PWS_Appendix_A.pdf

Appendix A – Performance Work Statement

APPENDIX A

PERFORMANCE WORK STATEMENT (PWS)

FOR THE

JOINT FOLLOW-ON REPAIR (JFOC) FOR OVERHAUL AND

REPAIR OF T56 Series 3.0 and Series 3.5 Engines with QEC, Power

Sections, and Components

Management of Items Subject to Repair (MISTR)

PREPARATION DATE: 1 2 N o v e m b e r 2 0 2 4

(REVISION 02) PREPARING ORGANIZATION:

421st SCMS/GUMF

TINKER AIR FORCE BASE (AFB), OK

TABLE OF CONTENTS Page

SECTION I DESCRIPTION OF SERVICES/GENERAL INFORMATION

1 Background 3

1.1 Workload Scope 3

1.2 Transition Phase-in 5

1.3 Receiving/Contractor Acceptance Inspection 8

1.4 Overhaul, Repair and Modification 8

1.5 Quality Representative and Quality Assurance 12

1.6 Deficiency Report Investigation and Resolution 15

1.7 Non-Conforming Material Review 15

1.8 Packaging/Handling/Shipping/Transportation 17

1.9 Material Management 18

1.10 Mission Essential Services 19

1.11 Reporting Requirements 19

1.12 General Program and Management Requirements 21

1.13 Technical Library Maintenance 22

1.14 Surge 24

1.15 Over and Above (O&A) 24

1.16 Transition Phase-Out 26

1.17 Supply Chain Risk Management (SCRM) 27

SECTION II SERVICE SUMMARY

2.0 Service Summary 29

2.1 Service Summary Requirements 29

2.2 Performance Objectives and Thresholds 29

2.3 Surveillance Methods 29

2.4 Contractor Performance Evaluation 29

SECTION III GOVERNMENT FURNISHED PROPERTY AND SERVICES

3.1 Government Furnished Material (GFM) 33

3.2 Government Furnished Equipment (GFE) 33

ATTACHMENTS

A Technical Orders and Time Compliance Technical Orders

B Demonstration of Critical Processes

C Contractor Line-Item Number (CLIN) Structure with Best Estimated

Quantities (BEQ)

D Definitions

E Material Review Board Exemptions

F Government Furnished Material

G Government Furnished Equipment

J Acronyms

K, K1, & K2 Navy Specific Requirements

M Comprehensive Engine Management System (CEMS)

M-1 Technical Data Agreement

N Supplemental Packaging Information

O CAV AF Reporting Requirements

P SCRM- Supply Chain Risk Management

SECTION I – DESCRIPTION OF SERVICES/GENERAL INFORMATION

1. Background

The Rolls Royce T56 military turboprop engine is a single spool, constant speed, gas turbine power section connected to a reduction gear assembly by a torquemeter shaft.

The United States Air Force (USAF) uses them to power Lockheed legacy C-130

Hercules transport aircraft.

USAF T56 engines are certified and managed by the Air Force Program Management

Office (PMO), located at Tinker Air Force Base. The end-user or customer is the lead

Major Command (MAJCOM), the USAF Air Mobility Command, in addition to three other MAJCOMs. USAF T56 engines are inspected and repaired at various intermediate and organizational level facilities throughout the world.

1.1. Workload Scope

The purpose of this Performance Work Statement (PWS) is to specify the T56 assembly and component technical, logistics management, and repair/overhaul requirements for the JFOC contract.

Contractor will provide depot-level overhaul/repair of United States Air Force (USAF), United States Navy (USN), and Foreign Military Sales (FMS) T56 engines, modules, and components including Management of Items Subject to Repair (MISTR) items.

Additional requirements specific to the USN are included in Attachment K, K1, and K2 with reference to the USN-specific Contract Data Requirements List (CDRL).

This PWS shall take precedence over the contractor’s technical proposal.

The contractor shall provide the services as described in paragraph 1.1.1. Should any changes occur in the technical requirements due to maintenance philosophy, changes in maintenance procedures, incorporation of new materials, or any required changes driven by the Government Technical Orders, the Contractor shall assess the impact of the changes. Should these required changes drive a change in contract price, a price will be jointly negotiated for the impacted CLINs.

Table 1.1-1: T56 Engine Subassemblies

Power Section

Reduction Gearbox

Torque Meter

Quick Engine Change

1.1.1 Contractor Provided Services

The contractor shall provide the services listed in this paragraph. Table 1.1.1-1 provides the respective engine model and user.

• Depot level overhaul and repair of USAF and USN modules, components, and whole engine contingency support

• FMS whole engines which include Quick Engine Change Kit (QECK), modules, and components.

