly period. The Contractor shall document task status, data deliverable, contract issues and actions, expenditure data, and anticipated task requirements for the next reporting period. The Contractor shall provide monthly status reports no later than ten working days after accounting close. The contractor’s report shall be complete and accurate so that the number of report rejections shall not exceed one per quarter. Rewritten reports shall be resubmitted to AFLCMC/WIUBA within five working days. (DI-MGMT-80368A) (CDRL A005)

4.2.1 - The PDM process shall include thorough and complete documentation of all inspections and testing, rework and repair tasks accomplished on each aircraft. An Inspection and Testing Report will be submitted to the CFA by the rework facility to identify specific defects and deficiencies on each PDM aircraft. A Rework Report shall be developed by the rework facility to identify specific rework tasks to accomplish as a result of the Inspection and Testing Report. Any repair task that does not meet authorized rework criteria must be approved by the CFR. During the PDM effort, the rework facility shall document all repair, inspection and quality control tasks. The Repair Report will be used by the rework facility and CFA to verify repair tasks were accomplished satisfactorily. The PDM process documentation must meet the approval of the CFA. The Contractor provides draft report ten working days prior to scheduled telecon to discuss the results of the inspection and recommended rework on each aircraft inducted into the Programmed Depot Maintenance (PDM). Final report will be submitted at final aircraft delivery. (DI-MISC-81391/T, Analytical Condition Inspection Report) (CDRL A007)

4.3. Services – The contractor shall provide logistics/program management services to support all reviews; e.g., program audits, Program Management Reviews (PMRs), Weapon System Review (WSR), In Process Reviews (IPRs), etc.

4.4. Performance Of Service During Crisis - The Functional Commander/Director has determined, by placing in writing their decision, that this requirement is not Mission Essential (M-E) in accordance with DoDI 1100.22, Policy and Procedures for Determining Workforce Mix and DFARS 237.76, Continuation of Essential Contractor Services.

4.5. Administration – Only the Procuring Contracting Officer (PCO) has the authority to represent the Government in cases where the contract requires a change in the terms and conditions, delivery schedule, scope of work, and/or price of the products and/or services acquired.

4.6. Inspection Of Services Clause - The Government reserves the right to invoke the provisions/remedies under FAR 52.246-4, Inspection of Services-Fixed Price, FAR 52.246-5, Inspection of Services-Cost Reimbursement, and FAR 52.246-6, Inspection of Services-Time & Materiel (T&M) for any “Service” determined by the Government to be unacceptable.

4.7. Environmental Management System (EMS) - In accordance with the SAF Requirements for Contracts Performed on Air Force Installations, dated 11 Dec 06, and the AFMC/CV Policy Letter, Conformance with Air Force Environmental Management System (EMS) Requirements Policy Letter, Conformance with Air Force Environmental Management System (EMS) for Contracts Performed on Air Force Installations, dated 1 Aug 07, Contractor personnel who perform work on any USAF installation shall comply with the EMS requirements established by the installation.

4.7.1 The prime Contractor shall ensure subcontractors comply with the EMS requirement

4.8 Green Procurement Program (GPP) - GPP is a mandatory federal acquisition program that focuses on the purchase and use of environmentally preferable products and services. GPP requirements apply to all acquisitions using U. S. Government appropriated funds, including services and new requirements. FAR 23.404(b), Agency Affirmative Procurement Program, applies and states the GPP requires 100% of EPA designated product purchases that are included in the Comprehensive Procurement Guidelines (CPG) list that contains recovered materials, unless the item cannot be acquired: (a) competitively within a reasonable timeframe; (b) meet appropriate performance standards, or (c) at a reasonable price. The prime contractor shall be responsible for ensuring that all subcontractors comply with this requirement.

4.9 SECURITY REQUIREMENTS (UNCLASSIFIED)

4.9.1 General - Actual knowledge of, generation, or production of classified information is not required for performance of the contract. Cleared personnel are required to perform this service because security measures which are in force do not preclude access to classified information.

