SOW REPAIR F-18F_G DOUBLE CANOPY FRAMED ASSEMBLY Rev A 12-17-20 Final.pdf

12/17/2020 Revision A

STATEMENT OF WORK

Repair: F/A-18F/G DOUBLE CANOPY FRAMED ASSEMBLY

TABLE OF CONTENTS

Section/Paragraph:

Applicable Part Numbers Repair Manual/Procedures/Technical data Analysis procedures and references

1.0 Scope

2.0 Parts and Material

3.0 Configuration Management

4.0 Quality Assurance Requirements

5.0 Preservation, Packaging and Shipping

Prepared by Approved by

HUNT.TRACY.

W.1362516303

Digitally signed by

HUNT.TRACY.W.1362516303

Date: 2021.02.02 10:42:05 -08'00'

WAGNER.T

IM.R.10400

89574

Digitally signed by

WAGNER.TIM.R.10

40089574 Date: 2021.02.03 06:48:01 -05'00'

APPLICABLE PART NUMBERS:

P/N 74A350006-2037 / NSN: 1560-01-622-7235

REPAIR MANUAL/PROCEDURES/TECHNICAL DATA:

Repair IAW with the following Government Furnished Information (GFI) Technical Data:

A1-F18EF-IETM, Release date 12 FEB 2019 or latest o LES NIF18-0070-03, Depot Level Rework Procedures for F/A-18F and E/A-18G Canopies Transparency Replacement or latest, Release Date 12 APR 2019 o LES NIF18-0068-03, Amend 1, Installation of F/A-18F Canopy onto Overhaul Fixture or latest, Release Date 17 NOV 2008 o LES-F18-0071-03, Rev B Amend 1, Depot Level Removal and Replacement Procedures for F/A-18E/F Canopy Weather Seals or latest, Release date 01 JUL 2020 o LES NIF18-0072-03 Rev B Amend 2, Depot Level Removal and Replacement Procedures for F/A-18A/G Canopy Pressure Seals or latest, Released date 16 APR 2020 o LES NIF18-0073-03 Rev B, Depot Level Remove and Replacement Procedure for F/A-18E/F and EA-18G Canopies EMI Seal or latest, Release Date 08 SEP 2018 o LES NIF18-002-09, Rework of F/A-18 Canopy Transparencies or latest, Release Date 23 JUL o LES NIF18-0002-18 Amend 1, Application of Coatings on the F/A-18F and EA-18G Two-Place Canopy or latest, Release Date 13 NOV 2018 o LES NIF18-0069-03, Depot Level Rework Procedures for Canopies Component Replacement or latest, Release Date 08 JUL 2016 o LES NIF18-002-08, Depot Repair, F/A-18 A-G Canopy Glass or latest, Release Date 01 MAR

ANALYSIS PROCEDURES AND REFERENCES:

NAVAIR PUBLICATION:

o NAVAIR NI Structures Standard Operating Procedure, SOP F18 AG-002-11, Rev A with amendments 1 and 2.

METHODOLOGY REFERENCES

o MACAIR- Report Number 339, Structures Handbook, dated 1 June 1973 o MACAIR-Report 338, Structural Analysis Bulletins, dated 1 June 1973 o MDC-8500 NARF Fatigue Information Report, dated 14 July 1986 o F/A-18 Hornet Fatigue Analysis Procedure Manual (FAPM), REV D, dated 21 February 2014

1.0 SCOPE This statement of work (SOW) defines the requirements for the complete overhaul (teardown, inspection, repair, and test) of the F/A-18F/G DOUBLE CANOPY FRAMED ASSEMBLY, including the inspection, repair of corrosion/wear damage and the replacement of corrosion protection coatings on select components to a Ready for Issue (RFI) condition.

Compliance with this SOW will yield F/A-18 EF and EA-18G MLG and NLG assemblies that are in a Ready for Issue (RFI) condition.

1.1 General. The items to be furnished hereunder must be repaired, upgraded, tested, inspected, and accepted in accordance with the terms and conditions specified in this contract. Government Furnished Property (GFP), including equipment such as fixtures, jigs, dies, patterns, mylars, special tooling, special test equipment, or any other manufacturing aid required for the repair, manufacture, and/or testing of the subject item(s), will not be provided by the Government and will be the responsibility of the Contractor. This limitation regarding the furnishing of GFP applies notwithstanding any reference to the contrary in any drawing, manual, or specification for the Contract items.

1.2 Repair and upgrade requirements. The Contractor must provide the necessary facility, labor, materials, parts, and test and tooling equipment required to return the items to a Ready For Issue (RFI) condition. The Contractor must perform all repairs at their facility using the same subcontractors if applicable, that successfully completes first article testing requirements If clarification or engineering disposition is required, the contractor will request support by submitting a Request for Technical Information (RFTI) to the NAVAIR Engineering Fleet Support Team (FST). An RFTI must be submitted for any noted non-conformance that falls outside of blueprint specification and cannot be repaired within specified Repair Specifications (Technical Manual, SRM, IETM, LES, 74R, AAC, etc). Examples of non-conformances include, but are not limited to, dimensions that do not meet drawing and/or specification tolerances before or after damage removal. Repairs performed by the contractor or subcontractor shall be performed in accordance with the applicable technical manuals and drawing specifications listed below:

P/N 74A350006-2037 / NSN: 1560-01-622-7235

LES NIF18-0070-03

Drawing Specification 74A350006, Rev AN or latest

1.2.1 Changes to repair manuals/documents and changes to drawings or specifications for the manufacture of parts utilized in these repairs require Procuring Contracting Officer (PCO) approval in accordance with the Configuration Management provisions of this Contract. In addition, as provided for in Section 2.3, requests for changes to a repair source or repair facility will be submitted in writing to the PCO and must be approved prior to making any such change.