• Collect and deliver data in support of Government systems and the Contract Data

Requirements List (CDRL) summary (RFP PWS - Exhibit A).

Table 1.1.1-1:T56 Configuration and Customer

Engine User

USAF USN FMS

Series 3.0

T56-A-15 * * T56-A-14 * * T56-A-16 * * T56-A-425 * *

T56-15LFE *

Series 3.5

T56-A-15A * *

1.1.2 USAF Maintenance Program

The majority of USAF T56-A-15 engines have been recently converted to T56-A-15A configuration. Some T56-A-15 engines remain in USAF inventory and may require repairs as needed. The USAF maintenance program for T56 end items/components under this

PWS is based on current USAF configuration management IAW IPB 2J-T56-54 and other applicable USAF T56 repair/overhaul technical orders. There is no established flying hour limit to remove the engine for repair or overhaul. Instead, maintenance is based on the actual condition of the item as determined by inspection, testing, occurrence of a specific event, or expiration of operating time limits. Primary causes for removal are: exceeding serviceable limits, Time Compliance Technical Order (TCTO) modifications, and exceeding critical rotating component life limits.

1.1.3 Applicable Technical Data

“Applicable technical data” or “applicable T.O.s” is defined as all technical documents or requirements listed in the latest National Stock Number (NSN)-specific Repair Data

List (RDL), their reference documents, and all applicable TCTOs, Unless Otherwise

Specified (UOS) in writing by the government Cognizant Engineering Authority (CEA).

For consumable or one-use items without a RDL, it refers to the latest revisions of 2J-

T56-53, 2J-T56-54, and their reference documents. Non-consumable T56 components without a valid RDL must be quarantined by the contractor pending disposition by the

CEA.

The contractor shall perform no more or less than all applicable technical data requirements when specified.

1.1.3.1 Repair Qualification Requirements (RQRs) / Source Approval Request (SAR)

The latest revision of RQR-PSD-1 (available on SAM.gov) establishes requirements which a potential contractor must satisfy to obtain CEA approval to disassemble, clean, inspect, assemble, or repair critical-application USAF T56 modules and components.

The contractor shall ensure all T56 cleaning, inspection, assembly, and repair is accomplished by USAF-qualified sources IAW the latest revision of RQR-PSD-1.

The Contractor must have a CEA-approved SAR for disassembly, cleaning, inspection, assembly, and repair of engine subassemblies listed in Table 1.1-1 and their accessories prior to contract award.

Additionally, the Contractor must show proof that the SAR for the Quick Engine Change

(QEC) Kit has been submitted to the System Program Office (SPO) AFLCMC/WLN prior to proposal deadline. The Contractor shall communicate sufficiently to ensure that the QEC SAR is fully supported to enable the SPO CEA to approve the package.

In addition to the CEA SAR approval process to be eligible for award, the Contractor shall submit current proof of Original Equipment Manufacturer (OEM) Authorized

Maintenance Center (AMC) and/or Authorized Military Overhaul Facility (AMOF) certifications and proof of current ISO 9001:2000 or higher version certification.

1.1.4 Government Forecasts and Delivery Orders

The Government will provide an annual Fiscal Year Best Estimate Quantity (BEQ) for all Contractor-produced items no later than 30 June of each year. The Government will provide an updated forecast for each quarter no later than 30 calendar days prior to the beginning of that quarter.

The Government will submit delivery orders on a quarterly or as required to support mission requirements, which will include adjusted end item output schedules as applicable to Government needs. The Government will send reparable T56 components to meet the delivery order quantities.

1.2. Transition Phase-In

The Contractor shall achieve transition phase-in plan activities within 45 calendar days of contract award. The Contractor shall provide to the Procurement Contracting Officer

(PCO) a finalized Transition Phase-In Plan for Government acceptance/approval to support the requirements of this PWS no later than 10 calendar days after contract award.