4.9.2 Operations Security (OPSEC) - Contractor personnel will participate in the OPSEC program locally administered by the Air Force (AF) activity.

4.9.3 Employee Clearances - Contractor employees that need access to Government owned Automated Information Systems (AIS) will require the minimum of a Favorable National Agency Check (NAC). Submit a Standard Form 85P, Questionnaire for Public Trust Positions, (fingerprint cards if available) to the AFLCMC WIU Security Office for processing.

4.9.4 Security Incidents and Violations - The contractor will immediately notify the AFLCMC/WIUBA division security team of any actual security violation, security incident, or of any indication of a potential unauthorized disclosure or compromise of classified or sensitive but unclassified information.

4.10 SAFETY REQUIREMENTS

4.10.1 Contractor Compliance - Contractors shall comply with Occupational Safety and Health Act (OSHA) Public Law 91-596, OSHA Standard 29 CFR 1910, and OSHA Standard 29 CFR 1925 for the protection of their employees. To ensure the protection of Air Force personnel, assets and interests, the contractor shall be solely responsible for compliance with all federal, state and local laws, codes, ordinances, regulations, the Occupational, Safety and Health Act (Public Law 91-596) and the resulting OSHA Standards 29 CFR 1910 and OSHA Standards 29 CFR 1925, all Air Force Occupational Safety and Health (AFOSH) Standards, and any applicable local guidance. The contractor shall establish and maintain a safety and health program detailed in a written Contractor’s Safety and Health Plan. The Air Force is part of the OSHA Voluntary Protection Program (VPP). All shall familiarize themselves with the requirements of VPP.

Information on the VPP can be accessed at http://www.osha.gov/dcsp/vpp/index.html. Additionally, the contractor is responsible for the safety and health of all subcontractor employees.

4.10.2 Mishap Notification - The contractor shall telephonically notify the Safety office within four (4) hours of all aircraft mishaps entrusted by this contract operation. No more than one instance of late mishap notification per calendar year is acceptable. Follow all other reporting requirements as identified on the DD1423, CDRL A006, for Accident/Incident Report (Mishap Notification & Reporting) (DI-SAFT-81563/T).

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

4.11 Packaging - (MIL-STD-2073-1d, 10 May 02, Standard Practice for Military Packaging and MIL-STD-129P (4), 19 Sep 07, Military Marking for Shipment and Storage). When shipping containers are received that meet the requirements of the AFMC Form 158, Packaging Requirements, and are suitable for return shipment of serviceable assets, they shall be reclaimed, stored and protected for reuse. Unserviceable containers shall be disposed of and replaced as directed by the SPO.

4.12 Item Unique Identification (IUID) Requirements: The contractor shall comply with Office Secretary of Defense (OSD) mandate regarding the Item Unique Identification (IUID) program which requires each qualifying Air Force (AF) asset to be uniquely identified with a permanent marking that can sustain its information throughout the life of the asset. IUID requirements are specified in Defense Federal Acquisition Regulation Supplement (DFARS) 252-211.7003, Item Identification and Valuation and Department of Defense (DoD) 4100.39-M, Federal Logistics Information System (FLIS). All TH-1H aircraft and components that have IUID marking accomplished are recorded in the DoD IUID Registry. If during the DLM process, the Unique Identifier (UII) is removed the contractor shall ensure that it is reapplied per the attached TH-1H IUID label replacement guide, Appendix G, and the applicable TCTO.

4.13 Contractor Manpower Reporting Requirements - Per reference SAF/AQ Memo, 13 Nov 12, “The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the USAF via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil (select Dept of the Air Force option if you you’re working an AF requirement). Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October* of each calendar year. Contractors may direct questions to the CMRA help desk.”

4.13.1 Uses and Safeguarding of Information - Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.

4.13.2 User Manuals - Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for Government personnel and contractors are available at the CMRA link at http://www.ecmra.mil (select Dept of the Air Force option if you you’re working an AF requirement).