1.2.2. Any repairs performed using unapproved changes to manuals, drawings, specifications, or unapproved changes to a repair source or facility are not permitted.

1.2.3. The Contractor is not entitled to any equitable adjustment to the price or Contract terms based on the Government’s disapproval of a requested change to manuals, drawings, specifications, or to a repair source or facility.

1.3 Teardown & Inspection Requirements: The disassembly and inspection actions are as described below. Contractor must comply with the following:

1.3.1 Install F/A-18F/G Canopy into Overhaul Fixture.

1.3.2 Visually inspect Canopy structural parts and fastener holes for damage/wear.

1.3.3 Mask for plastic media blast.

1.3.4 Remove LO coatings, paint and primer using government approved plastic media blasting technique or hand sanding. DO NOT blast any areas where skin damage was noted, but perform hand sanding instead.

1.3.5 Remove and process Side Fairings, P/N 74A350824.

1.3.6 If Side Fairing has severe corrosion, replace.

1.3.7 Remove transparency, P/N 74A350060.

1.3.8 Inspect transparency.

1.3.9 If the transparency does not meet acceptable inspection criteria limits, then replace transparency.

1.3.10 If the transparency meets acceptable limits, then rework transparency as necessary.

1.3.11 Inspect Forward Arch, P/N 74A350801.

1.3.12 If inspection criteria for Forward Arch, P/N 74A350801, fails acceptable limits, then replace.

1.3.13 Inspect Lower Fairing Support, P/N 74A350823, 74A350888.

1.3.14 If inspection criteria for Lower Fairing Support fails acceptable limits, then replace.

1.3.15 If Channel, P/N 74A350826, shows damage, replace.

1.3.16 If Latch Housing, P/N 74A350818, show damage, replace.

1.3.17 If Control Cam, P/N 74A350842, shows damage, replace.

1.3.18 Inspect Side Seal Retainer, P/N 74A350864, 74A350817, 74A350830, 74A350816.

1.3.19 If inspection criteria for Side Seal Retainer fails acceptable limits, then replace.

1.3.20 Inspect Hinge, P/N 74A350835, and Pivot Stop, P/N 74A350874.

1.3.21 If inspection criteria for Hinge and/or Pivot Stop fails acceptable limits, then replace.

1.3.22 Inspect Cross Beam, P/N 74A350860.

1.3.23 If inspection criteria for Cross Beam fails acceptable limits, then replace.

1.3.24 If AFT/FWD Rocket Motor Support, P/N 74A350861, 74A350862, shows damage, replace.

1.3.25 If Rocket Motor Pan, P/N 74A350863, shows damage, replace

1.3.26 Inspect Aft Fairing, P/N 74A350825, and Aft Bulkhead, P/N 74A350844.

1.3.27 If inspection criteria for Aft Fairing and/or Aft Bulkhead fail acceptable limits, then replace.

1.3.28 Inspect Center Splice, P/N 74A350822.

1.3.29 If inspection criteria for Center Splice fails acceptable limits, then replace.

1.3.30 Inspect Seal Guide, P/N 74A350819, 74A350802, 74A350849.

1.3.31 If inspection criteria for Aft Seal Retainer fails acceptable limits, then replace.

1.3.32 Evaluate the entire canopy structure for any remaining corrosion.

1.3.33 Evaluate the remaining canopy structure for dents, nicks, scratches, cracks, holes, and any other damage.

1.3.34 Evaluate the L/H and R/H Alignment Pin Holes (P/N 74A350814, Latch #1) for proper diameter. The pin holes must be .6875” + .0010/- .0000”.

1.3.35 Install transparency.

1.3.36 Add LO coatings and other finishes.

1.3.37 Contact NAVAIR F/A-18 FST Engineering for Beyond Normal Repairs.

1.4 Repair & Upgrade Requirements:

1.4.1 Compliance with this SOW will yield Double canopy framed assemblies P/N 74A350006- 2037/ NSN: 1560-01-622-7235 that are in a RFI condition. RFI is defined in paragraph 1.2 Repair Requirements.

1.4.2 Replace damaged structure per LES NIF18-0070-03 and / or applicable USN Local Engineering Specifications (LES), and the applicable blueprint drawings.

1.4.3 Prime and Paint Requirements: The Contractor shall remove exterior primer and paint via a government approved plastic media blasting technique or hand sanding. Canopies shall be primed and painted in accordance with LES NI F18-0002-18 and applicable drawing requirements.

1.5 Beyond Physical Repair (BPR)

1.5.1 Scope. An item is BPR when the item is not capable of being repaired in accordance with the Statement of Work due to the extent of physical damage. Examples of BPR damages include, but are not limited to, extreme corrosion such that major structure has been compromised, impact damage such as being hit or run over by a fork lift, etc.