The Transition Phase-In Plan may require adjustments due to Work-In-Process (WIP) of the previous and/or existing contracts for Series 3.0 and Series 3.5 workloads. The

Contractor’s transition plan shall incorporate the phase-in requirements, master schedule to include milestones, and identification of any risks and associated mitigation strategies to meet all requirements for end item production in this PWS. The Contractor shall achieve the overall 45 calendar day transition phase-in period with no more than 10% average error in meeting transition plan milestones. The Contractor shall identify all completed actions of their plan through written notification to the PCO. The Contractor shall provide status of transition phase-in progress to the Government every other week until phase-in activities are completed, no later than 45 calendar days after contract award. The Contractor shall report status of the transition phase-in IAW CDRL A00F as well as via scheduled telecoms with the PMO and PCO. At a minimum the Contractor’s transition plan shall address the following:

a) Provide a detailed plan on how GFE (Attachment G) will be moved from existing location to vendor facility (para 1.2.2.). NOTE 1: This only applies if the vendor requires any movement of GFE. NOTE 2: Movement of GFE can only occur when prior contract work-in-process utilizing GFE is completed. During this period or any period that GFE is not available, the Vendor must have their own equipment to support any delivery order work requirements or process demonstrations.

b) Provide a plan on how GFE will be set-up / qualified as ready for repair of the requirements during transition phase-in and the full capability requirements within this PWS. NOTE: This only applies if the vendor requires GFE

c) Accomplishment of hiring/retaining skilled personnel as described in paragraph 1.2.3

d) Provide a facilities plan (to include location where repairs will be accomplished along with the percentage of repair for each item that is to be performed at the repair location(s) IAW paragraph 1.2.4. NOTE: If a move in facility location is anticipated and/or planned to occur after contract award, the Contractor shall provide a timeline of anticipated or planned move actions along with a new SAR package for the new facility location and a complete back-up plan for how mission requirements shall be accomplished during any such facility movement.

If facility move is known at time of award, then Contractor shall provide a detailed plan to the PCO via email no later than 5 business days after award for approval. If facility move date is anticipated, but not yet finalized in detail, the

Contractor shall notify the PCO via email 30 calendar days prior to finalized plan and submit a detailed plan upon finalized details completion (no later than

5 business days after completion).

e) Approach to acquiring access / installation of Government required data / reporting systems and any associated systems training as addressed via CDRLs and other requirements IAW PWS 1.11.1.

1.2.1. T56 Series 3.0 and 3.5 Initial Production Evaluations (IPE)

The Contractor shall perform a one-time IPE for all T56 Critical and Sensitive Repair procedures IAW PWS Attachment B as required by the CEA or a CEA-appointed agent on their behalf. Each IPE shall be substantiated consistent with the level/categories identified in Attachment B. In support of performing on-site review of the critical repair procedures by the Government CEA, the Contractor shall allow the Government CEA, or an agent on their behalf, access to the Contractor’s facility. The Contractor shall notify the Government CEA and PCO 14 calendar days prior to having all required IPE material and equipment (GFE or non GFE) ready to support a Government on-site verification for a critical repair procedure. For items identified in Attachment B Table 2, the Government shall provide the following number of each asset for IPE repair substantiation:

- Group 2a: 1 asset

- Group 2b (Procedures 43-51): 3 assets

- Group 2b (Procedures 52-59): 1 asset

- Group 3: 1 asset

- Group 4: 1 asset

IPE is deferred for repair procedures in PWS Attachment B Table 2 Groups 3 and 4 until after completion of IPE for Groups 1, 2a, and 2b. The IPE for Groups 3 and 4 will be performed when a Government order is placed for the assets necessary to complete the

IPE.

Initial Contractor submittal of IPE Substantiation Packages IAW Attachment B shall be accomplished within 45 calendar days of IPE asset induction by the contractor. Any IPE

Substantiation Package rework by the Contractor directed by the Government is to be performed within 7 calendar days. The Contractor and Government CEA shall jointly work together to meet a completion target of 90 calendar days from the date of IPE asset induction. The Contractor and Government CEA shall schedule the timing and reviews of the Government on-site verification of critical repair procedures via shop floor demonstration to meet the completion target of 90 calendar days from IPE asset induction. The Government CEA shall maintain the right to waive the IPE requirement after contract award.

1.2.2. GFE Transition

The Government will offer Government Furnished Equipment (GFE) “condition as is” for contractor use IAW applicable technical data. GFE will only be provided if the winning vendor requests to use GFE item(s) in their Transition Phase-In Plan and submits as part of their proposal a GFE Matrix specifying what and how many GFE items are needed within the Government allotted quantities.

The Contractor shall be responsible for the movement, set-up, and qualification of GFE from the prior contractor’s facility to their facility at no cost to the Government. NOTE:

the prior vendor will be allowed to keep required GFE to produce any work-in-process (WIP) before transitioning the GFE item. GFE for potential vendor use is provided in Section III, Government Furnished Property, and Attachment G. If GFE is not serviceable after movement or setup, the Government will allow up to 75% of latest replacement GFE cost for Over and Above (O&A) -funded contractor repair. If GFE repair is beyond 75% of replacement cost, or needs to be replaced, the Government will not replace nor repair the item, and the item will no longer be considered as GFE for use in supporting contract requirements.

