Attach_B_-_FINAL_Palletized_Seating_Statement_of_Work_-_31_Aug.pdf

FOR OFFICIAL USE ONLY

Tanker Directorate (AFLCMC)

KC-46 Division

WRIGHT-PATTERSON AIR FORCE BASE, OHIO 45433

Statement of Work

For

KC-46 Palletized Seating System

Contract No: FA8609-16-R-6726

Date: 31 Aug 2016

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Contents

1.0 Scope

2.0 Applicable Documents

2.1 Government Documents

2.2 Contractor Documents

3.0 Core Tasks

3.1 Program Management

3.2 Technical

3.3 Systems Engineering and Technical Management

3.4 Specification Updates

3.5 Quality Management (QA)

4.0 Engineering Change Proposals, Contract Change Proposals and Notice of Revisions

5.0 Certifications

5.1 Airworthiness

5.2 System Safety Risk Assessment Packages

6.0 Test

6.1 Acceptance Testing

6.2 Test Readiness Review (TRR)

7.0 Logistics Support

7.1 Logistics Support Management

7.2 Training

7.3 Technical Orders

7.4 Provisioning

8.0 Production

Acronyms and Abbreviations

1.0 Scope

The Government requests the contractor provide palletized seating systems to accommodate passenger carriage in KC-46 aircraft in both a 10-seat configuration and a 12-seat configuration.

The contractor shall provide a recommended solution to the government, along with necessary design information for fabrication and implementation. The contractor shall be able to produce a total quantity of thirty-two (32) palletized seating systems: twelve 10-seat pallets and twenty

12-seat pallets in the timeline and quantities established by the government under the “Core

Tasks” section of this Statement of Work (SOW). Further, the contractor will produce up to an additional forty-three seat pallets: twenty-four 10-seat and nineteen 12-seat pallets.

2.0 Applicable Documents

The contractor shall abide by all specifications, standards and handbooks specifically referenced herein. The most current version of each document, as of the date of this SOW, shall be used.

Revisions to contractor documents require Government concurrence prior to implementation under this contract. Second tier references called out by the Government documents listed in this section, and any referenced documents not specially imposed by the SOW, shall be used for guidance.

2.1 Government Documents

Standard Title Date

MIL-HDBK-516C Airworthiness Certification Current Version

MIL-STD-882E System Safety Current Version

MIL-HDBK-502A Product Support Analysis 3/8/2013

DoDD 4151.18 Maintenance of Military Materiel 3/31/2004

SAE AS8049 Performance Standard For Seats In

Civil Rotorcraft And Transport

Airplanes

Table 1 – Government Documents

2.2 Contractor Documents

Standard Title Date

Palletized Seating

Specification

Component Maintenance

Manuals

Table 2 – Contractor Documents

2.2.1. All documents developed and/or generated by this contract, and approved by the

Government, shall be specifically referenced and incorporated herein.

3.0 Core Tasks

The contractor shall develop, design, integrate, fabricate, acquire, assemble, test, document, deliver, and provide all technical, planning and management efforts to meet the performance criteria and detailed requirements set forth within this SOW and referenced documents. The contractor shall notify the Government of any Quality Management System certifications, e.g., ISO9001, AS9100, and provide evidence of the same, to include Risk Management Plan, Configuration Management Plan, and Quality Management Plan.

3.1 Program Management

The contractor shall provide a point of contact (POC), title and qualifications for this effort to act as the single POC responsible for managing and directing the contractor’s activities with respect to this contract and interfacing with the Government. The POC is responsible for any and all tasks required to direct and support development, production and program execution. The POC shall be responsible for all planning, organizing, scheduling, staffing, directing, controlling, orderly resource management and reporting required in the execution of this contract. All program management requirements shall be flowed down to subcontractors. The contractor shall coordinate and direct other contractual efforts under the contractor’s control to ensure the successful execution of the activities covered by this SOW.

3.2 Technical

3.2.1 In accordance with MIL-STD-1791B, the seat pallet shall be compatible with existing KC-46 cargo restraint system and existing USAF Material Handling

Equipment (MHE). Seat pallet base, where it interfaces with both the USAF Material

Handling Equipment (MHE) and KC-46 cargo restraint system, shall be dimensionally identical to an HCU-6/E, 463L cargo pallet, 88 inches by 108 inches. Seat pallet configurations must include a 108 inch bias capable of holding 10 forward facing seats and an 88 inch bias capable of holding 12 forward facing seats. Markings on the seat tracks will make it easy to install the seats in the correct location for each of these configurations.