1.5.2 Procedures. The Contractor must obtain written concurrence from DCMA for all units determined by the Contractor to be BPR. All such determinations, including the basis for the determination and the DCMA written concurrence shall be provided by the Contractor to the PCO, with a copy to the Inventory Manager (IM). After receipt of the required documentation, the PCO shall provide the Contractor disposition instructions. If provided disposition instructions, the contractor must submit a proposal for BER pricing to the PCO within 30 days of receipt of these instructions. Any disposal ordered shall be performed by the Contractor in accordance with all applicable regulations and the Contractor’s approved Government property disposal procedures.

1.6 Beyond Economical Repair (BER)

1.6.1 Scope. An item is BER if the cost of the repair exceeds 85% of the replacement price. This replacement price is for the purposes of BER determinations only, and may not be used or relied on by the offeror in the pricing of the repairs required by this Contract.

1.6.2 Procedures. Items determined BER will be separately priced if the repair is authorized by the PCO. The Contractor must obtain written concurrence from DCMA for all units determined by the Contractor to be BER. All such determinations, including the basis for the determination, the repair required, the proposed price to repair and the DCMA written concurrence, must be provided by the Contractor to the PCO, with a copy to the IM. After receipt of the required documentation, the PCO shall provide the Contractor disposition instructions or contractual authority for repair of the item. The Contractor is not authorized to proceed with the repair until notification is received from the PCO. If provided disposition instructions, the contractor shall submit a proposal for BER pricing to the PCO within 30 days of receipt of these instructions. Any disposal ordered shall be performed by the Contractor in accordance with all applicable regulations and the Contractor’s approved Government property disposal procedures.

1.6.3 The following additional procedures may apply, if authorized, for the replacement of a BER SRA (Shop Repairable Assembly) within a WRA (Weapons Repairable Assembly) when the SRA has not been separately inducted. The Contractor may request authorization to:

1.6.3.1 Ship in place an accepted item from an existing spares or repair Contract, if any, or MILSTRIP the SRA(s),

1.6.3.2 Authorization to ship in place or MILSTRIP must be provided by the IM in writing to the Contractor and must be appropriately documented in accordance with Section III.I.2.a of the WEB- BASED COMMERCIAL ASSET VISIBILITY (WEBCAV) STATEMENT OF WORK. The Contractor must provide written notification of any item shipped in place or MILSTRIPed to the PCO and an equitable adjustment may be required. If authorization to ship in place or MILSTRIP is not provided, the Contractor shall contact the PCO for further instructions.

1.7 Missing on Induction (MOI).

1.7.1 Scope. A WRA is subject to this MOI provision if the item received by the Contractor for repair is missing one or more SRAs and the SRA is not a separately inducted item. Contractor replacement of MOI SRAs is not included in the contract price. Items received by the Contractor missing consumable parts are not MOI items. Rather, repair of such items and replacement of the missing consumable parts are included in the contract price and the item will be inducted and repaired by the Contractor under this Contract.

1.7.2 Procedures. The Contractor must immediately notify DCMA when an item is received with MOI SRA(s) and shall obtain written verification from DCMA for all WRAs determined to have MOI SRA(s). The Contractor shall provide written notice of all such determinations, including identification of the missing SRA(s), and the DCMA written verification, to the IM with a copy to the PCO and ACO prior to induction and/or repair of the WRA. The Contractor will not proceed with repair of WRAs with MOI SRAs until instructions on how to proceed are provided to the Contractor.

1.7.3 The following additional procedures may apply, if authorized, for the replacement of a MOI SRA within a WRA. The Contractor may request authorization to:

1.7.3.1 Ship in place an accepted item from an existing spares or repair Contract, if any, or MILSTRIP the SRA(s),

1.7.3.2 Authorization to ship in place or MILSTRIP must be provided by the IM in writing to the Contractor and must be appropriately documented in accordance with Section III.I.2.b of the WEB-BASED COMMERCIAL ASSET VISIBILITY (WEBCAV) STATEMENT OF WORK. If either of these options is not authorized, the Contractor shall contact the PCO for further instructions.

1.8. Swapping SRAs

1.8.1 Scope. On rare occasions the Contractor may request authority to replace a failed but repairable SRA (within an inducted WRA) that is not BPR, BER or MOI.

1.8.2 Procedures. The Contractor may request authorization to replace the failed SRA unit from the Contractor’s production line, by MILSTRIP for an RFI item from Government stock, or with another repairable WRA, i.e. cannibalization. Permission from the PCO must be obtained and an equitable adjustment may be required. Authorization to ship in place from the Contractor’s production line or MILSTRIP must be appropriately documented in accordance with Section III.I.2.c of the WEB-BASED COMMERCIAL ASSET VISIBILITY (WEBCAV) STATEMENT OF WORK. Although permission from the PCO is required if the SRA is obtained from another repairable WRA (cannibalized), that transaction does not have to be input into CAV.

1.9 Over and Above Repair (OAR).

1.9.1 Scope. An item sent to the Contractor shall be considered to require Over and Above Repair (OAR) effort if the repair required is highly unusual, not the type of repair that would be anticipated as a result of normal Navy operation of the item and is not included in the contract pricing due to the nature or scope of the repair needed for that particular item. Therefore, repair of OAR items may be subject to equitable adjustment.

1.9.2 Procedures. To the maximum extent possible, OAR shall be identified by the Contractor as part of the price proposal. If this is an undefinitized contract action, the Contractor shall identify OAR with the submission of the proposed ceiling price.

