Attachment_1_SOW_FRCASE_Maintenance_Final_-_OCTOBER_2016_REV_2-final.docx

STATEMENT OF WORK

For Commander Naval Air Systems Command

Fleet Readiness Center Aviation Support Equipment (FRC ASE)

Maintenance Support

October 2016 – REV 1

POINTS OF CONTACT:

A. Contracting Officer Representative (COR):

Ms. Elizabeth (Vicky) Lamb Contracts Division Lead, Command Fleet Readiness Center (COMFRC) Aviation Support Equipment (ASE) Naval Air Station (NAS) Patuxent River Solomons Annex Building 105 B Street Solomons, MD 20688

COMM: (410) 326-7556

Email: elizabeth.lamb@navy.mil

B. Functional Director:

Mr. Michael Belcher Director, ASE NAS Patuxent River Solomons Annex Building 105 B Street Solomons, MD 20688

COMM: (410)326-7500

Email: michael.e.belcher@navy.mil

C. Contracting Officer’s Representative (COR) Supervisor:

Ms. Christine Blinn Deputy Director, COMFRC ASE NAS Patuxent River Solomons Annex Building 105 B Street Solomons, MD 20688

COMM: (410)326-7501

Email: christine.blinn@navy.mil

Table of Contents

1.0. INTRODUCTION ………………………………………………………………………………………………. 5

2.0 SCOPE ………………………………………………………………………………………………………….. 5

3.0. DOCUMENTS/DIRECTIVES ………………………………………………………………………………….. 7

4.0. TECHNICAL / PERFORMANCE REQUIREMENTS ………………………………………………………. 8

5.0. REPORTING REQUIREMENTS …………………………………………………………………………….. 16

6.0. SPECIAL REQUIREMENTS …………………………………………………………………………………. 17

7.0. DELIVERABLES ……………………………………………………………………………………………… 24

8.0. TEAM COMPLEMENT …………………………………………………………………………………….…. 25

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1.0 INTRODUCTION

Fleet Readiness Center Aviation Support Equipment (FRC ASE) is a Naval Air Systems Command (NAVAIR) whose mission is to provide agile, relevant, quality aviation support equipment (SE) maintenance, repair and overhaul services to meet Naval Aviation Enterprise entitlements and the Navy’s Fleet Response Plan requirements with improved efficiency and reduced cost. FRC ASE provides seamless integrated SE maintenance repair and overhaul services with a goal of reducing repair cycle time while improving the availability of Ready For Use (RFU) SE in the fleet and its supporting infrastructure.

1.1 The headquarters element of FRC ASE is located aboard the Naval Air Station Patuxent River Solomons Annex, Solomons Island, MD. FRC ASE Solomons provides centralized management for fourteen other FRC locations. FRC ASE supports the development and execution of the Navy’s 1C7C – Equipment Maintenance budget which funds the rework of fleet aviation SE and that for the New Ships Construction Outfitting, Refueling Complex Overhaul and Maritime Prepositioning Forces Programs. FRC ASE Solomons provides centralized management of SE Rework planning and scheduling. FRC ASE Solomons provides a centralized source for quality assurance management, kitting, and maintenance support. FRC ASE Solomons has developed a series of Standard Operating Procedures (SOPs) that outline government processes for planning, scheduling, maintenance execution and management, and material management for all FRC ASE managed sites. These processes have been standardized in order to provide an easy interface between Contractor and Government process inputs and outputs. In addition to the Navy 1C7C Programs, FRC ASE Solomons manages and executes Special Programs some of which include: Naval Supply Systems Command Weapon System Support Quick Engine Change Kit Repair/Overhaul and Component Repair, Coast Guard SE Rework, Foreign Military Sales (FMS) and Program Manager AIR support.

1.2 FRC ASE is tasked with supporting SE in support of deployed United States Navy and United States Marine Corps fleet forces. The different categories of support equipment are identified in NAVAIR Instruction 13650.1 (series), Naval Air Systems Command Aircraft Maintenance Material Readiness List Program. That instruction defines Support Equipment as the equipment required to make an aircraft system, support system, subsystem, or end item of equipment (i.e., support equipment for SE) operational in its intended environment. This includes all equipment required to install, launch, arrest (except Navy shipboard and shore based launching and arresting equipment), guide, control, direct, inspect, test (including automated test equipment hardware and software), adjust, calibrate, appraise, gauge, measure, assemble, disassemble, handle, transport, safeguard, store, actuate, service, repair, overhaul, maintain, or operate the system, subsystem, end item, or component. SE is categorized as either common or peculiar. In addition to its primary mission, as a Center of Excellence for SE, FRC ASE has been tasked to support the SE needs of its Special Program customers as indicated above and other customers seeking maintenance support for their specialized SE needs.

1.3 Continuous Process Improvement. FRC ASE embraces Continuous Process Improvement (CPI) as a means to improve its products and services. The intended goal of its CPI initiatives is to decrease cycle time, identify and eliminate non-value added work and inefficiencies, and reduce the variation in products and services; all with the intent of improving the quality of service to the fleet.

2.0 SCOPE

2.1 Purpose. The purpose of this Statement of Work (SOW) is to identify the services required to ensure FRC ASE’s success as the Naval Air Systems Command Center of Excellence for Naval Aviation SE repair and rework. The Contractor shall provide services as described in the below subparagraphs.