1.2.3. Personnel

The Contractor shall provide qualified personnel necessary to meet contractual requirements for both maintenance and supply activities. The Contractor shall ensure that the Contractor maintenance employees who inspect and certify work as completed are certified IAW International Organization for Standardization (IOS) standards and

Aerospace Standards (AS).

1.2.4. Facility Plan

IAW FAR 52.246-2, the Contractor shall provide to the Administrative Contracting

Officer (ACO) the facility lay-out, workflow, location and methodology for where and how the workload will be performed at the beginning of contract period of performance.

Plan shall also include any anticipated or planned facility movement as described in PWS

1.2.d.

1.3. Receiving/Contractor Acceptance Inspection

The Contractor shall visually inspect incoming T56 components and Government

Furnished Material (GFM) for missing parts, damage associated with improper handling and shipping, and damage other than normal failures IAW applicable technical data.

Upon discovery of discrepancies for items of supply received for overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damage, improperly packaged shipment, shipped short or missing parts. The Contractor shall enter all discrepancies into the web-based system, Web Supply Discrepancy Report (WebSDR) and place part(s) into suspension and request further guidance from USG. Upon receipt of USAF disposition, the Contractor shall complete the directed action and close the supply discrepancy IAW Appendix B. In those situations where the SDR initiator is unable to gain access to the AF WebSDR, continued use of manual forms is permitted. A copy of the form will be forwarded through the ACO and Quality Assurance (QA) activity for corrective action.

1.3.1. Custody of Assets

The Contractor shall have a system of internal controls to manage (control, use, preserve, protect, repair and maintain) T56 components in its possession IAW Federal Acquisition

Regulation (FAR) Part 45. The Contractor shall be liable for all Contractor induced damage to Government property while in their custody to the extent allowed under FAR

Property Clause 52.245-1. The Contractor shall be liable for any damage to components due to machining errors or dropped item damage.

1.3.2. Preservation

The Contractor shall inspect all items received no later than the third workday after receipt to determine the adequacy and proper documentation of preservation. T56 components with inadequate preservation shall be inducted or re-preserved IAW applicable T.O.s within ten (10) working days after inspection.

1.4. Overhaul, Repair and Modification

1.4.1. Performance Standard

The Contractor shall meet the following performance standards, which will be measured on an annual basis:

a) The Contractor shall produce CLINs (in aggregate) at a minimum of 95% of the delivery order output schedule. On an annual basis, it will be determined if the

Contractor met the 95% minimum by dividing the total quantity of end item CLINs delivered on time by the total number of end item CLINs required to be delivered. For example, at the conclusion of the year of performance, if the Contractor was required to deliver an aggregate total of 1000 items across all CLINs and delivered 960 on time, the Contractor’s on time delivery would be 96%.

b) The Contractor shall ensure major modules, turbine rotors and associated components provide a warranty of a minimum of 200 Engine Flying Hours (EFH) Time-on-Wing without failure. The Contractor shall repair/replace all failed/unserviceable parts to restore serviceability of part at no cost to the Government within the first 200 EFH regardless of failure mode. If GFM must be replaced, the Contractor shall requisition

GFM from the Government (except in the case of a USG determined Contractor quality escape, the Contractor shall be liable for all cost(s) obtaining GFM). All associated labor cost to remove and replace any GFM will be the Contractor’s sole responsibility. The Contractor shall notify via email the PCO, DCMA/QA, and CEA upon receipt and again upon induction of less than 200 EFH asset for repair. The

Contractor shall notify via email and provide a report of the actions taken to return the asset to serviceability to the PCO, DCMA/QA, and CEA upon completion of the asset.

The Contractor shall repair and return warranty assets back to the USG within 90 calendar days and notify via email the PCO, DCMA/QA, CEA and the 421st supply planner lead upon shipping the asset back to the Government. All reporting and actions to return the less than 200 EFH asset to serviceability shall be at no cost to the

Government. Failures due to Foreign Object Damage (FOD), fuel/oil contamination, and other field maintenance induced faults are excluded. The Contractor shall notify via email the PCO, DCMA/QA, and CEA of all determinations for exclusion and shall include a description of the damage, contamination and/or field maintenance induced faults with the contractor rationale used to make the determination(s). If less than 200

EFH, warranty assets returned for repair do not require Government (DCMA) investigation but require Government personnel (DCMA) be present during asset container/package opening to confirm no missing parts or field unit induced discrepancies.

c) For the basic period and any option exercised, the Contractor total quality deficiencies determined to be workmanship after an Engineering Investigation for parts operating longer than 200 EFH time on wing, shall not exceed .5% of all modules and .05% for all components produced.