3.2.2 12-seat pallet must be re-configurable to remove one row of seats, as required, to provide a cross aisle for egress when seat pallet is installed near the over-wing exits. Re-configuration must be accomplished without the use of specialized tools, rather using standard maintenance tools.

3.2.3 Seat cover material will be medium to dark gray or blue in color and must be rugged enough to withstand the harsh conditions of austere environments (e.g. Kevlar, Nomex) with the ability of being easily maintained. Additionally, each seat will have padded arm rests, reclining seats backs and tray tables.

3.2.4 Each seat must have storage capability to store oxygen equipment such as an

Emergency Passenger Oxygen System (EPOS).

3.2.5 The fully loaded pallet shall not exceed a total weight of 3,520 pounds on the 108-inch bias or 4,320 pounds on the 88-inch bias. A fully loaded pallet includes: all passengers with a maximum weight of 250 pounds each; personal bags for each passenger weighing no more than 10 pounds; EPOS; floatation device; and bridge plate.

The fully loaded seat pallet shall not exceed a center of gravity (C.G.) height of 30.75 inches. Each seat will have room underneath to store a hand-carried personal baggage not to exceed 18 inches wide by 15 inches long by 8 inches tall, and 10 pounds in weight.

(A011)

3.2.6 Seat pallets must meet the following USAF air-worthiness certification requirements per MIL-HDBK-516C:

3.2.6.1 KC-46 passenger movement operations to include crash load survivability, Sections: 9.7.1, “Seating System Load Capability”; 9.7.3, “Restraint

Systems Loads”; 9.7.4, “Occupant Strike Envelope”, and 18.1.1, “Passenger

Seating and Restraint Systems”

3.2.6.2 Flammability and toxicity requirements, section 8.4.14, “Fire

Resistance”

3.2.6.3 Each seat must meet standard floatation capability, section 18.1.14, “Floatation Devices”

3.2.6.4 Each seat must have a single point release restraint system per section

18.1.2, “Restraint System Release Point”.

3.2.6.5 If contractor seats are certified to Federal Aviation Administration

(FAA) TSO-C127, they may use that certification as verification of meeting the

SAE AS8049 requirements for their seats. This, however, only applies to the seats. The entire palletized system must still be qualified. (A001)

3.2.7 The palletized seating system shall have the capability of restraining a 250 pound passenger to each seat, and the seat and passenger to the pallet, when the pallet is secured by the aircraft cargo restraining system(s). It must be able to withstand static forces per SAE AS8049 Table 4 and dynamic forces per SAE AS8049 section 5.3. The pallet shall remain in one piece. Otherwise, permanent deformation is permitted. The palletized seats need not be serviceable after undergoing such a load. The contractor shall provide a complete structural analyses and/or full scale assembly testing at proposal submission to verify the restraint requirements are met.

3.2.8 Supplemental restraints, such as braces, struts, guy wires, or other “add-ons” are not permitted to enhance performance of palletized seats if emergency egress, loading/unloading, locking into the KC-46 cargo restraint system or proper use of existing USAF MHE is hindered.

3.2.9 Pallets must be equipped with "anti-rattle" clamping devices to minimize pallet movement with a minimum slip force of 200 pounds.

3.2.10 The contractor shall verify, by analysis, passenger egress per MIL-HDBK-

516C, section 9.1.2. (A011)

3.2.11 Contractor shall demonstrate proposed 10 and 12 seat pallets installation on a KC-46 aircraft. Time of demonstration to be after minimum delivery per section

3.2.13 below. Demonstration will take place at delivery location.

3.2.12 Contractor shall deliver a minimum of two 10-seat pallets and four 12-seat pallets within 120 days after receipt of order. The remainder of the 32 seat-pallets (ten 10-seat pallets and sixteen 12-seat pallets) shall be delivered within 60 days after initial minimum delivery. The contractor may deliver as many of the required seat pallets as capable at time of minimum delivery requirement.