2.1.1 FRC ASE provides repair and rework support for SE that is inducted either on a scheduled basis as determined by the Support Equipment Controlling Authorities (SECAs), on an emergent basis as the need arises, or on an emergency basis when requested by the fleet. To satisfy these requirements, the SE requiring rework may be scheduled in to one of the FRC ASE sites, transported to a FRC ASE site immediately, or repaired by a dispatched Field Team from a FRC ASE Site. Field Teams may be dispatched to areas around the world (ashore and afloat) in order to assist units in returning their SE to a serviceable condition. The mission critical factor related to this workload is ensuring that items are returned to their custodians in a serviceable condition within the planned workload standard hours and turnaround time days. These measures are used to plan work into the sites and to set FRC ASE customer expectations for their equipment being returned. Workload standards and turnaround times are updated throughout the year as engineered standards or analysis of historical performance determine that a change to the workload standard or turnaround time is necessary. The most current applicable workload standards and turnaround times are maintained in the Support Equipment Management System (SEMS) by the government. This work may be conducted at any of FRC ASE sites, aboard Navy and Marine Corps bases or other sites around the world and aboard Naval vessels at sea or in port.

2.1.2 FRC ASE provides SE maintenance in support of surface ship and Maritime Prepositioning Ship off-loads and redeployments. Although this work is primarily preventative maintenance support, it has historically included making any necessary repairs (e.g., testing of hoisting devices, pallet slings, and other Logistics Support Equipment/Materials Handling Equipment) to the associated SE. This SE support is scheduled by the SECAs, Blount Island Command (BIC), and Commander Naval Surface Atlantic/Pacific, and the mission critical factor related to this workload is to ensure that all work inducted, have all preventative and/or unscheduled maintenance actions required completed in accordance with the Government and Contractor agreed upon Sail Plan. The Sail Plan is a Contractor developed and Government approved plan that identifies all required activities on a timeline to ensure that all SE is available to meet ship’s planned redeployment schedules. This work is conducted at FRC ASE BIC primarily, however other FRC ASE sites may be required to support this workload based upon capacity and schedules.

2.1.3 FRC ASE supports the repair, rework, configuration, modification and reclamation (including conversion or reclamation in lieu of procurement) of SE for Naval Air Systems Command Program Managers. These tasks are scheduled and are normally accomplished in accordance with a technical directive. In the event that an effort is not conducted in accordance with a technical directive the work shall be estimated using FRC ASE’s Estimating SOP. The result of the estimating process is a product estimate, which shall include a planned turnaround time and workload standard hours that shall be used to set customer expectations for the return of their equipment. This same process is used when new items of SE are scheduled for induction for which a workload standard or turnaround time has not been established. The mission critical factor related to this work is producing to an agreed upon schedule and accomplishing the work at or under the amount estimated/budgeted. This work is conducted at FRC ASE Beaufort, Cherry Point, Fort Worth, New Orleans, BIC, Jacksonville, Norfolk Navy Ship Yard (NNSY), North Island and Solomons sites, however due to capacity the other FRC ASE sites may also perform this work.

2.1.4 FRC ASE supports Logistics Support Equipment/Materials Handling and Support Equipment maintenance support for numerous customers which include the day to day scheduled (preventative) and unscheduled (restorative) maintenance, corrosion control, modification, overhaul, preoperational checks and check-in and out of the equipment. The mission critical factor in this work is ensuring that the equipment is maintained, ready for tasking and that it performs its mission successfully. This work is conducted primarily at the FRC ASE NNSY, Blount Island Command, and North Island sites; however, due to capacity the other FRC ASE sites may also perform this work.

2.1.5 FRC ASE provides SE maintenance for SE located at Fleet Readiness Center Southwest (FRCSW) Detachment El Centro and NAF El Centro.

2.2 Objective. The objective of this Statement of Work is to establish the maintenance requirements for the Contractor that supports FRC ASE. The Contractor shall be responsible for the receipt, inventory, induction, repair, overhaul, modification, and reclamation of SE as defined in the introduction section of this statement of work. In addition; the Contractor shall ensure that all services provided are in accordance with (IAW) Commander Naval Air Force (CNAF) CNAF Instruction 4790.2. As part of the quality maintenance process the Contractor shall identify and participate in activities to improve maintenance processes and procedures. The work associated with this SOW shall be accomplished at FRC ASE sites, as Field Teams on any ship, or at any designated shore, afloat or Carrier Support Group sites.

The Contractor shall identify material requirements to support said maintenance activities in accordance with FRC ASE standard operating procedures. FRC ASE supports each of its locations using a “hub and spoke” support strategy. All support functions are provided from the headquarters site (Solomons) and pushed to the strategically located FRC ASE maintenance facilities around the country. The Contractor shall provide maintenance support capable of supporting all SE rework maintenance functions associated with FRC ASE programs.

The Naval Weapons Station (NWS) Yorktown, Cheatham Annex site, manages support equipment removed from New Ships Construction (NSC) and Refueling Complex Overhaul (RCOH) ships, and manages the movement of equipment to the various rework sites.

