Statement_of_Work.pdf

STATEMENT OF WORK

OVERHAUL OF VARIOUS AIRCRAFT GEARBOXES

1.0 General

1.1 Background

The United States Coast Guard (USCG) Aviation Logistics Center (ALC), Medium Range Recovery (MRR) Product Line Division located in Elizabeth City, North Carolina has a requirement to overhaul various aircraft gearboxes which are installed on the USCG’s MH-60T aircraft.

The gearboxes, listed in 1.2, are inspected during prescribed maintenance periods and during the programmed depot maintenance. They are replaced due to corrosion, leaks, and failures.

1.2 Scope

Overhaul the following gearboxes to like new condition on an as needed basis.

Nomenclature NSN P/N Modified and Overhauled NSN /

P/N Main Gearbox (Minor) 1615-01-552-3522 70351-38100-049 1615-01-552-3522, 70351-38100-049 Main Gearbox (Major) 1615-01-552-3522

1615-01-552-3522, Input Module Gearbox 1615-01-230-6218 1615-01-353-3825 1615-01-527-8175

70351-08001-046 70351-08001-049 70351-08001-050

1615-01-527-8175, 70351-08001-050

Intermediate Gearbox 1615-01-074-5152 1615-01-201-5623

70357-06300-042 70357-06300-043

1615-01-201-5623, 70357-06300-043

Tail Rotor Gearbox 1615-01-291-7572 1615-01-372-5467

70358-26600-044 70358-26600-045

1615-01-372-5467, 70358-26600-045

Accessory Gearbox 1615-01-078-5718 1615-01-383-8992

70351-08080-043 70351-08080-045

1615-01-383-8992, 70351-08080-045

The Contractor shall possess the ability to complete the overhauls specified for each gearbox listed herein.

The gearboxes shall be overhauled in accordance with the procedures prescribe within this Statement of Work (SOW). Latest revision and change shall apply to any prescribed manual or publication. The gearboxes shall be returned by the Contractor in an airworthy condition and in all respects suitable for installation on the USCG’s MH-60T aircraft.

The Naval Supply Weapons Systems Support (NAVSUP WSS), Philadelphia, PA, is the Primary Inventory Control Agency and has sole authority and responsibility for certifying sources of supply and support for H-60 components. Public Law 108-136 Section 802 of the Defense Appropriations Act of 2004 and Naval Air Systems Command Instruction (NAVAIRINST) 4200.56 states that Naval Air Systems Command (NAVAIR) shall approve sources for flight critical safety items (CSIs) and the procurement, overhaul, and repair of CSIs is restricted to sources approved by NAVAIR.

To obtain NAVSUP WSS certifications follow the guidelines provided on the following Navy web site;

https://www.navsup.navy.mil/navsup/ourteam/navsupwss/business_opps https://www.navsup.navy.mil/navsup/ourteam/navsupwss/business_opps

The information is located under the Business Opportunities section, sub paragraph Commodities, document Source Approval Request Brochure – Repairs. Contractors and subcontractors are required to be NAVSUP WSS or ALC MRR Engineering approved. Where applicable, the front cover of each manual will address if the Export Control Act applies.

1.3 Objective

The basic objective of this requirement is to preserve service life, reduce life cycle cost, and increase mission capabilities through the performance of overhaul services. The USCG considers gearboxes ready for issue (RFI) upon delivery acceptance.

2.0 Applicable documents

2.1 Compliance Documents

The following documents provide specifications, standards, or guidelines that must be complied with in order to meet the requirements of this contract. Latest revision and change shall apply for each.