1.9.3 The Contractor must obtain written concurrence from DCMA for all units determined by the Contractor to require OAR effort. All such OAR determinations, including the basis for the determination, the repair required, the proposed price to repair and the DCMA written concurrence, shall be provided by the Contractor to the PCO prior to undertaking repair of the item. After receipt of the required documentation, the PCO shall provide the Contractor disposition instructions or contractual authority for repair of the item. Any disposal ordered shall be performed by the Contractor in accordance with all applicable regulations and the Contractor’s approved Government property disposal procedures.

1.10 Repair and Consumption Data:

1.10.1 The Contractor will be responsible for maintaining a complete summary of all repair actions associated with a repaired SUU-79 pylon. This includes data related to the specific repair actions required and the parts removed and/or replaced to complete the repair activity. The Contractor will provide copies of engineering dispositions and supporting analyses to NAVAIR FST, upon request.

2.0 PARTS AND MATERIAL

2.1 General. The Contractor is responsible for supplying all parts and material necessary to perform the required repairs under this Contract. All parts and material used in performance of this Contract shall be in accordance with the latest approved revision of applicable drawings and specifications. The Contractor shall ensure it has access for the duration of this Contract to updated drawings and specifications for parts and material required for repairs performed under this Contract. Any change to such parts/material drawings or specifications requires Government approval in accordance with the Configuration Management provisions of this Contract.

2.2 All parts and material shall be new in accordance with FAR 52.211-5, Material Requirements, which is incorporated by reference herein. Authorization to use other than new material as defined by FAR 52.211-5 requires written approval from the PCO. In addition, cannibalization of piece parts must be approved by the PCO. Cannibalization of units that have not been inducted is not typically authorized and requires specific additional approval by the PCO. Cannibalization or swapping, including any actions authorized under paragraphs 1.4, 1.5 and 1.6, shall not render an item BER or BPR.

2.3 Written approval from the PCO must be obtained prior to any change to the manufacturing source or manufacturing facility for all parts which require source approval.

2.3.1 Where there has been a change to a manufacturing source, the Contractor must complete all qualification testing that was required when that item or component was originally qualified. Any changes in such testing must be submitted to the Contracting Officer for Government review and approval. Any repairs performed using unapproved changes to drawings, and / or specifications, are not authorized, unless approved by the NAVAIR FST.

2.3.2 The Contractor is not entitled to any equitable adjustment to the contract price or terms based on the Government’s disapproval of a requested change to the drawings, specifications or manufacturing source or facility.

2.4 Purchased Material Control and Parts Control: The Contractor must establish and maintain a system of control over purchased parts and material. Such controls shall, at a minimum, assure that the parts and material purchased are in compliance with the requirements of this Contract.

2.4.1 Critical Parts: Critical Safety Item (CSI) or Critical Application Item (CAI) (see definitions section 3.2.1 and 3.2.2) must be defined prior to fabricating or procuring a part. The official repository for this information, along with any approved sources of supply, is in the Joint Deficiency Reporting System (JDRS). CSI/CAI parts may only be procured from Navy approved sources. If the criticality of the part is not listed in JDRS, the Contractor shall contact the F/A- 18E/F and EA-18G FST in order to obtain this information.

2.5 Receiving Inspection of Purchased Parts and Material. Purchased parts and material must be inspected by the Contractor upon receipt at the Contractor’s facility to assure conformance with all requirements of the applicable drawings and specifications.

2.5.1 Evidence of such inspections shall be maintained by the Contractor or Subcontractor for Government review at least twelve (12) months following the conclusion of the contract. The inspection report shall, at a minimum, include a record of all dimensional data

(coordinate/positional), material, finish, and processes with appropriate pass/fail criteria, such as certifications, and actual dimensional readings.

2.6 Acceptance testing shall be conducted under the surveillance of the DCMA QAR. These tests shall include all tests necessary to assure that the items repaired conform to the performance required to provide Ready For-Issue material. The DCMA retains the authority to require the Contractor to conduct or reconduct any tests deemed necessary to ensure compliance with the manuals, drawings and specifications applicable to this contract.

3.0 CONFIGURATION MANAGEMENT

3.1 The Contractor must maintain the total baseline configuration of the contract items, including, but not limited to, hardware, software and firmware, in accordance with the configuration management provisions of this contract.

3.2 Definitions

3.2.1 Critical Application Item (CAI) – CAI is defined as an item that is essential to weapon system performance or operation, or the preservation of life or safety of operational personnel, as determined by the military services. The subset of CAIs, whose failure could have catastrophic or critical safety consequences (Category I or II as defined by MIL-STD-882), are Critical Safety Items (CSI).

3.2.2 Critical Safety Item (CSI) - CSI is defined as a part, an assembly, installation, or production system with one or more critical or critical safety characteristics that, if missing or not conforming to the design data, quality requirements, or overhaul and maintenance documentation, would result in an unsafe condition that could cause loss or serious damage to the end item or major components, loss of control, un-commanded engine shutdown, or serious injury or death to personnel and unsafe conditions, which relate to hazard severity categories I and II of MIL-STD- 882, System Safety Requirements. CSIs are a subset of CAIs and include, but are not limited to, items determined to be life-limited, fracture critical, or fatigue sensitive. A Critical Safety Item may also be known by terms such as a Flight Safety Critical Aircraft Part, Flight Safety Part, or Flight Safety Critical Part. For purposes of this contract, the term used will be Critical Safety Item.