1.4.2. Specific Work Requirements

1.4.2.1. Disassembly and Cleaning

The Contractor shall disassemble and clean all T56 assemblies IAW applicable technical data and any specific work-scope document(s) authorized by the CEA.

1.4.2.2. Inspection

The Contractor shall inspect all engine components IAW applicable technical data.

Prior to assembly, the contractor shall inspect component marking to verify that the

Part Number (PN), Serial Number (SN), and CAGE code are IAW all requirements in 2J-T56-54.

The Contractor shall submit all components and assemblies that exceed the reparable limits of the applicable technical data to MRB for disposition (paragraph

1.7), with the exception of items identified in PWS Attachment E, Material Review

Board Exemptions.

1.4.2.3. Repair

The Contractor shall repair all T56 components and assemblies that exceed the serviceable limits and are within the reparable limits of the applicable technical data.

Prior to repair of each component or assembly specified in the applicable technical data, the Contractor shall estimate the total costs of all required repairs and use this estimate to determine whether the subject item is Beyond Economical Repair (BER). Final BER disposition shall be determined by the 421st Supply Chain.

For FMS assets, a component that exceeds the serviceable limits of the applicable technical data, inform the PCO and T56 International Engine Management Program

Office as necessary for disposition. Additional work using criteria other than applicable technical data shall be specified in the subject delivery order and evaluated for O&A funding.

1.4.2.4. Failure Data Collection (Depot Only)

The Contractor shall record and store IAW PWS 1.4.2.6 the following information on non-consumable engine components on all USAF modules, reduction gearboxes, and turbine rotors inducted for repair. The Contractor shall document all inspections and findings and provide to the CEA IAW CDRL A00J.

1. Item/Assembly Part Number

2. Item/Assembly Serial Number

3. A detailed description of subject failure condition, including rationale and measurements when applicable.

4. Date of inspection.

1.4.2.5. Overhaul

The Contractor shall overhaul any engines, power sections, modules, assemblies, and

MISTR components that are not inducted as part of the whole engine IAW applicable technical data and delivery order schedules. The Contractor is responsible for the procurement of all materials required for overhaul except items to be provided as

Government Furnished Material (GFM).

Attachment F lists all current GFM. This list is subject to change as required by the government. Some QEC GFM items on Attachment F are ordered per GFM MORDs

(like O&A) due to cost and demand usage factors.

Series 3.0: The Contractor shall evaluate, T56 reduction gearboxes, compressor and turbine modules, and turbine rotors for minor overhaul IAW T.O. 2J- T56-53 Work

Package (WP) 002. The Contractor shall perform a major overhaul for all T56 components not complying with the minor overhaul criteria IAW 2J-T56-53 WP 002. The

Contractor shall use or save for build-up any T56 modules, MISTR components, piece parts and assemblies that are determined serviceable or can be economically repaired. The

Contractor shall route items to the Material Review Board (MRB) IAW PWS 1.7.

Series 3.5: Upon receipt of unserviceable Series 3.5 compressor or turbine modules, the contractor shall disassemble, clean, and inspect the modules IAW applicable technical data and submit a written TT&E repair report via email to the PCO, 421st Supply Chain section with proposed overhaul cost estimate and verification of need the contractor shall not commence any maintenance repair actions in advance of specific PCO authorization(s). Inspection and acceptance at destination to be completed at

Government location.

When directed by the PCO, the Contractor shall induct, clean, inspect, troubleshoot, repair, replace and test any worn, broken, damaged, or otherwise failed Series 3.5 components and assemblies. The Contractor shall evaluate USAF compressor and turbine modules for minor overhaul IAW 2J-T56-53 WP 002 and any other applicable technical data. The Contractor shall perform a major overhaul for all T56 components not complying with repair or overhaul criteria IAW applicable technical data.

Series 3.5 Upgrade (FMS as applicable): The Contractor shall major overhaul the 3.0 compressor and turbine modules, install the new 3.5 upgrade kit hardware, and perform all compressor and turbine module repairs IAW with all applicable T56 technical data and TCTOs (Attachment A) to provide serviceable 3.5 compressor and turbine modules.

The Contractor shall perform a major overhaul for all engine components IAW 2J-T56-

53 and applicable technical data. All 3.5 upgrade kit(s) will be provided by FMS country. The Contractor shall provide all contractor furnished material (CFM), labor, and maintenance and overhead services to produce upgraded 3.5 compressor and turbine modules for the overhaul / upgrade of compressor and turbine modules as specified above in this PWS as required throughout the life of the contract.