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

4.15 Travel – The Contractor may be required to travel for the performance of the work described within this PWS. Travel may include locations within/outside of the continental United States. Contractor agrees that while flying commercial air travel allocable to this contract/order, to use air coach, tourist class or similar accommodations to the extent consistent with the successful and economical accomplishment of the mission for which the travel is being made. All travel by the contractor in support of this PWS shall be performed IAW the Joint Travel Regulation (JTR). Travel will reimbursed according to the rates outline in the Federal Travel Regulations for travel within the continental United States (CONUS) and the rates established by the Department of State for travel outside of the continental United States (OCONUS). The applicable rates are those in effect at the time of travel and are subject to the limitations outlined in FAR Part 31.205-26. Airfare shall consist of no more than coach class seating while vehicle rentals shall be consistent with the most economic and reasonable rates available. In most circumstances, economy class vehicles will suffice. All travel must be concurred with by the AFLCMC/WIUBA Program Manager (PM) and approved by the Procuring Contracting Officer (PCO), five business days in advance of the travel. Trip reports shall be submitted to AFLCMC/WIUBA NLT five working days upon return from the trip. (DI-MGMT-80368A/T) (CDRL A005)

4.16 COGNIZANT FIELD AUTHORITY (CFA)/GOVERNMENT COGNIZANT FIELD REPRESENTATIVE (CFR)

4.16.1 Cognizant Field Authority (CFA) - The CFA is responsible for ensuring all Government interests are met and all requirements of the DLM contract are accomplished. The CFA is also assigned the responsibility and the authority to approve all or portions of in-service engineering functions, to determine logistic requirements, to negotiate contractual requirements, to review budgeting, and to coordinate necessary program and material management to support the DLM effort. In addition, the CFA is responsible for monitoring and evaluating the maintenance effort. The CFA will determine effectiveness and efficiency of the depot facility in accomplishing the required depot level maintenance tasks, in maintaining acceptable quality standards, and in meeting required delivery schedules. The designated USAF CFA is listed below:

Department of the Air Force

Special Operations Forces (SOF)/ Personnel Recovery (PR) Sustainment Group

AFLCMC/WIUBA

235 Byron Street, Suite 19A

Robins Air Force Base (AFB) GA 31098-1670

4.16.2 Government Cognizant Field Representative (CFR) - The CFR is the on-site Defense Contracting Management Administration (DCMA) Government representative for the CFA at the depot facility. Their responsibilities and authority are delegated by the CFA, and are partly defined by this PWS. The CFR is responsible for on-site monitoring of the DLM process to ensure proper compliance and execution by the depot facility of the requirements stated herein. The CFR is also responsible for accomplishing CFR tasks assigned in the PWS and as directed by the CFA. In addition, the CFR is the contractor facility’s direct point of contact for addressing DLM implementation issues.

4.16.3 Authority - This DLM PWS has been reviewed and approved by the CFA for the U.S. Air Force (USAF), and is authorized for use on all USAF TH-1H aircraft. Program management of the DLM process is the responsibility of the CFA. Execution of the DLM requirements will be monitored by the CFR.

4.16.4 Maintenance actions such as modifications or special inspections may be required on an over-and-above basis with prior Cognizant Field Authority/Cognizant Field Representative (CFA/CFR) approval.

4.17 Drop-in Maintenance/Depot Field Team (DFT)

4.17.1 Drop-in maintenance (un-programmed requirement) shall be performed on aircraft received from the using activity that require maintenance at a depth and skill level greater than that available at O&I maintenance levels. Contractor shall accomplish inspection, correction, and repair of drop in maintenance aircraft. Aircraft shall be estimated, negotiated, and charged to the contract IAW the Over and Above procedures. The Contractor shall accomplish repair of aircraft at no additional charge and with minimal delay to delivery schedule. Technical inspection of the completed work shall be accomplished by the CFR. Examples of drop-in maintenance include:

Battle damage repair

Mishap repair

Damage to primary structural elements (PSE)