3.2.3 Engineering Change Proposal (ECP) – An ECP is the documentation by which an engineering change and its implementation for items to be delivered under this contract is proposed, justified and submitted to the appropriate authority for approval or disapproval. Class I and Class II ECPs will be classified as follows:

3.2.3.1 Class I ECP. An engineering change will be classified as Class I if it affects any physical or functional requirement in approved functional or configuration documentation, or it affects any approved functional, allocated or product configuration documentation, cost to the Government, warranties or contract milestones, or it affects approved product configuration documentation and one or more of the following: Government furnished equipment (including Government test equipment and associated programs such as Test Program Sets/Software); safety;

compatibility, interoperability, or logistic support; delivered technical manuals for which changes are not funded; will require retrofit of delivered units; preset adjustments or schedules affecting operating limits or performance to the extent a new identification number is required;

interchangeability, substitutability, or replacement of any item down to non-repairable assemblies, sources on a source control drawing; or skills manning, training, biomedical factors or human engineering design.

3.2.3.2 Class II ECP. An engineering change is Class II if it does not impact any of the Class I factors specified above.

3.2.4 Deviation – A deviation is the specific written authorization to depart from a particular requirement of the item’s configuration for a specific number of units or for a specific amount of time. It is also a specific written authorization to accept items, which are found to depart from specified requirements, but which nevertheless is considered suitable for use “as is” or after correction by a specified method. The term deviation encompasses what previously had been defined as both a deviation and waiver, and therefore includes requests to depart from a known requirement before, during or after manufacture. Deviations will be classified as follows:

3.2.4.1 Major. A deviation is major when it involves a departure from requirements or specifications involving: health, performance, interchangeability, reliability, survivability, maintainability or durability of the item or parts, effective use or operation of the item or system, weight or size, and appearance (when a factor).

3.2.4.2 Critical. A deviation is critical when the deviation involves or impacts safety.

3.2.4.3 Minor. A deviation is minor when the deviation does not involve factors listed above for either critical or major deviations.

3.3 Engineering Change Proposal (ECP)

3.3.1 The Government will maintain configuration control and change authority for all modifications or changes affecting form, fit, function, or interface parameters of the contract items and sub-assemblies. Guidelines for preparing Class I and Class II ECPs may be found in MIL- HDBK-61B, Configuration Management Guidance and ANSI/EIA-649, National Consensus Standard for Configuration Management. The Contractor will maintain configuration of the items in accordance with the requirements of this contract.

3.3.2 The Contractor must submit an Engineering Change Proposal (ECP) for any Class I or II changes that impact the items covered by this contract. An ECP shall be designated Class I or Class II, as defined in this contract.

3.3.2.1 If the Contractor has an ECP pending with another Government activity, has an approved ECP that the Contractor proposes to incorporate under this contract, or has an ECP pending or approved under a production contract, the Contractor will notify the PCO of the status of the ECP and provide a copy of the ECP submission. Any such Class I ECPs, however, will be incorporated only by modification to the contract.

3.3.2.2 A properly documented ECP submitted under this contract shall be processed as follows:

3.3.2.2.1 Any Class I ECP must be submitted to the contracting officer for approval/disapproval.

A Class I change will not be implemented until a contract modification is issued by the contracting officer.

3.3.2.2.2 Any Class II ECP involving a non-critical item or a CAI shall be submitted to the cognizant Defense Contract Management Agency (DCMA) for concurrence in classification and may be implemented only upon receiving DCMA concurrence. Any Class II ECP involving a CSI must be clearly identified as involving a CSI, must be submitted to the contracting officer for review by the contracting officer and the Navy’s Basic Design Engineer, and may be implemented only upon the approval of the contracting officer. If, however, authorized in writing by the contracting officer or if the NAVAIR/NAVSEA Systems Command has delegated authority in writing to the DCMA to concur in Class II ECPs involving CSIs for the Contractor (which is specific to the Contractor’s location and CAGE code), a Class II ECP involving a CSI may be submitted to the DCMA and implemented upon DCMA’s concurrence with classification. If the affected Class II ECP item or items have not been identified as CAI, CSI or as non-critical by the Government, the Contractor will contact the contracting officer to obtain a classification for the affected items. The Government will not be responsible for any contract delay or disruption or any increased costs of performance of the contractor due to a misclassification of an ECP by the contractor, including those costs associated with replacement of delivered items resulting from such a misclassification. Class II changes shall be made at no additional cost to the Government.

3.3.2.3 The Contractor must coordinate with the cognizant NAVAIR/NAVSEA PMA office prior to any ECP submission. The Contractor will provide copies of configuration changes affecting FMS customers to NAVSUP WSS, FMS Code P751 (Philadelphia buyers) / Code M852 (Mech buyers).

3.3.2.4 Under this contract, a Class I ECP may be prepared in the contractor’s format but in a medium compatible with Government information management systems. In addition, a Class I ECP must provide all information required by DI-CMAN-80639E– Engineering Change Proposal.

A Class II ECP may be prepared in the contractor’s format. The minimum required data is: name and part number of item affected; name and part number of next higher assembly; description of the engineering change; need and reason for the change; all government contract numbers for which the change applies; and the change document number. Justification codes are not required for Class II ECPs.

3.3.2.5 The contractor is not entitled to any equitable adjustment to the contract price or terms based on the Government’s disapproval of a Class I or Class II ECP.