• Naval Air Systems Command Technical Manual Main Module Assembly, A1-862QA-MDB-200 Latest Revision

• Naval Air Systems Command Technical Manual Main Transmission Assembly, A1-866QA- MDB-300 Latest Revision

• Naval Air Systems Command Technical Manual Intermediate Gearbox Assembly, A1-862QA- MDB-000 Latest Revision

• Naval Air Systems Command Technical Manual Tail Gearbox Assembly, A1-862QA-MDB-100 Latest Revision

• USCG Aviation Logistics Center Instruction 4200.3A, ALC Spare Parts Breakout/New Product Development Latest Revision

• USCG Aviation Logistics Center Instruction 4100.1, Aviation Logistics Center Material Disposal Procedures Latest Revision

3.0 Specific Requirements

The gearboxes, listed in paragraph 1.2, shall be overhauled to like new condition. Note, the input NSN may differ from the required output NSN. These gearboxes shall be overhauled in accordance with the prescribed technical manual(s) as specified herein; latest revision and change shall apply. If the applicable technical manual does not cover a procedure, the original equipment manufacturer (OEM) manual shall be used. If the OEM manual does not cover the procedure, the Contractor shall utilize the best commercial business practice on behalf of the government.

The Contractor shall provide all necessary parts, material, tooling, labor, repair/overhaul manuals, test equipment and facilities to evaluate and overhaul gearboxes listed. Parts found to be defective shall be replaced with new parts.

A DD Form 1577-2, Unserviceable Tag-Material, or a CG-1577-A (11-90), Unsatisfactory Report Tag will be attached to each Not Ready for Issue gearbox describing faults. Once the gearbox has been restored to like new condition, the Contractor shall remove the unserviceable tag from the gearbox.

The information contained in this SOW is not intended to be all-inclusive or to detract from procedures outlined in any specification listed except where noted herein. The USCG does not own, nor can it provide any of the required directives for this requirement. The gearboxes shall be overhauled in accordance with this SOW and Federal Aviation Regulations Parts 43 and 145.

3.1 Inspection of Gearboxes

The gearboxes shall be inspected at the Contractor’s place of performance for serial number(s) received per paragraph 4.1. The Contractor shall perform a visual and technical inspection of each gearbox and correct all additional deficiencies found. This shall include replacement of broken parts and the removal of any foreign matter or corrosion. Parts found to be defective shall be replaced with new parts.

The following definitions shall apply:

Minor: The process of disassembly sufficient to inspect all the operating components and the basic end article. It includes replacement or servicing as necessary followed by reassembly and testing. Upon completion of the overhaul process, the component or end article will be capable of performing its intended service life or tour.

Major: In addition to those actions required for a minor overhaul, a complete disassembly, to include 100% visual and 100% Nondestructive Inspection of all components, 100% replacement of housing with Rockhard coated zero time unit shall include new main bridge dowel pin. Replace the carrier assembly with a zero time Improved Durability Gearbox Improved Planetary Carrier. Replace any time/life component with less than 3,500 hours remaining to retirement with a zero time component.

3.2 Corrosion Issues

USCG aircraft operate primarily in a saltwater environment and are subject to corrosion. Corrosion is expected on these gearboxes to be overhauled under this contract. During inspection and functional test, the presence of corrosion in a component or subcomponent thereof shall constitute reason for a more thorough disassembly and inspection. Should corrosion be found, disassembly shall be made only to the extent necessary to remove corrosion or replace the part(s) affected. Corroded parts shall be replaced except in those cases where removal of corrosion from a part will not impair efficiency or safe operation of the part. Corrosion removal and treatment of affected areas shall be accomplished in accordance with the applicable technical manual specifications and drawings.

The main gearbox assembly is subject to excessive corrosion in the vicinity of the mounting feet. As part of the overhaul process, the Contractor shall provide the effort necessary for the restoration of the corroded areas, to include any necessary disassembly, part replacement, and reassembly required in connection with the corrosion removal.

The USCG approved application of Rockhard coating will be performed on all gearboxes. The coating shall be applied in accordance with OEM specifications within the fixed prices established at contract award.

3.3 Replacement Parts

All parts noted in the respective technical manual shall be replaced as required. Replacement parts found to be defective shall be replaced as specified in the respective technical manual or as otherwise authorized in writing by the KO. All parts and replaced defective parts shall be new. A copy of the Contractor's work order, listing all replacement parts, shall be provided for each gearbox. The Contractor shall maintain a copy of replacement part certification documentation for inspection by the USCG for a minimum of twenty-four (24) months after delivery.