Maintenance induced damage

Corrosion damage repair/parts replacement

Hard Landing Assessments

4.17.2 Depot Field Teams (DFT) will be deployed off -site IAW the applicable contract Time & Materiel Man Hour (T&M MH) CLIN rate to inspect the aircraft in order to accomplish limited depot level maintenance separate from their primary facility in cases where a TH-1H is not safe for flight or to accomplish aircraft modifications off-site. DFTs shall be responsible for performing all maintenance related tasks as defined by AFLCMC/WIUEC’s engineering disposition provided by AFLCMC/WIUEC on a form T.O. 00-25-107 (Maintenance Assistance Request) and the accompanying PWS. Labor shall be charged to the CLIN and material shall be estimated, negotiated, and charged to the contract IAW the Over and Above procedures.

4.18 DLM REQUIREMENT

4.18.1 All documents required for execution of this PWS are identified in this document. If a situation arises where work is required for which no documentation exists, AFLCMC/WIUBA is to be notified. Temporary instructions will be originated and approved by AFLCMC/WIUEC. These instructions will be identified in the next revision to this document or will be incorporated into an existing document which is already identified.

4.18.2 The total DLM cost for each Air Force TH-1H Helicopter shall not exceed the negotiated repair price as agreed upon between the Government and the Contractor. The target goal for the PDM completion is 120 working days from induction of the aircraft at the contractor’s facility to ready for departure to home station.

4.18.3 Sequence of Work - The typical repair process is outlined in Figure 1. This is a generalization from the delivery to the depot level maintenance facility up to the final acceptance check flight and receipt by the custodian. The organization of the DLM PWS outlines the sequence of work performed during the repair process.

Figure 1. Typical DLM Process Flow

4.18.4 DLM Repair Standards and Defect Classification - A fundamental task associated with the DLM process includes objectively classifying defects in order to determine if a defect requires correction during the DLM process. The following paragraphs outline the methods for classifying defects discovered during the repair process to determine if the defects require maintenance under the DLM program and to establish a general level of expectation as to the quality of repair.

4.18.5 Defect Classifications - A defect (synonymous with discrepancy) is defined as any deviation, disagreement, difference, or inconsistency, physical or otherwise, of an aircraft part or assembly from the design specification, usage, or operation. A defect classification decision tree is provided in Figure 2.

4.18.6 Critical Defect - A critical defect is a defect that is likely to result in hazardous or unsafe conditions for individuals operating or maintaining the aircraft, system, or component. All critical defects discovered as a direct result of, or incidental to, compliance with DLM requirements shall be corrected.

4.18.7 Major Defect - A major defect is a defect other than critical that is likely to result in failure, or to materially reduce the usability of an aircraft system or component from its intended purpose. All primary airframe structural cracks shall be classified as major defects at a minimum. Major defects discovered as a direct result of/or incidental to, compliance with DLM requirements that require depot level maintenance, affect minimum mission equipment required for delivery, or as approved by the CFA/CFR shall be corrected.

4.18.8 Minor Defect - A minor defect exceeds negligible limits, however, is not likely to materially 8reduce the usability of a system or component for its intended purpose, or is a departure from established standards having no significant bearing on the effective use or operation of the system or component. As a general rule, minor defects should not be corrected, but recorded on the Noted But Not Corrected (NBNC) report unless otherwise directed by the CFA/CFR.

4.18.9 Defect Correction Criteria - Defect classification determines whether or not a defect shall be corrected. A decision tree is provided in Figure 3 to determine defect correction disposition. Defect correction shall be subject to the approval of the CFA/CFR.

4.18.10 Defects Caused by Depot Facility - All defects caused by the depot facility shall be corrected at no cost to the customer.