The Contractor shall maintain custody, responsibility, and inventory of all Individual Material Readiness List GSE/SE for FRCSW at Detachment El Centro and Naval Air Forces (NAF) El Centro in accordance with applicable Commander Navair Air Forces Instruction. The Contractor shall perform organizational (O-level) and intermediate level (I-level) maintenance, issue and receive SE to resident and transient commands, and perform shipment and receipt of RFU and Non-Ready for Use (NRFU) SE. The Contractor shall report physical custody and status of all SE in the Support Equipment Resources Management Information System (SERMIS) utilizing the Local Asset Management System (LAMS). Material required to complete the maintenance shall be ordered through the Naval Aviation Logistics Command/Management Information System. The Contractor shall provide support and assistance to maintenance shops in accomplishing customer generated requests for SE maintenance. The Contractor shall provide workload induction and monitoring services to the Command Maintenance Control Centers for repairs and upkeep of industrial SE throughout FRCSW.

3.0 DOCUMENTS/DIRECTIVES

3.1 All work performed by the contractor shall be accomplished in accordance with applicable publications, technical directives, instructions, standards and procedures contained in pertinent manuals utilizing blueprints, drawings or schematics as provided at each FRC ASE site Technical Publications Library. All applicable technical manuals, forms, publications, bulletins, directives, specifications, standards, and field procedures guides shall be utilized and will be provided. When a publication provided by the government is subsequently revised, supplemented, replaced or rescinded, the contractor, upon notification or receipt of it, shall comply. The contractor shall be required to correct any contractor rework discrepancies noted as authorized by FRC ASE. The contractor shall notify the FRC ASE COR in the event these changes have associated costs.

The Contractor shall adhere to the following documents in accordance with the Technical Requirements of this statement of work:

Document Type

No./Version

Title

NAVAIR Instruction

13650.1(series) Naval Air Systems Command Aircraft Maintenance Material Readiness List Program

NAVAIR Instruction

13680.1(series) Depot Level Rework Program For SE End Items

Instruction

4790.4 (series) Ships Maintenance / Material Management(3-M) Sys Policy

NAVAIR Manual

NAVAIR 17-1-125

Support Equipment Cleaning and Corrosion Control

NAVAIR 00-25-100

Naval Air Systems Command Technical Manual Program

NAVAIR 00-80T-96

Support Equipment Common Basic Handling & Safety Manual

NAVAIR 01-1A-34

Aeronautical Equipment Welding

Operational Navy (OPNAV) Instruction

5100.23 (series)

Navy Safety and Occupational Health Program Manual

Secretary of the Navy Instruction (SECNAV)

5220.13 (series) Validating and Leveraging Financial Benefits Associated with Lean Six Sigma for Continuous Process Improvements

OPNAV Instruction

5100.12 (series)

Navy Traffic Safety Program

NAVSUP Pub

P-538 Management of Materials Handling Equipment and Shipboard Mobile Support Equipment

DLAI 4145.3

Joint Service Publication: Preparing Hazardous Materials for Military Air Shipments

Standard Test Method (ASTM) D3591

Commercial Packaging

NAVAIR

Maintenance Instruction Manuals

NAVAIR

Technical Manuals and Directives

NAVAIR

Engineering Drawings / Changes

NAVAIR

Military Specifications

NAVAIR

Maintenance Requirements Cards

P-700

Common Naval Packaging

ISO 9001:2000

Quality Program

3.2 Maintenance Records, Forms and Technical Data. All technical data to include, technical manuals, bulletins, directives, drawings, specifications, standards, FRC ASE SOPs and OPNAV Forms will be provided by the Government through the FRC ASE COR and shall be utilized in the performance of all work associated with this SOW. Any referenced publications used shall include the latest changes.

3.3 FRC ASE SOPs. FRC ASE SOPs document the Government’s management processes that are to be used by the Government Commodity Managers and Government Site Leads at FRC ASE locations. The Contractor shall use each SOP as a guideline and ensure an integrated process interface between their process and the process inputs and outputs as identified in the SOPs.

4.0 TECHNICAL / PERFORMANCE REQUIREMENTS

The Contractor shall provide SE O-level, I-level and Depot level (D-level) scheduled (preventative) and unscheduled (restorative) maintenance; which includes the servicing, functional / operational testing, repair and replacement of unserviceable parts, assemblies, subassemblies and components; making structural repairs, fabrication of parts; incorporation of modifications, support configuration, reclamation, and conversions; perform corrosion control to include paint and final finish of SE.

4.1 General Management Practices

4.1.1 Personnel. The Contractor shall maintain personnel and skill levels as defined by the Government to perform at a level that enables FRC ASE sites to meet its workload and mission commitments. The Contractor shall ensure that all personnel are trained on the equipment and processes in their respective work areas and use the requisite personal protective equipment required to accomplish their work in a safe manner as identified in CNAFINST 4790.2, the Naval Aviation Maintenance Program, and OPNAVINST 5100.23 (series), The Navy Safety and Occupational Health Program Manual and in accordance with Occupational Safety and Health Administration (OSHA) Standards.