Series 3.5 Sustainment (FMS as applicable): Sustainment repair of T56 3.5 kit items

(turbine vanes and segments, accessory gearbox housing drive) will be done as a part of a TT&E Firm-Fixed-Price CLIN effort. All 3.5 Sustainment will be performed with contractor furnished material (CFM). Excessive Defense Articles (EDA) for T56 will require inspection and test without teardown.

1.4.2.6. Records Maintenance

The Contractor shall document and retain all maintenance/inspection/test work records generated during repair, overhaul, or modification of contractor-produced items identified in CDRL A00L. The Contractor shall convert all records to a scanned digital format and maintain an index of each component package. Upon request of the PCO or

ACO (whether at contract expiration or at any time during the contract period), the

Contractor shall provide maintenance records for any contractor-produced items within

24 business hours of request. Upon expiration of the contract, the Contractor shall send a records index and all records to the Government IAW CDRL A00L. IAW FAR

4.703, the Contractor shall retain any records generated for three years after final payment. Additionally, for any Critical Safety Items records generated, the Contractor shall retain records for up to seven years after completion of the maintenance and repair work or longer as determined by the ALC/CC. Furthermore, at the end of this period, or in the event of relocation or shutdown, all records should be offered to the procuring activity prior to disposal.

1.4.2.7. Preservation

The Contractor shall follow the preservation/re-preservation requirements IAW TO 2J-

T56-53 and 2J-1-18, unless otherwise specified by the CEA or RDL. The Contractor shall inspect all T56 components received no later than the third workday after receipt to determine the adequacy and proper documentation of preservation. T56 components with inadequate preservation shall be inducted or re-preserved IAW TO

2J-T56-53 and 2J-1-18 within 10 business days after inspection. For all other end items, the Contractor shall preserve items IAW applicable TOs.

1.4.2.8. Disposition of Excess Non-Reuse 3.0 Parts- (FMS only if applicable during 3.5

Conversion)

The Contractor shall provide a monthly listing via email to the PCO of excess non-reuse 3.0 parts for disposition. Listing shall contain the National Stock Number

(NSN), Item Name (nomenclature), Part Number (PN), Quantity, and Reason for

Excess all provided in written email correspondence. The Contractor shall retain all excess 3.0 non-reuse parts and store them in a manner that does not cause any damage, promotes preservation (i.e. climate-controlled storage), and are segregated between

FMS Partner Nations (not to be comingled). The contractor shall clearly mark removed parts and their associated storage containers with easily viewable and appropriate nomenclatures, NSNs, PNs, and FMS End User identity.

1.4.3. Final Acceptance

The Contractor shall perform a final inspection and test on all engine components IAW applicable technical data. The Contractor shall deliver all MISTR components in a tested, serviceable and Ready For Installation (RFI) condition. For the FMS assets, the

Contractor shall also document on AFTO Form 95.

The Contractor shall maintain performance data and test cell maintenance logs during each item’s acceptance testing with the records.

The Contractor shall perform a full final inspection per applicable T.O.s and document with date and inspector's stamp or other identification.

1.5. Quality Representative and Quality Assurance

The Contractor shall identify to the Government their Quality Point of Contact at post award.

Government Quality Assurance Surveillance

The Contractor shall support DCMA for manning, research assistance, demonstration of processes, etc. The QAR shall conduct Government quality assurance surveillance to periodically evaluate the Contractor’s performance.

Corrective Action

The Contractor shall implement appropriate corrective actions to bring the quality system into compliance when Government issues a Corrective Action. DCMA QAR issued corrective actions shall be IAW DCMA Policy and Instructions as required.

Production Asset Audits

The Contractor shall support DCMA for manning, research assistance, demonstration of processes, etc. in regard to product examinations (acceptance), process reviews

(important manufacturing processes), and Quality Management System(s) at the determination of the Government. The Contractor shall support product examinations, process reviews, and Quality Management System audits at the Contractor facility/location where the work is accomplished.

Important Manufacturing Processes

The Contractor shall seek CEA support and courtesy copy the DCMA QAR for manning and research assistance for the demonstration of processes as per Facility Plan, submitted in accordance with PWS. The processes are IAW the latest revision of USAF RQR-

PSD-1.

1.5.1. Request for Deviation

The Contractor shall submit all requests for deviation from applicable technical data

IAW CDRL A00Q.

The Contractor shall submit to the USAF CEA and the DCMA QAR all non-MRB requests for deviation from applicable technical data and requests for CEA disposition of technical problems not covered by applicable technical data using the Air Force Material

Command (AFMC) Form 2 0 2 IAW AFMCMAN 21-1 Chapter 5.