4.18.11 Noted But Not Corrected Defects (NBNC) - O/I-level defects not authorized to be corrected by the above criteria shall be identified by type, location, and description on the NBNC Report for appropriate action by the gaining custodian

4.18.12 Nonstandard Repairs - Any nonstandard repair discovered during the DLM process shall be considered a defect. Any previous repair that is not authorized by, or does not meet the standards of quality, security, or strength of the applicable maintenance references shall be considered a defect.

Figure 2 - Defect Classification & Disposition

Figure 3

4.18.13 Over-and-Above Maintenance - Any DLM maintenance task that is not negotiated as part of the aircraft work package will be considered over-and-above maintenance. All over-and-above maintenance must be approved by the CFA/CFR prior to correction.

4.18.14 Nonstandard Modifications - Any airframe or structural modification that is intended to be temporary and is discovered during the DLM process shall not automatically be considered a defect. The depot facility shall notify the CFA/CFR and the engineering support activity prior to correction of any nonstandard modification.

4.18.15 Special Work Requests - A Special Work Request, which includes AFTO Form 103, contains inspection or maintenance actions that are not considered part of the DLM process. These are considered over-and-above maintenance requirements that must be negotiated separately between the contractor and the CFA/CFR. Owning activities shall submit these Special Work Requests in sufficient time to permit an evaluation by the contractor, and approval and funding by the Government. Special Work Requests must be submitted to the CFA via the appropriate chain of command. A Special Work Request shall be accomplished only if agreed upon by the repair activity, and approved and funded by the Government.

4.18.16 Workmanship and Repair Standards - The depot facility shall ensure that all maintenance tasks are assigned to and performed by personnel with sufficient experience, qualifications, and supervision to accomplish the tasks IAW standards and criteria specified herein.

4.19 Acceptance and Rejection Criteria - The CFA/CFR shall judge whether defects have been corrected satisfactorily, and that applicable maintenance standards have been met with respect to materials, workmanship, design, construction, cleanliness, quality, and documentation. The CFA/CFR shall have final approval on determining if the aircraft has been delivered in acceptable condition and that all applicable quality control standards have been met.

4.19.10 AFTO Form 103 –Areas on the aircraft that are beyond the capability of the unit and need to be worked during the DLM process will be submitted by the owing activity on an AFTO Form 103. Organizational maintenance, inspections, and Time Compliance Technical Orders (TCTOs) may be identified for negotiations. If a TCTO is dependent on a kit, the unit will supply it. Supplemental 103’s are permissible at the time of aircraft induction.

4.19.11 Reporting Requirements - The responsible office at the depot facility shall prepare reports IAW the requirements specified herein and in Appendix A. All reports required by this specification shall be submitted to AFLCMC/WIUBA.

4.19.12 Technical Order System Deficiency Report (AFTO Form 22) - When a deficiency exists in official publications, deficiencies shall be reported. An AFTO Form 22 shall be submitted IAW T.O. 00-5-1 (Air Force Technical Order System). Technical data errors relating to work stoppage shall be submitted to AFLCMC/WIUBA for resolution.

4.19.13 Nondestructive Inspection Technique Change (AFTO Form 242) - If any inspection contained in T.O. 1H-1(U)N-36 (Nondestructive Inspection, USAF Series UH-1N/UH-1H/TH-1H Helicopters) is found to be deficient, AFLCMC/WIUBA will be contacted for clarification and procedures to correct the deficiency. If required, prepare and submit an AFTO Form 242 IAW T.O. 33B-1-1 (Non-Destructive Inspection Methods, Basic Theory).

4.19.14 Photographs - Copies of any photographs taken to illustrate or better depict major defects shall be delivered to AFLCMC/WIUBA. Each photograph shall be marked to show discrepancy location, identified by aircraft serial number, part number and T.O. 1H-1(U)N-36 (Nondestructive Inspection, USAF Series UH-1N/UH-1H/TH-1H Helicopters) inspection number. The series of photographs shall begin at a broad level and zoom in to the defect so that the defect location can be easily identified.

4.20 DLM Documentation - The depot facility shall perform or participate in certain reporting functions required to ensure technical accuracy, quality, timeliness, effectiveness, efficiency, and safety of the DLM process.