3.4 Requests for Variance (RFV)

3.4.1 The Contractor will not manufacture any item for acceptance by the Government that incorporates a known departure from technical or contractual requirements unless an RFV has been approved. Authorized RFV’s are a temporary departure from the requirements only and do not authorize a change to the item’s configuration baseline.

3.4.2 RFV’s will be prepared in accordance with DI-SESS-80640D REQUEST FOR VARIANCE (RFV). Guidelines for preparing RFV’s may also be found in MIL-HDBK-61B Configuration Management Guidance and ANSI/EIA-649, National Consensus Standard for Configuration Management.

3.4.3 Major, critical and minor deviations are classified in accordance with the definitions in this contract.

3.4.4 Upon submission of a properly documented request, an RFV will be processed as follows:

3.4.4.1 For items involving a major or critical deviation, delivery and/or shipment of such items under this contract is not permitted until authorized in writing by the contracting officer.

3.4.4.2 For any non-critical item, or CAI involving a minor deviation, delivery and/or shipment of such items under this contract is not permitted until authorized by the cognizant DCMA. Minor deviations affecting CSI must be identified as involving a CSI and must be submitted to the contracting officer for review by the contracting officer and the Navy’s Basic Design Engineer, and may be delivered only upon the approval of the contracting officer. If however, authorized in writing by the contracting officer or if the NAVAIR/NAVSEA Systems Command has delegated authority in writing to DCMA to approve minor deviations involving CSIs for the Contractor (which is specific to the Contractor’s location and CAGE code), a minor deviation affecting a CSI may be reviewed by the DCMA and may be delivered if authorization from DCMA is received. If the affected item or items have not been identified as CAI, CSI or as non-critical by the Government, the Contractor will contact NAVAIR FST via an RFTI to obtain a classification for the affected items.

3.4.5 Recurring deviations are discouraged and shall be minimized. The contractor is not entitled to any equitable adjustment to the contract price or terms based on the Government’s disapproval of a major/critical or minor deviation. In addition, the Government may be entitled consideration from the contractor if a deviation is approved.

3.4.6 Request for Variance repair procedures and/or approval for repairs deviating from the authorized procedures will be maintained in accordance with paragraph 4.3.1 of this SOW.

Travelers / Routers will be amended with the approved repair procedure and a reference to the approval document. The amended/updated travel will have the unique serial number of the component being process.

The following data items is applicable:

CDRL DATA ITEM NO. 003 DI-SESS-80640E REQUEST FOR VARIANCE

4.0 QUALITY ASSURANCE REQUIREMENTS

4.1. The Contractor must establish, implement, document and maintain a quality system/program that conforms to or addresses all applicable elements of the latest revision of ISO 9001 or SAE AS9100 Quality Management Systems. The Contractor’s quality management system/program must be designed to promptly detect, correct and prevent conditions that adversely affect quality.

4.2. CALIBRATION SYSTEM REQUIREMENT

4.2.1. The Contractor must maintain a calibration system that meets the requirements of ANSI/NCSL Z540, ISO/IEC 17025:2005 or an equivalent calibration program acceptable to the Government.

4.3. MANUFACTURING/PROCESSING PLAN REQUIREMENTS

4.3.1. Manufacturing, assembly, processing and inspection records must be retained for a minimum of ten (10) years from the date of delivery/government acceptance. The contractor must maintain records of any Corrective Action Requests (CARs) issued by DCMA related to the overhaul of this assembly and its component piece parts during the duration of the assembly and component overhaul. These records must be attached to the end of the travels/routers/inspection records.

4.3.2. Inspection is required for any vendor other than the Prime Manufacturer. 100% of all overhauled units if applicable will be tested / inspected by the contractor IAW the technical manuals and drawings listed in paragraph 1.0 of this SOW

4.3.3. “Critical Safety Item” markings will be indicated on each page of the traveler/router when the detailed part is designated a CSI. Traveler/Router for assemblies that contains CSI parts will include “Critical Safety Item” markings on each page.

4.3.4. Additional quality assurance steps and/or documentation may be necessary that are specific to the repair process that allows for multiple process flows based on inspection results. These additional documents may take the form of an repair plan flow chart or a worse case condition final inspection checklist that contains all available processing steps. The Engineering Service Activity (ESA) will determine the need for this documentation during FAT review. The contractor will provide this document for review prior to FAT approval.

4.3.5. The router/traveler will satisfy the technical requirements of the technical data. NAVAIR engineer will determine the necessary details that satisfy the technical requirement for safety and quality considerations

4.4. Technical Data Updates.

4.4.1. Contractor must ensure they have the latest revision of applicable technical manuals and drawing specifications listed in paragraph 1.2 of this SOW. In the event, there is an update to technical manuals and / or drawing specifications the following will apply:

4.4.2. The contractor must provide updated traveler/router to the Navy for review and approval for the technical data update(s). Updated traveler/router will be submitted to the PCO and the ESA for review not to exceed 60 calendar days from the original date technical data was issued by the PCO. Subsequence adjustment/corrections to the traveler/router will be submitted for review no later than 14 calendar days following the previous ESA’s response.

4.4.3. Failure to comply with the required response time may result in an initial non-compliance warning of an impending freeze on induction provided through the PCO with direction from the ESA. The contractor has 7 calendar days to submit an appropriate response that satisfies the original requirement prior to the non-compliance warning. ESA may direct the PCO to issue a notice to stop new component induction upon failure to comply with the initial warning.