4.1.1.1 Manning Level Report. The Contractor shall provide a weekly Manning Level Report to the FRC ASE COR that provides personnel planning and execution information in the following six key areas: Total Numbers by Site; Detailed Contractor Manning by Site, Function and Shift, Overtime and Temporary Additional Duty information. The Manning Level Report will identify the following by FRC ASE Site: start date, completion date, projected team complement, assigned team complement. The Contractor Manning by Site section shall include total numbers of people in each Department of Labor (DOL) skill code assigned to each site. The Detailed Contract Manning by Site section shall include a section that identifies all Contractor personnel assigned by site, including any overhead employee names, the function provided, DOL skill Code assigned, shift, any remarks concerning the person/assignment and should be totaled by site with the billable persons to the contract. An Overtime section shall identify by site and DOL skill code the number of overtime hours expended reflecting the current month and cumulative. The Temporary Additional Duty section shall identify each temporary additional duty trip, where the persons leave from, the destination, the total number of people traveling by DOL skill code, the duration of the temporary additional duty period, the total man-days expended and the purpose of the trip. (Contractor Manning Level Report – Contract Data Requirement List (CDRL) A001)

4.1.2 Safety and Security of Work Spaces. The Contractor shall ensure that throughout the work day all Contractor workspaces are maintained in a safe condition. The Contractor shall conduct a cleanup and remove all trash from assigned work areas at the end of each work shift, or more frequently if needed, to maintain work areas in a safe condition. The Contractor shall be responsible for the cleanliness of assigned work areas. The Contractor shall be responsible for securing work areas throughout the work shift and at the close of normal service hours.

4.1.3 Deliverables and Reports. All reports associated with this SOW shall be delivered in an editable digital format using the Microsoft Office Suite of products (Word, Excel, Access and PowerPoint) as stated in the associated CDRLs except where explicitly requested otherwise to the FRC ASE COR.

4.2 Technical Publications Library. The Contractor shall maintain all technical data provided by the government within the individual FRC ASE site Quality Assurance (QA) Technical Publications Libraries. All technical data shall be maintained in accordance with the procedures outlined in NAVAIR 00-25-100, Naval Air Systems Command Technical Manual Program and CNAFINST 4790.2 for the maintenance and upkeep of Technical Publications Libraries.

The Contractor shall maintain the Technical Publication Libraries adequate to complete the assigned functions of the activity (this includes ensuring technical publications are available for all equipment planned or assigned to FRC ASE Designated Repair Points) and maintaining master copies of publications within the Library. The Contractor shall requisition, receive, screen, review, and distribute publications, technical directives and bulletins, and interim rapid action changes as necessary, to ensure that the technical data used by the mechanics is up to date. The contractor shall establish library control functions, develop and maintain an automatic verification program and maintain procedures for the distribution of technical data. The Contractor shall ensure that Contractor personnel are notified of technical data changes upon receipt and that changes are incorporated in site publications within three working days. The Contractor shall develop an effective checklist so that discrepancies identified during audits can be identified and corrective action noted. Refer to CNAFINST 4790.2 Computerized Self Evaluation Checklist.

The Contractor will be furnished all rework specifications required to complete rework inspection assignments.

4.3 Production Control. The Contractor shall maintain production control at all FRC ASE production sites which shall report SE maintenance status to the Enterprise Contractor Production Control at FRC ASE Solomons. The Enterprise Contractor 01270 Production Control Clerk located at FRC ASE Solomons shall be capable of providing financial and production status for all Contractor workload at all sites supported by this SOW to include the workload awaiting induction or in transport to the sites.

4.3.1 Workload Priorities. The Contractor shall ensure that all efforts are made to ensure that the equipment inducted is produced in accordance with ships movement schedules, delivery deadlines, and oldest workload.

In such instances where the Government desires to hold equipment from either induction or production, the Government Scheduler will notify the Contractor in writing that a particular Control Number (CNUM) will not be worked and provide a reason for such decision. The Government will update SEMS accordingly.

All CNUMs will be established by the Government and provided to the Contractor.

4.3.1.1 Workload Management. The Government uses its NAVAIR Depot Maintenance System (NDMS) Maximo system to collect expended time, labor, and material information that shall be used by the Contractor in addition to any corporate labor reporting systems. The Contractor shall ensure that the work order status of all workload tracked in Maximo is kept up to date. After equipment has been received by the site, each of the following work order statuses shall be entered into Maximo in the following order - Received, Inducted, Examination and Evaluation (E&E) and In Progress.

4.3.1.2.2 For purposes of this SOW only, equipment that is returned to the user/customer in a “Ready for Issue/Use (RFI/U)” status, that have been signed off by the government on the Certificate of Completion and Acceptance (COCA) and their status changed to complete in SEMS at the close of business the last working day of the month will be scored in the monthly performance metrics. The Contractor shall ensure that all SEMS and Maximo status updates are made before the close of business the same day as the COCA is signed off. The Contractor shall provide a copy of each signed COCA to the FRC ASE COR for all FRC ASE locations. (CERTIFICATE OF COMPLETION AND ACCEPTANCES – CDRL A002)

4.3.1.2.3 Production Status. The Contractor shall conduct production status reviews and ensure they are meeting schedule and cost goals. The Contractor shall provide a weekly production status report. This report shall include the following information:

Control Number (CNUM) or Transaction Item Reporting (TIR) Number Maximo Work Order Number Designated Repair Point Code National Item Identification Number (NIIN) Serial Number Part Number Nomenclature Date Pending (Date SECA initiated request to schedule in SEMS) Aircraft Maintenance Material Readiness List (AMMRL) Activity Identifier Code AMMRL Activity Identifier Name Contractor’s Production Status Funding Type (Repair/Overhaul) Workload Standard (WLS) New (negotiated) / Planned Hours (Includes WLS hours and additional hours authorized in approved Work Guide) Actual Hours Original Estimated Completion Date at Induction Revised Estimated Completion Date Original / Planned Turnaround Time (TAT) Days Revised Planned Turnaround Time Days (Based upon Revised Estimated Completion Dates) Actual Turnaround Time Scheduled Induction Date Date Received at FRC ASE Date Inducted Date Completed Percent Complete Program Actual Labor Costs to Date Actual Material / Service Costs to Date 80% Expended Cost Flag *All NAVSUP TIR numbers are to be included in this report.

These Production Status Reports shall provide the capability to view the data contained in both a site specific workload production status view and an enterprise workload production status view. This will allow both the Contractor and the Government to make enterprise decisions to support site specific needs. (PRODUCTION STATUS REPORT – CDRL A003)

4.3.1.2.4 The Contractor shall conduct a monthly reconciliation of outstanding requisitions ordered and received against each inducted end-item; ensuring that corrections identified during the reconciliation of outstanding requisitions are identified against the proper end item in Maximo.

4.3.1.2.5 Items cannibalized from one item to another in order to meet production priorities shall be approved by the affected Government Commodity Manager prior to the cannibalization action. The Contractor shall ensure that all outstanding items on order are identified against the new control number in Maximo by close of business the same day of the cannibalization action.

4.3.1.2.6 Production and Financial Management Data/Reports. The Contractor shall maintain data relative to the production status (cost, schedule, labor hours, and material usage) for all processed equipment. Annually, and at the end of the contract, all historical data associated with this contract shall be provided to the FRC ASE COR in a flat file (i.e., comma-separated-value [.csv] or text [tab-delimited] [.txt] that can be read by Microsoft Excel/Access). (PRODUCTION AND FINANCIAL MANAGEMENT DATA REPORT – CDRL A004)

4.3.1.2.7 Funds Tracking. The Contractor shall provide a weekly Contract Line Item Summary Report that shall provide the status of all funds against each Contract Line Item Number (CLIN) as well as an aggregate for all CLINs on one report. For each CLIN the report shall provide Accounting Classification Reference Number (ACRN), Detailed Task Description, Total Funds Authorized/Passed, Total Cumulative Expenditures, Total Holdback Amounts, Total Burdened Amounts and the Available Balance. (CONTRACT LINE ITEM SUMMARY REPORT- CDRL A005)

4.3.1.2.8 Monthly Maintenance Report (MMR). The Contractor shall provide a Monthly MMR report for all FRC locations to the FRC ASE COR. (MONTHLY MAINTENANCE REPORT- CDRL A006)

4.3.1.2.9 Item Master Management. Upon the identification of an item not previously ordered against an end item of SE Rework Control Number/Maximo Work Order, the Contractor shall initiate an Item Master Request Form (IMRF). The Contractor shall complete an IMRF identifying all of the requisite information to update the Maximo Item Master. The completed form will be submitted to the appropriate end item Commodity Manger for approval. Upon approval the Contractor shall update Maximo with the appropriate information allowing the site Contractor personnel to place the Government-authorized order for the requirement. All IMRF requests shall be processed in Maximo within an average time period not to exceed seven (7) working days. The Contractor shall provide a monthly status report on all outstanding IMRF requests to the FRC ASE COR.

4.3.1.3 Maintenance Records Management. The Contractor shall maintain all maintenance records applicable to the equipment being serviced, repaired, reworked or otherwise completed in accordance with CNAFINST 4790.2 or local management instructions.

Records associated are: Aeronautical Equipment Service Records [AESR] (Various CNAF forms) SE Custody and Maintenance History Record, CNAF 4790/51.

If an end item of SE is received without its SE Custody and Maintenance History Record, the Contractor shall initiate a new record only when all attempts to obtain the CNAF Form 4790/51 or AESR have been exhausted. The Contractor shall ensure that any CNAF Form 4790/51 initiated contains all of the required historical information, to include technical directive compliance information available from the central repository, per CNAFINST 4790.2.

4.3.1.4 Material Ordered. The Contractor shall provide a monthly Materials Ordered Report which shall identify all materials ordered via the Material / Non-Material CLIN during that month in support of FRC ASE operations. The Report shall include the site that the material was ordered for, requisition number, part number, nomenclature, quantity, CLIN, ACRN, unit cost, extended cost, and all associated Control Number/Maximo Work Orders. (MATERIALS ORDERED REPORT – CDRL A007)

4.3.1.5 Material Requirements Identification. Upon the identification of a material requirement, the Contractor shall submit a material requisition in Maximo before the end of the work shift. The Contractor shall assign Required Delivery Dates (RDDs) for material requirements that adequately identify the priority of acquisition so that the parts are received in time to meet the work-related requirements/days identified in the Work Guides. RDDs assigned should be no later than the begin date for that section of work identified in the Work Guide. All site material/service requirements shall be submitted for purchase within 24 hours of identification for each unit. The Contractor shall monitor the status of material requirements.