4.20.1 The depot facility shall maintain records of work accomplished on DLM aircraft. However, upon request AFLCMC/WIUBA shall have access to all depot facility records of any DLM aircraft. The depot facility shall ensure that all aircraft records and documentation are updated and accompany the aircraft when returned to the customer. The depot facility shall maintain archives of all maintenance performed in accordance with depot facility instructions.

4.20.2 A notation shall be made in the "Significant Historical Data” column of the airframe AFTO Form 95 indicating day, month, year and aircraft time that DLM was accomplished IAW T.O. 00-20 series (Aerospace Equipment Maintenance Inspection, Documentation, Policy and Procedures). Annotate “DLM complied with”.

4.20.3 As DLM is completed and prior to AF acceptance, inventory all components with AFTO 95s and verify the correct match of serial numbers between forms and components. AFTO Form 95 discrepancies will be immediately reported to AFLCMC/WIUBA. No aircraft is to be released until all such discrepancies have been corrected.

4.20.4 Process Reports - The DLM process shall include thorough and complete documentation of all inspections, testing, and repair tasks accomplished. An Inspection and Discrepancy Report shall be submitted to the CFA/CFR by the depot facility to identify specific defects and deficiencies. The repair documentation shall be used by the depot facility and the CFA/CFR to verify that repair, inspection, and quality control tasks, were accomplished satisfactorily. The DLM process documentation shall meet the approval of the CFA/CFR.

4.20.5 DLM Inspection and Testing Record - The depot facility shall maintain adequate records of all DLM inspections and tests. The use of locally-designed and reproduced worksheets to facilitate recording information is authorized subject to the approval of the CFA/CFR. As a minimum, all discrepancy data will include a detailed description of the discrepancy (crack, wear, corrosion etc.) size (length, width, depth etc.), and location (WL, FS, BL coordinates). All DLM data shall be captured in an electronic data base and submitted to the CFA in electronic format (Excel, Word, Access etc.) within 30 days aircraft acceptance following DLM completion.

4.20.6 DLM Repair Report - Information and data collected during inspection and testing shall be used by the depot facility and the CFA/CFR for determining the extent of repair, modification, or replacement necessary to make the aircraft serviceable. Information and data collected shall also be used for the preparation of man-hour and cost estimates, and for determining required parts. The resulting analysis shall generate a DLM Repair Report, agreed to between the CFA and the depot facility that identifies the specific repair tasks to accomplish.

4.20.7 DLM Completed Repair Report - A complete and thorough report that lists and describes all of the inspection, repair, and quality control tasks accomplished by the depot facility during the DLM process shall be submitted to the CFA/CFR. This document is intended to be used by the CFA/CFR for verification of the completed repair process.

4.20.8 DLM Status Reports - The depot facility shall submit routine DLM process status reports to the CFA/CFR, as required.

4.20.9 DLM Management Reports - The objective of the DLM program is to introduce mechanisms to reduce costs, manage materials, refine production time estimates, and permit control of the DLM process. To accomplish this objective, the CFA/CFR will require information from the depot facility in regard to costs, man-hours, materials, and scheduling.

4.20.10 Initial Bill of Materials (BOM) - For each aircraft, a BOM shall be developed by the depot facility to identify, as early as possible, those aircraft parts that will require repair or replacement and provided to the CFR in electronic format.

4.20.11 Rough Order Of Magnitude (ROM) Cost Estimate - For each aircraft, a Rough Order of Magnitude (ROM) cost estimate shall be developed by the depot facility to estimate the costs of accomplishing O&A repair on each aircraft. The ROM cost estimate shall contain an itemized breakdown of all material, man-hour, and total costs to repair the subject aircraft. Material costs for the ROM cost estimate may be derived from information contained in the Initial BOM. Man-hour cost estimates may be derived from information gathered from the Inspection and Testing Record. The ROM Cost Estimate shall be submitted to the CFA/CFR through the agent of the depot facility.