3.2.13 Each seat pallet shall come with an all-weather cover to protect it from environmental elements, such as extreme cold, heat, humidity and precipitation. The cover shall be pliable enough to fold up, and have its own bag for stowage. Stowage bag and seat pallet cover shall be marked with seat pallet serial number, or other identifying number to match it up with the seat pallet.

3.3 Systems Engineering and Technical Management

The contractor shall identify and provide a POC responsible for the technical and management efforts of directing and controlling the integrated engineering efforts on the Palletized

Seating program.

3.4 Specification Updates

The contractor shall update and maintain the specifications as required to incorporate all requirements for the Palletized Seating Statement of Work (SOW) and Technical

Requirements Document (TRD). The contractor shall generate, deliver and maintain the required engineering data to support sustainment, installation and fielding. The contractor and its suppliers shall prepare and maintain any new specifications as required under this contract.

3.5 Quality Management (QA)

3.5.1 Quality Management (QA)

3.5.1.1 The contractor shall demonstrate compliance with the requirements of AS9100.

3.5.1.2 The contractor shall maintain a quality management system which satisfies program objectives, and reduces risk in the areas of cost, schedule and performance.

3.5.1.3 The contractor shall make available, upon request by the

Government, quality system procedures, Acceptance Test

Procedures (ATPs), quality planning documents, and any other documentation and data relevant to the contractor’s quality system.

3.5.2 Subcontractor/Supplier Quality

3.5.2.1 The contractor shall be responsible for subcontractor/supplier quality management IAW the latest revision of its subcontract management plan.

3.5.2.2 The contractor shall ensure that all quality requirements, associated specifications and any other contractual agreements contained herein, to also include Diminishing Manufacturing Sources and

Material Shortages (DMSMS), are flowed down to its lower tier subcontractors/suppliers and that compliance is verified.

3.5.3 Non-Conforming Material

3.5.3.1 The contractor shall utilize its Material Review Board for documenting, evaluating and disposition of non-conforming material IAW AS9100, Section 8.3.

3.5.3.2 This system shall be used for tracking, analyzing to determine root cause and assuring effective preventative/corrective action implementation. Installation or use of non-conforming productions without specific Government authorization is not permitted.

3.5.3.3 Non-conformances shall not be given a disposition of “use as is” or “repair” through contractor action without Government approval. Rework to print or specification may be acceptable.

3.5.3.4 The contractor shall maintain a procedure to control the identification, documentation, evaluation, disposition requirements of non-conforming productions.

3.5.3.5 The contractor shall notify the Government immediately of any discovered non-conformances that may exist in previously delivered production.

3.5.3.6 Notifications shall include a description of the suspected non-conformance, potential risk or product impact, contract number, part number, affected serial numbers or lot numbers, when applicable.

3.5.3.7 The contractor shall be responsible for defining a mitigation plan for any major non-conformance conditions arising from the production/installation of the palletized seating hardware to the hardware itself or to disturbed systems.

4.0 Engineering Change Proposals, Contract Change Proposals and Notice of Revisions

In the event that an Engineering Change Proposal (ECP) or Contract Change Proposal (CCP) is necessary, the contractor shall include the documentation by which the change is described and recommended. A Notice of Revision (NOR) shall accompany each ECP/CCP. The ECP shall also include a complete analysis of the technical, interface, cost, schedule and logistic impacts of the proposed change. All ECPs and CCPs shall be prepared in accordance with the Configuration

Management Plan and the CDRL, as required. (A006; A007, A013)

5.0 Certifications

5.1 Airworthiness

The contractor shall provide, documentation and results necessary to ensure an updated

KC-46 airworthiness certification based on MIL-HDBK-516C. The contractor shall prepare and submit integrated Modified Airworthiness Certification Criteria (MACC) for inclusion of the KC-46 Military Type Certification (MTC) submission the Airworthiness

Authority. (A001)

5.2 System Safety Risk Assessment Packages

The contractor shall create a System Safety Risk Assessment (SSRA) package for every airworthiness criterion that is in non-compliance to the certification basis. USAF

AWB 013 shall be used as guidance when preparing the SSRA.