The Contractor shall obtain access to the approved USAF online system to submit and record Form 202s, currently AutoTAR.

All Form 202 requests that result in a cost impact shall be clearly identified by the

Contractor as “Cost Impact 202” and submitted to the PCO and courtesy copied to the

ACO prior to approval / funding to implement requested deviation. For 202 efforts that are less than 10 labor hours, the Contractor shall rework with no additional costs.

Either monthly or at mutually agreed-upon intervals, the Contractor shall engage in a joint discussion with at least the CEA and others as needed to identify opportunities to reduce overall maintenance costs. The output of this meeting will be to identify applicable technical data changes that will reduce GFM, CFM, and/or labor costs.

1.5.2. Repair and Manufacturing Qualification

The Contractor shall ensure all repairs and sub-vendor repairs of critical processes are provided by Government qualified sources and the latest revision of USAF RQR-PSD-

1. The Contractor shall ensure all changes to critical and sensitive repair procedures are made IAW Attachment B.

1.5.3. Government Approved Sources

The Contractor shall ensure all components and assemblies applicable to RQR-PSD-1 are procured from Government-approved sources in accordance with the Contractor Furnished

Material (CFM) requirements in PWS Section 1.9.3. Source-controlled components and assemblies must be procured from the source(s) specified by the subject manufacturing drawing, unless otherwise specified by the CEA or the subject RDL.

The Contractor shall obtain the most current listing of USAF and USN T56 Critical

Safety Item (CSI) components from DCMA. In the event of a disparity in the criticality listing between the USAF vs. USN, the most stringent CSI criticality rating for an item will be used for the purposes of this workload. The higher criticality rating will apply to both USAF and USN engines.

For CSI parts repaired by or purchased from sources other than Government Source of

Supply (e.g. DLA, NAVSUP), the Contractor shall provide DCMA with an electronic copy of any initial Purchase Order (PO) issued to a supplier, within two (2) working days of the PO being issued to the supplier. Upon change of supplier, DCMA shall be notified and provided with an electronic copy of the PO issued, within two (2) working days of issue. DCMA may request current electronic copies of POs be provided to DCMA for audit and delegation purposes. The Contractor shall ensure that all POs contain appropriate FAR/DFAR clauses for Inspection of Supplies and Services and Higher-

Level Contract Quality as applicable.

The Contractor shall provide DCMA an electronic listing in Microsoft Excel format of all

CSI part numbers along with NSNs, and nomenclatures that are subcontracted, sent to another facility for repair, or purchased from outside suppliers, and where they are sent / purchased (i.e. vendor name, CAGE code, address etc.). The Contractor shall maintain and update this list as parts.

The Contractor shall provide 1st tier Subcontractor(s) performance data to DCMA on a monthly basis. The data shall be delivered no later than the 5th working day of the month.

Data is to be provided in a Microsoft Excel format and shall include the following information for each Subcontractor(s):

- Company Name

- CAGE Code

- Address

- Total number of parts reviewed during the previous month

- Number of parts rejected during the previous month

- Part Numbers on rejected parts during the previous month

- Reason(s) for rejections of parts

- Number of parts delivered on time

1.5.4. Foreign Object Damage Prevention Program

The Contractor shall maintain a FOD prevention program IAW National Aerospace

Standard (NAS) 412. If a FOD incident occurs, the Contractor shall notify the ACO and

PCO by email within three (3) business hours of confirmation of the FOD event occurring and email a FOD Incident Report IAW NAS 412 within three (3) working days to the

ACO and PCO.

1.5.5. Contractor Induced Damage

The Contractor shall notify the DCMA Property Administrator (PA) within 24 hours of all

Lost/Damage/Destroyed/Theft (LDDT) incidents involving Government property, excluding DLA material, caused by the Contractor or their Subcontractor(s). Government material (assets / GFM) received damaged, misdirected, or missing parts will be reported using WebSDR to obtain a replacement item and for logistical and financial adjustment tracking by using the SF364 process IAW T.O. 00-35D-54 and under 52.245-1. The

Contractor shall submit a LDDT report to the ACO and DCMA PA. The Government will provide to the Contractor disposition instructions for the damaged item IAW T.O. 00-

35D-54. The Contractor shall be liable for all Contractor induced damage to Government property while in their custody to the extent allowed under FAR Property Clause 52.245-

1.

1.5.6. Disposal Actions

The Contractor shall be responsible for the management and disposal of Petroleum, Oils, and Lubricants (POL) products IAW local, state and federal regulations. The Contractor shall handle all condemned material IAW DOD 4160.21M and demilitarization IAW

DOD 4160.28M and/or the Commerce Control Act as applicable. The Contractor shall dispose of material that has been condemned as directed by DCMA/ACO.