4.20.12 Milestone and Schedule Report - For each aircraft, the depot facility shall develop a time-line (Integrated Master Schedule (IMS)) or MS Project, with significant milestones or benchmarks that clearly define the DLM process schedule and that is updated and submitted to the CFA on a monthly basis.

4.20.13 Material Management Report - For each aircraft, a Material Management Report shall be developed by the depot facility that summarizes the status of materials to be requisitioned, repaired, or locally manufactured, and that is updated and submitted to the CFA on a monthly basis.

4.21 ECONOMIC REPAIR, CONDEMNATION, AND REPLACEMENT OF PARTS

4.21.1 Economical Repair Determination - The economic repair limits for items shall be determined by the criteria of T.O. 00-20-3. Items beyond economic repair or nonreparable items shall be replaced with a serviceable item from Government supply. Items beyond economic repair shall be repaired or manufactured only when authorized by AFLCMC/WIUBA.

4.21.2 Condemnation - The depot facility shall not repair items where the cost of parts and labor exceeds 75 % of the replacement cost of the item unless authorized by AFLCMC/WIUBA due to the criticality of the item. Parts, components, subassemblies, or assemblies found worn or defective beyond economic repair shall be condemned and disposed of IAW applicable maintenance manual.

The depot facility shall not condemn reparable items without prior approval by AFLCMC/WIUBA. Reference T.O. 00-20-3 (Maintenance Processing of Reparable Property and the Repair Cycle Asset Control System).

4.21.3 Replacement of Parts – If during the DLM process, the contractor runs into a situation that requires the replacement of an unserviceable reparable item, the following procedures shall apply: Fort Rucker LRS will be the ordering point for all XD2 reparable (dynamic components). Parts shall be ordered with Signal Code “J”, (Ship to Supplementary Address/Bill to Requisitioner). The contractor shall be required to utilize a valid supplementary address assigned to their facility. Unserviceable components will be returned to the owning unit, Fort Rucker, for replacement and to clear Due In From Maintenance (DIFM) details. All applicable tags and AFTO 95 forms will accompany each returned component.

4.22 ENGINEERING

4.22.1 Engineering Support Services - The depot facility shall provide engineering support services to resolve technical and engineering issues that may arise.

4.22.2 Engineering Qualifications - Engineers directly responsible for authorizing the disposition of aircraft related discrepancies must have as a minimum a Bachelor's degree in Professional Engineering from an Accreditation Board for Engineering and Technology (ABET) accredited school. In addition to a degree, engineers must have a minimum of 3 years of engineering depot (commercial or military) support experience.

4.22.3 Process Engineering Support - The contractor shall provide engineering support to resolve engineering and technical process issues that may arise during the DLM, including continuous surveillance of the processes, or to solve problems, and to develop procedures, processes or repairs not provided by applicable technical publications. Evaluate and notify the CFA/CFR of any waiver or deviation to a required process or procedure.

4.22.4 TH-1H Engineering Support - The contractor shall provide engineering capability necessary for the depot level maintenance support of inspection and repair requirements for the TH-1H aircraft structure, aircraft systems, mission systems, and aircraft components. Any repair deemed a major structural repair (see Work Specification for definition of major structural repair) not covered by an applicable instruction, reference, or specification must be approved by the CFA/CFR. Prior to any repair disposition decision a judgment shall be made by the contractor that the repair will be cost-effective relative to other repair disposition alternatives.

4.23 DLM GENERAL MAINTENANCE

4.23.1 Policies and Practices - This section of the DLM PWS contains general policies and practices regarding the management of the DLM process.

4.23.2 Repair and Replacement of Flight Safety Critical Aircraft Parts (FSCAPs) - The contractor shall maintain an FSCAP program relevant to authorized DLM, preservation, and packaging. FSCAPs exceeding their prescribed maximum allowable limit shall be repaired or replaced IAW the applicable maintenance manual. A list of FSCAPs is provided in TH-1H DLM Work Specification TH-1H-13-070-001.