3.4 Environmental Requirements

All parts must be thoroughly cleaned in accordance with applicable Component Maintenance Manuals or Federal Aviation Administration (FAA) Advisory Circular 43-205, Guidance for Selecting Chemical Agents and Processes for Depainting and General Cleaning of Aircraft and Aviation Products, to ensure they are as free as practicable of all hazardous dust to include hexavalent chromium, cadmium, lead, etc., prior to being returned to the USCG. The USCG may take random samples of parts to ensure they are as free as practicable of all hazards. Information on these hazards can be found in Occupational Safety and Health Standards 1910-1025 (lead), 1910.1026 (Hexavalent Chromium) and 1910-1027 (Cadmium).

3.5 Changes to Government Depot Maintenance Manuals

The Contractor shall notify the KO when changes are made to the technical manual’s specifications or drawings which are applicable to the gearboxes specified herein. Such notification shall include the nature of the change and details sufficient for the USCG to evaluate the scope and impact of the change.

Prior approval to perform in accordance with revised specifications or drawings shall be obtained in writing from the KO before proceeding with the overhaul. The USCG reserves the right to waive any specification.

3.6 Service Bulletins, Modifications, Engineering Change Proposals (ECP), Local Engineering Change Proposals (LECP), Time Compliance Technical Orders (TCTO)

The KO shall notify the Contractor in writing of components requiring incorporation of a service bulletin, modification, ECP, LECP, or TCTO. Upon receiving such notice, the Contractor shall submit within thirty (30) calendar days, a firm-fixed-price quote for an incremental charge to be assessed each time the service bulletin or change is incorporated into a component. The quote shall contain a breakdown of material and labor costs based upon the firm-fixed labor rates and material factors. The incremental charge agreed upon for incorporation of a service bulletin shall apply only to those components which the Contractor incorporates a required service bulletin, not those into which the service bulletin has been previously incorporated. Upon agreement of an incremental charge and issuance of a contract modification to reflect this change, the service bulletin shall be incorporated into each subsequent component received at the overhaul facility if the service bulletin has not already been incorporated.

When service bulletin incorporation changes the part number of any of the components contained in this schedule, the new part number and national stock number (if applicable) will be added to the contract via modification.

3.7 Obsolete Part or Process

In the event certain parts or processes become obsolete, the Contractor shall, within thirty (30) calendar days after receipt of the gearbox, notify the KO and submit:

a) rationale and verification of any obsolete part or process; and

b) a written estimate of the effort required to make the overhaul.

Such estimates shall include nomenclature, part number, cost and quantity of replacement parts and total labor hours. The Contractor shall verify cost of parts with invoices or catalogs. The Contractor’s delivery obligation for the gearboxes identified shall be suspended as of the date of notice to the KO. The KO will, within thirty (30) calendar days after receipt of the Contractor’s written estimate, make a written determination as to the disposition of the gearbox. After receipt of the KO’s disposition instructions, the Contractor shall have thirty (30) calendar days for delivery.

4.0 Tracking System

4.1 Aviation Computerized Maintenance System (ACMS)

The gearboxes contained in the graph below are all FLIGHT CRITICAL and ACMS tracked;

Nomenclature NSN P/N Modified and Overhauled NSN /

P/N Main Gearbox (Minor) 1615-01-552-3522 70351-38100-049 1615-01-552-3522, Main Gearbox (Major) 1615-01-552-3522

1615-01-552-3522, Input Module Gearbox 1615-01-230-6218 1615-01-353-3825 1615-01-527-8175