4.3.1.6 Material Receiving. The Contractor shall annotate all items as received in Maximo on the same date of receipt and update statuses accordingly. All originally signed packing slips for all items received shall be forwarded weekly to FRC ASE Solomons. The Contractor shall use original 1348 Milstrip receipts when receiving material in Maximo.

4.3.1.6.1 The Contractor shall inspect all furnished materials and parts, including those purchased from Qualified Products Lists, to verify their condition and to ensure that they meet serviceability and configuration requirements specified for government furnished parts before installation on Government-owned SE.

The Contractor shall not maintain spare parts or inventory of parts for any program at their site or in individual workspaces, other than approved pre-expended consumable bins. All spare parts / inventory is maintained and managed at the FRC ASE Solomons location.

The Contractor shall manage and stock all Pre-Expended Bins (PEB). The Contractor shall maintain an inventory balance of all PEB material. The contractor shall provide a quarterly inventory list of all material maintained and stocked in the PEB. (PEB INVENTORY REPORT – CDRL A008)

4.4 Rework Estimates. The Contractor shall provide support and draft documentation to applicable Government Commodity Managers, Government Site Leads and the FRC ASE COR in support of the development of all rework estimates for all FRC ASE locations.

4.5 SE Repair/Rework Types

The work associated with the following subparagraphs of this section shall be performed by Contractor personnel in the following labor categories: 23380 GSE Mechanics, 23550 Maintenance Machinist, 05310 Automotive Painters, 23022 Aircraft Mechanic II/Non-Destructive Test Inspection (NDT/I), 23010 Aerospace Structural Welders, and 23382 GSE Workers.

23380 GSE Mechanics shall have the ability to troubleshoot malfunctions in various systems and be able to perform general mechanical maintenance of the assigned equipment. The Contractor shall ensure that a sufficient number of QAR/Collateral Duty Inspectors (CDI) from the GSE Mechanic labor category are available to support CNAFINST 4790.2 related Quality Control Plan requirements. Contractor designated QAR personnel must be able to obtain a security clearance to access required government websites / databases to perform QAR functions. QAR/CDI personnel when not involved with QA tasks shall perform the Ground Support Equipment mechanic duties.

23010 Aerospace Welders shall be trained and qualified to weld the following four basic metal groups: I - steel, II – stainless steel alloy, III – nickel base alloy, and IV – aluminum alloy, in welding positions 1G and 2F as identified in NAVAIR 01-1A-34 (or ISO positions PA and PB). The welders must be qualified in the following processes: Gas Tungsten Arc Welding (GTAW), Gas Metal Arc Welding (GMAW), Shielded Metal Arc Welding (SMAW) and Oxyfuel Brazing (OFB).

23022 Aircraft Mechanic II located at the FRC ASE Solomons, Norfolk Naval Ship Yard and North Island sites shall be trained and qualified to provide the following non-destructive inspection capabilities:

Solomons: Magnetic Particle, Dye Penetrant, Ultrasonic and Eddy Current.

Norfolk Naval Ship Yard: Magnetic Particle, Dye Penetrant, and Eddy Current.

North Island: Magnetic Particle, Dye Penetrant, and Eddy Current.

05310 Automotive Painters shall be trained and qualified to perform blast, paint and powder coat application.

23550 Maintenance Machinist shall be trained and qualified to perform machinist responsibilities.

4.5.1 Sail Plans. The Government will notify the Contractor Site Lead of the schedules and equipment expected to be worked / off-loaded for each ship supported. Upon notification, the Contractor shall develop a Sail Plan to address all equipment expected to be off-loaded from Carriers, L-Class Ships, Maritime Prepositioning Ships, and all equipment planned to be replaced/uploaded. The plan shall identify all activities required to be conducted (i.e., preventative and restorative maintenance actions) in order to produce all equipment within the available work days for that ship. The plan shall identify by item, the number of man-hours and turnaround time for each unit, and the estimated completion date for each item. The Contractor and the Government will review the document after the Contractor’s evaluation of the actual off-loaded equipment. At that time any changes will be identified to the plan, which shall be finalized and signed by both the Government and Contractor Site Leads as the Government Authorized plan of work. Contractor monthly performance shall be monitored against the Sail Plan using the metrics cited in the Surveillance Activity Checklist (SAC). (SAIL PLAN – CDRL A009)

4.5.2 SE Operational Support. The Contractor shall perform O-level and I-level SE planned and unscheduled maintenance in support of day to day fleet operations. The Contractor shall develop and maintain a SE Planned Maintenance Schedule for the performance of planned/scheduled maintenance requirements as identified in the SE item’s applicable maintenance requirements cards, maintenance instructions manuals, or original equipment manufacturers manuals (if no other manuals are available). The schedule shall identify each item of SE by serial number, each planned inspection, and its scheduled performance date. The Contractor shall ensure that Government SE Pool/Management personnel are aware of scheduled maintenance requirements so that the Government can return all equipment in time to meet planned maintenance schedules.