The contractor shall submit an updated SSRA package with each Airworthiness

Compliance Report submittal. The Government will update, as required, the SSRA package as the Airworthiness Compliance Report is being processed by AFLCMC/EZ for a Military Flight Release (MFR). The Government will provide the final SSRA package associated with the authorized MFR will be provided as GFI again to support the next

Airworthiness Compliance Report submittal. This process will continue until the final fielding Airworthiness Compliance Report is submitted. The contractor shall submit the

SSRA as an attachment to CDRL (A008)

The content of these SSRAs shall include:

a. Background/system description;

b. Root causes for hazard;

c. Hazard description;

d. Severity;

e. Probability;

f. Probability calculations/background information on the probability number and source of the information;

g. Hazard Risk Index (HRI) for the unmitigated hazard;

h. HRI for the mitigated hazard;

i. Estimated system loss/personnel loss for life of the fleet;

j. Sensitivity analysis/historical data for similar systems;

k. Existing mitigation for the hazard (list and explain);

l. Mitigation options (what can be done in the future); and

m. Recommendation(s) to Risk Acceptance Authority

The SSRA contents shall also

a. Include sufficient details (drawings, schematics, dimensions, etc.) to clearly describe the hazard;

b. Include information on criteria, standards and methods of compliance that were approved, completed, and satisfied and those that were not that lead to the Hazard

Risk Index (HRI);

c. Show the HRI calculation details (probability and consequence) to include inputs, confidence on the inputs, assumptions, where conservatisms exist due to lack of data, etc.;

d. Explain why further analysis, testing, etc. is NOT required to better characterize the risk;

e. Translate each risk (HRI value) into expected aircraft losses and fatalities as a function of time;

f. For risks to be accepted for an interim period, include information on production break-in effectively and date production capacity for retrofit kits, retrofit hours, retrofit schedule, etc. In other words, when will the risk be mitigated to a “medium” or “Low” HRI and what can be accomplished to accelerate the schedule. In addition, provide all reasonable and unreasonable options such as operational limitations, restrictions, etc. that would reduce the risk to medium or low during this period of time;

g. For all residual mishap risks without mitigations, provide all reasonable and unreasonable options such as limitations, restrictions, etc. that would reduce the risk to medium or low.

6.0 Test

6.1 Acceptance Testing

The contractor shall develop and submit the ATP IAW the CDRL The contractor shall conduct an ATP for each palletized seat prior IAW the latest Government-approved ATP.

For palletized seats used in testing, ATP shall be conducted prior to usage in formal testing.

The contractor shall prepare and deliver an Acceptance Test Report (ATR) for each palletized seat purchased under this contract. (A009, A010, A011)

6.2 Test Readiness Review (TRR)

The contractor shall conduct an Engineering Test Readiness Review (TRR) to establish that the palletized seating design is sufficiently mature to enter formal system test and qualification. The contractor shall use DOD Instruction 5000.2 as guidance in scoping the entry and exit criteria and content of the TRR. The contractor shall prepare and submit an agenda and minutes in accordance with their CDRLs. (A004, A005, A011)

7.0 Logistics Support

7.1 Logistics Support Management

The contractor shall designate a single POC who is responsible for managing and directing the logistics support tasks with respect to this effort. The responsibilities for the logistics support manager shall include providing program status, developing a program schedule, conducting supportability analysis, and providing support to required contractor and/or

Government meetings.

7.2 Training

The contractor shall provide on-site training and training materials on the handling, storage, installation and repair/upkeep of Palletized Seating. Training must also include an emphasis on proper handling to ensure material does not degrade over time. Training will take place after minimum delivery per section 3.2.12 at delivery location.

7.3 Technical Orders

The contractor shall develop, manage, and deliver all required Palletized Seating Technical

Orders (TOs) associated with this effort. The TOs shall be developed IAW TO 00-5-3, AF

Technical Manual Acquisition Procedures, and TM-86-01, Technical Manual Contract

Requirements (TMCR). (A012)

7.4 Provisioning

7.4.1 The Contractor shall provide data for and participate in the Provisioning process in accordance with Contract Data Requirement Lists (DD Forms 1423) and the

Initial Provisioning Performance Specification (IPPS) in the contract. GEIA-HB-0007A