70351-08001-046 70351-08001-049 70351-08001-050

1615-01-527-8175, 70351-08001-050

Intermediate Gearbox 1615-01-074-5152 1615-01-201-5623

70357-06300-042 70357-06300-043

1615-01-201-5623, 70357-06300-043

Tail Rotor Gearbox 1615-01-291-7572 1615-01-372-5467

70358-26600-044 70358-26600-045

1615-01-372-5467, 70358-26600-045

Accessory Gearbox 1615-01-078-5718 1615-01-383-8992

70351-08080-043 70351-08080-045

1615-01-383-8992, 70351-08080-045

Serial number tracking shall be used for validating the correct gearbox was received at the Contractor’s overhaul facility and returned to the USCG. Upon the receipt of any gearbox from the USCG, the Contractor shall verify the task order number and serial number of each gearbox. The Contractor shall notify the KO in writing only if a discrepancy is identified.

The USCG places high priority on parts integrity within aircraft components. As a result, any part which is determined to be in a serviceable condition as a result of inspection and functional testing shall be reused in the gearbox from which it was removed, if practical, with the exception of parts specifically replaced during the overhaul as required by the directives as specified within the contract.

ACMS is a computerized system used to record maintenance of aircraft components and assemblies. All gearboxes listed in this paragraph are ACMS and serial number tracked. Each gearbox will be shipped to the Contractor’s facility with a Significant Component History Record (SCHR) and a Component Repair Record (CRR). The Contractor’s responsibilities with ACMS consist of submission of required forms as outlined herein.

The Contractor shall verify the SCHR and CRR and ensure they correspond with the gearbox’s part number and serial number. All discrepancies shall be reported in writing to the KO prior to induction.

The Contractor shall complete the CRR.

The original copy of the CRR shall be mailed to:

Engineering Services Division ACMS Tracking, Bldg. 78 Aviation Logistics Center Elizabeth City, NC 27909-5001

A copy of the CRR shall be shipped with the overhauled gearbox and affixed to the outside of the shipping container. The Contractor shall maintain a copy of each complete CRR for a period of ninety

(90) calendar days.

5.0 Scrap Procedures

5.1 Condemned Parts and Material

All non-repairable parts, including parts replaced during the overhaul process, shall be scrapped, rendered unusable to the point they cannot be returned to service, in accordance with the USCG Aviation Logistics Center Instruction 4100.1, Aviation Logistics Center Material Disposal Procedures.

5.2 Beyond Economical Repair (BER)

In the event a gearbox cannot be overhauled to like new condition and is found to be BER, the Contractor shall immediately stop working on the gearbox and notify the KO in writing. The Contractor’s written notification shall include the following information at a minimum: contract number, task order number, line item number, nomenclature, national stock number, part number, serial number, and a brief description supporting the determination. The KO will provide disposition instructions via modification within thirty (30) calendar days after receipt of notification. The Contractor shall be entitled to BER/Scrap Fee on the schedule for that specific line item.

6.0 Certifications

Overhauls shall only be performed by NAVSUP WSS approved sources. The Contractor shall submit copies of their NAVSUP WSS certification to the KO for approval prior to execution of any contract/order award. The Contractor shall be subject to and shall comply with paragraph 2.0 within this statement of work.

6.1 Certificate of Conformance (COC)

The Contractor shall provide an Airworthiness Certificate (FAA Form 8130-3), OEM COC, or a COC in accordance Federal Acquisition Regulation (FAR) 52.246-15(d), Certificate of Conformance. Contractor shall provide a COC for each gearbox overhauled. The COC shall be included inside each shipping container and affixed to the outside of each shipping container.

7.0 Place of Performance

The place of performance shall be the Contractor’s facility.

8.0 Reporting Requirements

8.1 Monthly Production Report

The Contractor shall submit monthly production reports to the ALC MRR Supply Cell Leader and KO no later than the tenth day of each month. A production report shall provide the status of the contract line items received, being overhauled, or shipped. Any format is acceptable as long as the report provides the following information; nomenclature, part number, national stock number, serial number, delivery order and contract line item number, receipt date at Contractor’s facility, date scheduled to be inducted, date scheduled for delivery, total days in work, if the part is late and any comments.