SE scheduled maintenance requirements are performed on scheduled intervals, such as calendar time or operating hours. For inspections whose intervals are based upon calendar days, a +/- 3 days is authorized from the scheduled date to ease workload scheduling. For those based upon operating hours the deviation authorized is 10% of the interval (For example, if the interval was every 125 hours, the fraction would be 12.5 which would be rounded down to 12 hours. If at any time an inspection is conducted earlier than the deviation cited, the date that the inspection was conducted would become the base date for which all future planned inspections are scheduled. If an inspection is not conducted by the date the inspection was scheduled (plus the deviation time – 3 days or 10%) the equipment is considered down and cannot be used until the inspection is conducted. In cases where the inspection is conducted late, the equipment would remain on its planned maintenance schedule as if no deviation occurred.

4.5.2.1 The contractor shall ensure that all equipment scheduled for maintenance is conducted as planned, and unscheduled maintenance requirements are completed in a manner to ensure that SE is available to meet all SE needs. All inspections and maintenance shall be documented in accordance with CNAFINST 4790.2 or other applicable guidance. The Contractor shall ensure that “RFI/U” SE is available to support all evolutions requiring SE.

4.5.3 Support Equipment Rework. Support Equipment rework workload includes equipment inducted for repair from the NAVAIR Support Equipment Rework program, the NAVSUP Quick Engine Change program, the NAVSUP Component Repair program, and other Special Project workloads. Workload from all programs will be measured using the performance measures identified in the SAC.

4.5.3.1 Work Guides. Existing overhaul Work Guides will be provided to the Contractor by the Government. The Contractor shall ensure that standard Work Guides are available for each type of equipment inducted for overhaul into FRC ASE sites. If a Work Guide is not available the contractor shall prepare one in conjunction with the government; using the applicable technical manual as reference. The Work Guide shall list the work to be accomplished in easily managed increments sequenced according to the Contractor's actual production plan (for reference see Military Handbook 881A). Work tasks shall be listed in a logical sequence so as to provide an even workflow identifying both the planned work day each event would take place and the percent complete at that point in the work process.

Upon completion of the Work Guide, the document shall identify all Government approved work to be completed and provide a schedule for the completion of work, providing a standard basis for controlling and reporting the status of work throughout the work effort. The Work Guide will also provide the Government with the information necessary to establish updated estimated completion dates in SEMS and to identify to FRC ASE customers when their equipment will be returned to their custody. This Work Guide and its logical work breakdown and the estimated completion date shall also be used by the Contractor’s Production Controllers for reporting Contractor progress during the maintenance process. All Work Guides shall be maintained by the Contractor and updated as necessary to meet the requirements above. All Work Guide changes must be approved by the Government. Work Guides shall be reviewed for accuracy each time that changes are received for the guide’s associated technical manuals.

4.5.3.2 Examination and Evaluation (E&E).

4.5.3.2.1 Acceptance –The Contractor shall perform an acceptance inspection upon the receipt of each item of SE received for rework at each FRC ASE location. The Acceptance Inspection shall at a minimum include the following verification points:

· Review SEMS to validate that the item received is the item scheduled.

· Based upon the information from the previous step, determine if the item of SE received meets the criteria outlined in NAVAIRINST 13680.1 (series) for rework.

· Inventory all records (i.e., SE Custody and Maintenance Records) and components to ensure that all items that make up the item of SE have been received.

· Review the configuration to ensure that the item is in its latest configuration (all technical directives and bulletins incorporated).

· Conduct a preoperational inspection in accordance with the applicable maintenance requirements cards.

· Conduct a functional test to identify any electrical, mechanical or other problems.

In the event that any item of SE appears to have been cannibalized, misused or abused, the Contractor shall write a report detailing the condition of the item received. The report must be in sufficient detail to allow a SE Misuse and Abuse Report to be prepared (see CNAFINST 4790.2) by the Government.

The Contractor shall document the findings of the acceptance inspection in a Report of Acceptance Inspection. The Contractor shall provide a report of acceptance and findings for each item of SE for all FRC ASE locations to the FRC ASE COR. (REPORT OF ACCEPTANCE AND FINDINGS – CDRL A010)

4.5.3.2.2 The Examination and Evaluation process validates the scope of the maintenance action to be accomplished. For example, for a D-level repair, the final scope of the effort is determined and documented during the E&E process; while for an overhaul, the scope is defined by the Work Guide plus any additional effort determined by the E&E process.

For SE inducted for overhauls, the contractor shall use workbooks/specifications to define the hours required and the scope of work. Any necessary work outside of the scope specified in the workbooks shall be identified at the time of discovery, whether at the E&E or in-process, and be documented in the workbook. The change of scope will be agreed upon by the Contractor Site Lead and Government prior to work continuing. Signatures affixed to the workbook will acknowledge the change in scope. Upon acknowledgement, the WLS associated with the scope of work, either after E&E or upon an update, the WLS shall be updated in SEMS by the government.

Equipment inducted for D-level repairs, the contractor shall use the applicable sections of the workbook identified by the E&E to define the hours required and the scope of work. The E&E determined sections of the workbooks shall be agreed upon by the Contractor Site Lead and the Government prior to work being started. Signatures affixed to the Workbook will acknowledge agreement. Upon the identification of any additional work not noted at the time of the E&E, the necessary work shall be documented in the workbook and agreed upon by the Contractor Site Lead and the Government prior to work continuing. Signatures affixed to the workbook acknowledge the change in scope. Upon acknowledgement, the WLS associated with the scope of work, either when the WLS is established or updated, the WLS shall be updated in SEMS by the government.