4.23.3 Precision Measuring Equipment (PME) - Test equipment used in accomplishing inspection requirements of DLM shall be PME for each specific task as required. The contractor shall maintain calibration and certification of all PME, and shall ensure that any PME used is identified properly as being current within its calibration criteria.

4.23.4 Aircraft Servicing and Security - The contractor shall support all ground servicing of the aircraft while the aircraft is located at the contractor’s facility, including fueling and defueling; aircraft movement and ground handling; and aircraft security.

4.23.5 Fueling and Defueling - Fueling and defueling of aircraft shall be performed IAW applicable aircraft technical manuals and local directives. Handling and storage of fuels shall be accomplished IAW MIL-STD-1518, (Storage, Handling, and Servicing of Aviation Fuels, Lubricating Oils, and Hydraulic Fluids at Contractor Facilities)(or commercial equivalent) and local directives.

4.23.6 Aircraft Movement or Ground Handling - Aircraft movement, ground handling, parking, and qualification of personnel handling and operating aircraft shall be accomplished IAW the applicable aircraft operator’s manual and local directives for handling aircraft.

4.23.7 Aircraft Security - Once the aircraft arrives at the location of the contractor’s facility, the contractor shall be responsible for aircraft’s physical security, including aircraft tie-down, storage, and hangaring, as applicable.

4.23.8 Severe Weather and Hurricane Evacuation - The contractor shall be responsible for providing adequate security of the aircraft during severe weather.

4.23.9 Airfield Requirements - Suitable airfield facilities shall be provided by the contractor, including airspace available to perform check flights. Tie-down and ground run-up areas shall be provided.

4.23.10 Hazardous Materials - Handling and disposal of Hazardous Materials (HAZMAT) shall be IAW applicable Federal regulations and local facility instructions.

4.23.11 Petroleum, Oils, and Lubricants (POL) - POL and compounds used in servicing the aircraft shall be as specified in the applicable aircraft operating manuals.

4.23.12 Usage and Handling of Gases - Usage and handling of gases shall be IAW T.O. 42B5-1-2 (Use, Handling and Maintenance Instructions-Storage Type Gas Cylinders).

4.23.13 Abrasive Materials - The use of abrasive materials to clean, buff, polish, and grind surfaces shall be IAW T.O. 1-1-691 (Aircraft Weapon Systems – Cleaning and Corrosion Control).

4.23.14 Drawing Configuration Management - The contractor shall maintain a configuration management process for engineering drawings and technical data. The configuration management process shall ensure all recommended changes to engineering drawings for the TH-1H are captured and reviewed for accuracy and standardization, and that all approved changes are distributed, incorporated, and tracked.

4.23.15 Technical Data - The contractor shall be responsible for developing, maintaining, and updating a technical library to support the DLM process. The contractor shall ensure that all technical data required to accomplish inspection and repair of TH-1H aircraft is requested from the cognizant CFAs. A Listing of References is available in Section VII.

4.23.16 DLM Material Management - The contractor shall have material management processes and controls in place to ensure the proper security, storage, control, and accountability of aircraft parts and materials associated with the DLM process.

4.23.17 Disposition of Reparables and Consumables - Disposition of reparables and consumables shall be as prescribed by AFMAN 23-110 (USAF Supply Manual) or as directed by the CFA/CFR.

4.23.18 Nonconforming Material - The contractor shall establish and maintain a system for controlling nonconforming material, including procedures for identification, segregation, and disposition of repaired supplies.

4.23.19 Cannibalization of Parts - Cannibalization of any aircraft parts, avionics, accessories, or components shall not be conducted without authorization from the CFR.

4.23.20 Substitution of Parts - Replacement parts and material substitutions not specifically authorized by applicable documents shall be used only by authorization of the CFA/CFR. The engineering authority at the contractor shall perform an engineering review to ensure that any replacement component or substitute material has properties equal to or greater than those possessed by the original material or parts.