The Contractor shall provide a monthly, bi-weekly if needed, progress summary via email, telephone video conference or electronic submission. Progress summaries shall include those gearboxes listed in paragraph 1.2.

8.2 Quarterly Audits

ALC conducts quarterly audits validating government owned inventory at randomly selected commercial vendors. If selected by ALC for an audit, the Contractor shall validate all gearboxes identified by serial number at their location(s). Validation should take place the same date as the audit when possible. The Contractor shall follow and comply with the instructions provided each quarter by ALC Aviation Logistics Division.

9.0 Government Furnished Resources

The Government will provide the gearboxes as specified in paragraph 1.2. The Government will not furnish any drawings, parts, hardware, specifications, tooling, or any other overhaul documents required to overhaul any of the gearboxes specified herein.

10.0 Contractor Furnished Property

The Contractor shall provide all necessary parts, material, tooling, labor, repair/overhaul manuals, test equipment and facilities to fulfill the requirements of this contract, except for the Government Furnished Resources specified in SOW Paragraph 9.0, Government Furnished Resources.

The Contractor shall provide the data and documentation requirements specified within this SOW.

11.0 Government Acceptance

Final inspection and acceptance shall be performed by the Defense Contract Management Agency’s representative at the Contractor’s facility.

12.0 Deliverables

The Contractor is required to provide the gearboxes in accordance with the lead times below:

Nomenclature NSN P/N Lead Times

Rate

Main Gearbox 1615-01-552-3522 70351-38100-049 120 days 2 per month Input Module Gearbox 1615-01-527-8175 70351-08001-050 90 days 2 per month Intermediate Gearbox 1615-01-201-5623 70357-06300-043 90 days 1 per month Tail Rotor Gearbox 1615-01-372-5467 70358-26600-045 90 days 1 per month Accessory Gearbox 1615-01-383-8992 70351-08080-045 60 days 2 per month

If the number of gearboxes in the Contractor’s possession falls below what is needed to maintain the contract delivery rate, the contract will be allowed a one for one exception to the delivery requirement.

The USCG desires early deliveries therefore early shipments are encouraged at no additional costs to the Government. If the Contractor fails to deliver by the expected delivery date established within the delivery order and nonperformance is not covered by an excusable delay, FAR 52.212-4(f), Excusable Delays, the KO will negotiate consideration for delinquent deliveries on behalf of the Government.

Discounts negotiated in consideration for delinquent deliveries will be reflected in a modification to the task order. The lead times are based on when the gearboxes arrive at the Contractor’s Facility.

13.0 Urgent Requirements

In the event an Aircraft on the Ground (AOG) status occurs as a result of a lack of a gearbox specified herein, the Contractor will be notified and requested to provide a response within twenty-four (24) hours of the notification. The Contractor’s response shall provide status of the gearbox needed to satisfy the AOG situation and the requirements to expedite shipment.

An AOG situation may require that the Contractor ship directly to a specified USCG field unit. The gearbox shall be shipped by the fastest traceable means, i.e., air freight, next day delivery. The KO may issue a task order modification authorizing additional funding as agreed upon by the Government and the Contractor to accomplish the expedited overhaul. The Contractor shall mark the outside of the shipping container “AOG” in letters not less than 2” high.

14.0 Quality Control

14.1 Quality Deficiency Reporting

Gearboxes received from the Contractor as RFI and found to have deficiencies may be reported on a Product Quality Deficiency Report and returned to the Contractor for investigation. The Contractor shall report all findings of the investigation to the KO within thirty (30) calendar days after receipt of the gearbox identified as having a quality deficiency.

14.2 Warranty

The Contractor’s standard commercial warranty, including extended warranties, provided to the Government at no additional cost, shall apply.

14.3 Laws and Regulations

The Contractor shall be knowledgeable of and meet or exceed compliance with all applicable federal and state laws and regulations and certain local laws and ordinances regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the Contractor is required to comply with such laws which come into effect.