4.5.3.2.3 At the completion of the E&E process, all known material requirements to be replaced, repaired or manufactured in support of the rework process shall be identified by the Contractor on a work order sheet. It is expected that the materials that are identified during the E&E be ordered at that time and that the majority of the materials that are required to complete the rework be ordered by the end of the disassembly phase. The Contractor shall maintain each of the work order sheets for each item inducted throughout the rework process, adding requisition numbers, part information, status, and annotating receipt of each part ordered.

4.5.3.2.4 The 23380 GSE Mechanics shall examine each item of SE, component, accessory or part received for processing prior to disassembly, repair or other processing to determine and document its condition and to assure proper configuration and processing. The 23380 GSE Mechanics shall conform to requirements set forth in applicable Maintenance Instruction Manuals before reusing, repairing or replacing any accessories and/or components.

4.5.3.3 Technical Directives and Bulletins. The contractor shall ensure that all SE changes and bulletins are complied with during the rework/repair/configuration process in accordance with NAVAIRINST 13680.1(series). All technical directives and bulletins shall be documented in the equipment’s SE Custody and Maintenance History Record, (CNAF 4790/51) or AESR in accordance with CNAFINST 4790.2.

4.5.3.4. Beyond Economical Repair (BER). If during the Examination and Evaluation process it is determined that the cost of parts and labor would exceed 80% of the replacement cost of an item of SE, the Contractor shall recommend to the Government that an item be condemned/surveyed due to its being BER. The Government will work with the appropriate SECA to determine if the item should be surveyed. Once a decision has been made the Contractor shall not condemn any item without written direction from the FRC ASE COR. The Contractor shall affix a DD Form 1577-2 Unserviceable (Repairable) Tag to BER Candidate items annotated “Beyond Economical Repair” in the Remarks block, and preserve the item to keep it from deteriorating any further until a decision is approved to repair/survey the unit.

4.5.3.5 Corrosion Control. The Contractor shall protect end items and component parts of SE to ensure against damage. Disassembled end items delayed during processing shall be adequately maintained and protected to prevent damage and corrosion. SE corrosion prevention, treatment, preservation and de-preservation shall be accomplished in accordance with the appropriate maintenance instruction manuals, maintenance requirements cards or NAVAIR 17-1-125. The Contractor shall document these maintenance actions per CNAFINST 4790.2.

4.5.3.6 Corrosion Maintenance. After the completion of maintenance, the Contractor shall thoroughly clean areas affected, removing filings, chips, loose hardware and debris to reduce the possibility of Foreign Object Damage. The Contractor shall touch up protective finishes disturbed in accomplishing maintenance to prohibit corrosion. The Contractor shall prepare all surfaces for painting and paint using materials, application methods, and procedures set forth in the appropriate maintenance instruction manuals. NAVAIR 17-1-125 may also be consulted for guidance when specific maintenance instruction manuals are not available for an end item of SE. Under no circumstances shall white paint be applied over yellow paint.

4.5.3.7 Servicing / De-Servicing. After the completion of all work, the SE equipment/system shall be serviced in accordance with the applicable maintenance instruction manual/maintenance requirements cards. The Contractor shall document the maintenance action per CNAFINST 4790.2.

The Contractor shall de-service equipment in preparation for shipment in accordance with NAVSUP Pub 505/DLAI 4145. De-servicing shall take place after QA operational checks are conducted and prior to Government acceptance and shipment.

4.5.3.8 Transfer – The Contractor shall perform a transfer inspection upon completion of rework when the equipment is prepared for shipment back to its Reporting Custodian. The Transfer Inspection shall at a minimum include the following verification points:

· Conduct an inventory of all records and components that make up the item of SE to ensure that the item of SE is complete.

· Review the item’s configuration to verify the equipment is in its latest configuration.

· Conduct a preoperational inspection in accordance with its applicable maintenance requirements cards.

· Verify that forced removal/hydrostatic test dates have not expired.

· Verify current Non-Destructive Inspection / Load Test.

· Conduct a functional test of the equipment to ensure that it meets the operating specifications identified in the maintenance instructions manuals.

· Evaluate the preservation to ensure that the equipment is adequately protected in accordance with its applicable maintenance instruction manual, Maintenance Requirements Cards or the NAVAIR 17-1-125 to ensure its protection during its return to its Reporting Custodian.

4.5.3.9 Shipping. The contractor shall de-service all equipment prior to shipment. For SE requiring fuel in order to be driven during the unloading process, no more than ¼ tank of fuel shall remain in the tank. The Contractor shall ensure compliance with NAVSUP Pub 505/DLAI 4145.3 and certify the Shippers Declaration for Dangerous Goods at each FRC ASE site. The Contractor shall ensure that all support equipment is properly packaged for shipment to prevent damage of the equipment when returned to FRC ASE customers. The Contractor shall ensure that all equipment plates / tags are clearly marked with their current weight and cube information prior to shipment in accordance with maintenance instructions manuals.

Each FRC ASE location shall be responsible for the shipping of all SE assigned to each individual location. The Contractor shall designate a point of contact at each individual FRC ASE location who will obtain an account with the current shipping method for the scheduling of shipments for all SE for that particular location.