4.4.4. Updated traveler/router that has not been approved by the 180th calendar day after PCO technical data release the ESA may exercise the option to stop new component induction. The PCO will notify the contactor if a stop on new induction is exercise

4.4.5. Assemblies/Components that are in-process at the time of technical data release will be overhauled in accordance with previously approved routers. The use of revised routers will be required once they are approved for use by the ESA.

4.5. SUBVENDOR PROCESSES REQUIREMENTS

4.5.1. All sub tier suppliers/processors must be Navy approved sources.

4.5.2. All documentation from sub tier suppliers/processors must be marked “Critical Safety Item” on each page of the process documentation and/or certificates of conformance when processing critical safety items.

4.5.3. All sub tier process operation sheets, travelers/routers and certifications of conformance for sub tier suppliers form an integral part of the contractor’s records. These records must be maintained in accordance with paragraph 4.3.1. and made available upon request.

4.6. CRITICAL CHARACTERISTICS & PROCESSES

The router/traveler will identify specific critical characteristics (CCs) and processes as Quality Assurance “(QA)” or Quality Assurance Requirement “(QAR)”. Individual waivers for CCs identification may be provided during router/traveler review. The waivers will be provided as a result of successful completion of FAT and router/traveler approval. A certificate of conformance is acceptable for CCs identification performed at a sub-contractor when CCs identification is applied to the receiving inspection of the contractor’s router/traveler.

4.7. INSPECTION AND ACCEPTANCE CRITERIA

4.7.1. Witness/verification requirements:

4.7.1.1. At DCMA discretion, the Quality Assurance Representative (QAR) may witness the performance of any “QA” or “QAR” steps identified in the router.

4.7.1.2. Any QAR signed documents specific to the assembly and/or component must be maintained in accordance with paragraph 4.3.1

4.8. First Article Inspection Requirements:

The Contractor must develop a First Article plan IAW AS9102 or equivalent to validate the SUU- 79 repair process. This plan must include provisions to evaluate the impact of major process changes on the repair process. NAVAIR engineering(s) or its designated government representative will witness First Article assembly and testing. Contractor is responsible for providing the necessary personal and resources to expedite the First Article assembly and testing.

4.8.1 Contractor must provide draft traveler/ routers to the FST for approval before assembly begins processing. Traveler / routers (or equivalent documentation) will show all possible operations listed for the assembly. Draft traveler/ router must include any sketches required and detailing sequential operation procedures used to overhaul. Sheets within the package must have signed/stamped place holder for the in-process operator and or inspector and traceable to the Contract Number / Purchase Order Number / Serial Number of each assembly

4.8.2 Contractor must provide draft inspection sheets (or equivalent documentation) to the FST for approval before assembly begins processing. Draft inspection sheets will include a place holder for actual recorded min-max dimensions, accept/reject notations, and required Inspector/Quality Assurance stamps. Draft inspection sheets within the package must be traceable to the Contract Number / Purchase Order Number / Serial Number of each assembly Repaired/Overhauled.

The following data items are applicable:

CDRL DATA ITEM NO. 001 OT-21-XXXXX Repair/Overhaul Work Packages CDRL DATA ITEM NO. 002 OT-21-XXXXX Repair/Overhaul Inspection Work Packages.

4.8.3. Notification: At least 45 days before beginning of First Article Testing, the contractor must notify the PCO, in writing, of the time and location of the testing so that the Government may witness the testing. In addition to the PCO, the contractor must notify the Navy First Article Test manager via e-mail at navsupwssp_fat_mgr@navy.mil so that the Navy may witness the FAT or delegate FAT approval to DCMA QAR, according to the discretion of the Navy.

4.8.4. U. S. Government personnel, including the DCMA QAR and/or NAVAIR engineering(s) or its designated government representative, will witness testing at the contractor’s facility.

4.9. First Article Test Acceptance Criteria

4.9.1. Acceptance criteria are defined in the Technical Data as QA steps/processes consisting of but not limited to Geometry, Location and Orientation of features, Process requirements and if applicable Pressure, Function and Leakage test. The characteristics and processes associated with the QA identification are considered critical for CSI items.

4.9.2. A unit under FAT will be repaired to a RFI condition.

4.9.3. The contractor must successfully demonstrate for/ and witnessed by, NAVAIR Engineering or a designated representative. The contractor must contact NAVAIR FST via RFTI prior to disassembly to establish inspection points for the FAT.

4.9.4 At a minimum, the following processes will be successfully demonstrated and confirmed by NAVAIR FST Structural Engineering or their designated representative. NAVAIR FST Structural Engineering may waive demonstration of all, in whole or in part of any of these processes listed below:

Process North Island FST Local Process Spec

Boeing Process Spec equivalent

Degreasing LPS NI MATL-0113 BAC5191, BAC5750, PS12024, PS12020, PS12011

Organic Solvent Cleaning by Hand Wiping (Brushing), Spraying,or Immersion

LPS NI MATL-0132 REV J PS12010

PS12100

PS12105

Plastic Media Blasting LPS NI MATL-0138 PS12115

Abrasive Blasting for Cleaning and Surface Preparation Chemical Conversion Coating Aluminum and its Alloys