(Logistics Product Data Handbook) should be used as a guide. The Contractor shall recommend logical spare/repair parts sufficient to meet operability and supportability objectives. The Contractor shall provision 100% top down break down to provide all spare parts required to enable future organic sustainment and repair end item. Contractor shall deliver commercial manuals for Operations, Maintenance and Parts Listings on seats and pallet systems. These manuals shall be delivered for future USAF use. All technical data will be digital format and must be viewable on DoD (specifically USAF) standard desktop configuration (SDC) laptop and tablet devices. Technical data will include: Introduction: Descriptive Overview of Seat Pallets; Preparation For Use, Storage

And Shipment; System Operation; General Maintenance To Include: Preventative

Maintenance; Inspection And Cleaning, Troubleshooting And Approved Repairs;

Illustrated Parts Breakdown (IPB);. Contractor will provide Type-1 maintenance training as part of this contract. (A003)

7.4.2 The contractor shall recommend necessary spare parts and appropriate number of each for future Government planning. (A003)

7.4.3 Provisioning Technical Documents (PTD) will be submitted in a format compatible with the AFMC Automated Provisioning System (D220) as required by the

IPPS including attachments. Schedule for submitting the PTD shall be in accordance with the CDRLs and the Provisioning Performance Schedule (PPS) (AFMC Form 718) which will be completed at the Provisioning Guidance Conference (PGC).

7.4.4 Schedule and requirements for submitting the EDFP shall be in accordance with the CDRL for EDFP. (, A002)

7.4.5 Order of precedence for EDFP will be in accordance with the IPPS.

7.4.6 Provisioning Conferences: The Contractor shall support a PGC hosted by the Prime Provisioning Activity (PPA) at Tinker AFB within 45 days of receipt of the contract by the PPA. The Contractor shall support Spares Provisioning Conference(s) as determined at the PGC.

8.0 Production

The contractor shall perform all required Item Unique Identification Data (IUID) activities IAW DFARS clause 252.211-7003 and MIL-STD 130N “DoD Standard

Practice/Identification Marking of US Military Property” requirements.

8.1. Palletized Seating

8.1.1 The contractor shall procure, fabricate, assemble and integrate equipment necessary to provide all supplies necessary to procure, fabricate, assemble, integrate, produce and deliver palletized seating systems.

8.1.2 The palletized seating systems shall be incompliance with the

Government-approved specifications and requirements.

8.2. Quantities

8.2.1 The contractor shall deliver four 12-seat pallets with seats facing forward on the 88-inch bias, and two 10-seat pallets with seats facing forward on the 108-inch bias.

8.2.2 The contractor shall propose an additional forty-three seat pallets

(nineteen 12-seat pallets and twenty-four 10-seat pallets) apportioned in the remaining

IDIQ time period.

Contractor Data Requirements List

CDRL TITLE APPROVAL (Y/N)

A001 - Airworthiness Certification Y

A002 - Engineering Data For Provisioning (EDFP) N

A003 - Proposed Spares Parts List N

A004 - Conference Agenda(as needed) N

A005 - Conference Minutes(as needed) Y

A006 - CCP (if required) Y

A007 - ECP (if required) Y

A008 - System Safety Hazard Analysis Report (SSHAR) Y

A009 - Test Plan Y

A010 - Test Procedures Y

A011 - Test/Inspection Rpts Y

A012 - Technical Orders (TOs) Y

A013 - Notification Of Revision Y

Acronyms and Abbreviations

ATP Acceptance Test Procedures

CCP Contract Change Proposals

CDRL Contract Data Requirements List

CM Configuration Management

CMP Configuration Management Plan

DFARS Defense Federal Acquisition Regulation Supplement

DMSMS Diminishing Manufacturing Sources and Material Shortages

DO Delivery Order

DoD Department of Defense

ECP Engineering Change Proposal

GFI Government Furnished Information

HRI Hazard Risk Index

IPMR Integrated Program Management Report

MACC Modified Airworthiness Certification Criteria

MHE Material Handling Equipment

POC Point of Contact

SOW Statement of Work

SSRA System Safety Reliability Analysis

TMCR Technical Manual Contract Requirements

TO Technical Order

TDP Technical Data Package

TRD Technical Requirements Document

TRR Test Readiness Review

USAF United States Air Force