LPS NI MATL-0180 PS12040

Preparation, Application, and Repair of Conductive Coatings

LPS NI MATL-0302

REV B

PS13656

Thickness Verification of MMS440, MMS443, and MMS487 Elastomeric Materials

LPS NI MATL-0303 PS13690

PS13693

Preparation, Application, and Repair of Elastomeric Materials

LPS NI MATL-0304 PS13693

Application of Waterborne Epoxy Primer

LPS NI MATL-0356 PS13375

Application of High Solids Polyurethane Topcoats

LPS NI MATL-0358 BAC5896

Application of Solvent- Borne Epoxy Primer

LPS NI MATL-0365 PS13375

Use of Liquid Nitrogen for the Installation of Metal Bushings in Shrink-to-Fit Applications

LPS NI MATL-0416 PS17034

Machining of Quality Holes in Metallic Aircraft Structures Using Hand Held Tools

LPS MATL-0466 PS19402

Processing and Application of Polysulfide Sealing Compounds

LPS NI MATL-0616 PS11217, PS11215, PS11347,

PS11346

Use of Volatile Corrosion Inhibited (VCI) Film and Bags for Corrosion Protection of In-Process Parts

LPS NI MATL-0753 PS20001

Cleaning and Corrosion Control

NAVAIR 01-1A-509-2 Use NAVAIR 01-1A-509-2

Engineering Manual Series Aircraft and Missile Repair Structural Hardware

Use NAVAIR 01-1A-8 Use NAVAIR 01-1A-8

Nondestructive Inspection General Procedures and Process Controls

NAVAIR 01-1A-16-2

NAVAIR 01-1A-16-2

4.9.4.1 NAVAIR engineering may waive demonstration requirements for any specific processes, in lieu of verification of Certificates of Conformance.

4.9.4.2 NAVAIR engineering may waive FAT requirements if the following conditions are met within the last three years: (satisfaction of the following conditions does not automatically waive

FAT)

a. Prior FAT on F/A-18C Single-Seat Movable-Pilots Canopy was performed.

b. Repair of F/A-18C Single-Seat Movable-Pilots Canopy has been continuous.

c. Similar critical characteristics have been demonstrated successfully.

d. Critical processes have been demonstrated successfully.

e. Sub-contractors will have satisfactory quality audits.

f. The contractor will have no documented quality escape or outstanding corrective action requests.

4.9.4.3. NAVAIR engineering or its designated government representative must provide First Article Acceptance.

4.10. First Article Test (FAT) Report: The contractor must submit a FAT Report via the PCO within 15 days from the date of completion of First Article Testing to NAVAIR for approval. The FAT report will include the following:

4.10.1. Completed traveler/ routers. Completed traveler / routers (or equivalent documentation) will show all possible operations listed for the assembly. Completed traveler/ router must include any sketches required and detailing sequential operation procedures used to overhaul. Sheets within the package must be signed/stamped by the in-process operator and or inspector and traceable to the Contract Number / Purchase Order Number / Serial Number of each assembly

4.10.2 Completed inspection sheets (or equivalent documentation). Inspection sheets will include actual recorded min-max dimensions, accept/reject notations, and required Inspector/Quality Assurance stamps. Inspection sheets within the package must be traceable to the Contract Number / Purchase Order Number / Serial Number of each assembly Repaired/Overhauled.

4.10.3. A copy of the actual Certificate of Conformance (if applicable) from the process vendor traceable to the Contract Number, Purchase Order Number and Serial Number of each assembly Repaired/Overhauled. A Certificate of Conformance must be provided for each sub-vendor process such as Fluorescent Penetrant Inspection, Magnetic Particle Inspection, Etc. traceable to each assembly repaired/overhauled. Identify the facility that performed the special process and the method by which it was accredited, approved, or specified.

The following data items are applicable:

CDRL DATA ITEM NO. 001 DI-MISC-80678/T1 Completed Process/Operation Sheets CDRL DATA ITEM NO. 002 DI-MISC-80678/T2 Completed Inspection Method Sheets CDRL DATA ITEM NO. 004 DI-MISC-80678/T3 Process and Material Certifications

4.11. Disposition of First Article Test Sample(s):

4.11.1 Sample(s) may be considered as production items under the contract, provided the sample(s) can be refurbished to Ready for Issue (RFI) condition and have inspection approval of the cognizant QAR. Sample(s) may be shipped as production item(s) only after all other units required under the contract have been produced and are ready for shipment.

4.11.2. Form DD1222 including DCMA QAR comments must be forwarded with the FAT Report.

The cognizant government inspecting activity will issue a report accepting or rejecting the FAT sample(s). Final approval of the FAT Report is the responsibility of NAVAIR. FAT Report approval will be conveyed to the contractor through the PCO. Upon notification of approval/conditional approval, the DCMA QAR will provide disposition in the Wide-Area Work Flow (WAWF) system or Form DD250 to indicate Government acceptance of the test report.

5.0 Preservation, Packaging and Shipping

5.1. Preservation and Packaging: Preservation and packaging that shall afford adequate protection against corrosion, deterioration and damage shall be utilized. This includes parts in production, storage and shipment. Shipping crates shall be retained and used for the shipment of pylons. The repair of minor crate damage shall be considered within the scope of this SOW. If a crate is too heavily damaged for reuse, then a separate contract shall be pursued to obtain a replacement shipping container.

5.2 Shipping: The shipping instructions shall be defined in the NAVSUP Repair Order.