1.6. Deficiency Report Investigation and Resolution for Non-Warranty Assets

The Contractor shall investigate all non-warranty Product Quality Deficiency Reports

(PQDR) and Engineering Investigations (EI) in accordance with T.O. 00-35D-54. Using the Joint Deficiency Reporting System (JDRS) system, the Contractor shall review the reported discrepancy from the field and schedule exhibits for investigation. For PQDRs, the Contractor shall notify DCMA QAR upon receipt of the exhibit and DCMA shall be present for a joint opening of the exhibit. The Contractor shall schedule and investigate the discrepancy. For all EIs, a statement of work will be provided through the ACO. The

Contractor shall schedule exhibit inductions after receipt of exhibit and funding authorization by the ACO. The Contractor shall provide interim and final EI responses within the timelines IAW T.O. 00-35D-54 and format identified IAW CDRL A0AD. The

Contractor shall communicate projected Teardown Deficiency Report (TDR) completion dates to the PMO. A TDR shall be submitted by the Contractor with investigation findings to include root cause analysis, preventative actions, determination of responsibility, and a recommendation to preclude recurrence, as well as a corrective action against all PQDRs and EIs IAW CDRL A0AC / A0AD. The Contractor shall complete investigations within the following timelines: 15 calendar days from receipt of asset for

Category I Mishap, 30 calendar days from receipt of asset for Category II Mishap, 20 calendar days from receipt of asset for Category I DR, and 30 calendar days from receipt of asset for Category II DR. The Contractor shall report Failure Analysis IAW CDRL

A00V.

1.7. Non-Conforming Material Review

The Contractor shall establish a process and holding area to assist Government MRB disposition of all T56 components that exceed the applicable TO limits. The MRB shall consist of the Government’s CEA, the Contractor’s technical engineering representative, and other technicians, engineers, or subject matter experts (SMEs) as needed. The

Contractor shall provide a list of parts subject for review to each member of the MRB.

The list will contain the following information for each candidate item: Part Number, Part

Nomenclature, NSN, Unit Price, supply maintenance and recoverability (SM&R) Code, detailed description of technical nonconformance including measurements where applicable, non-conforming material NCM Classification (Minor, Major, Critical), Order

Number, and if CFM/GFM. Appropriate maintenance production inspectors will be made available upon request. The Contractor shall establish and maintain a holding area for material awaiting disposition and notify the Government CEA for disposition action. The

Contractor shall also notify DCMA at the same time of contact notice to the Government

CEA for records tracking / actions / awareness of MRB item. Government personnel will travel to MRB site monthly, or upon mutually agreed timeframe between contractor and

USG, for disposition actions. Authority to accept / reject all nonconformances, including nonconformances in CSI, is retained by the CEA. Parts disposition shall include one of the following:

(1) Use As-Is: The Government CEA may authorize use of component conditions exceeding or not covered by applicable technical data. Further discussion on disposition procedures will be required after initial JFOC contract award.

(2) Repair: These repair efforts will be approved by CEA. Contractor’s repairs that incur cost in excess of 10 hours of direct labor or 75% of the latest acquisition cost amount shall comply with PWS O&A Work Procedures. The Contractor shall not begin any work submitted for O&A that incurs cost without ACO approval. Further discussion on disposition procedures will be required after initial JFOC contract award.

(3) Scrap/Condemn: Based upon a joint Contractor and CEA review, the Contractor shall condemn any item that exceeds the applicable T.O. limits, cannot be used as is, or BER.

The ACO or PCO may authorize the Contractor to repair items BER when in critical supply status. All condemned parts shall be processed at the Contractor’s facility through the DCMA PA. The Contractor shall report condemnations IAW CDRL

A00H.

(4) Store as directed by government: The contractor shall store subject components in non-serviceable condition for future repair development or other reasons as directed by the

ACO or PCO.

(5) Ship to government-directed facility

All CSI parts dispositioned as condemned by the CEA shall be conspicuously and permanently marked or positively controlled until physically rendered unusable.

The Contractor shall submit for MRB all Prop Shafts, Main Drive Gears, Compressor

Wheels, Turbine Wheels and Turbine Spacers that fail NDI.

The Contractor shall not require Government MRB disposition for items listed in

Attachment E.

The Contractor shall notify PCO and ACO immediately of any discovered nonconformances that may exist in previously delivered CSI. Notification is required regardless of whether the characteristic in question has been classified as a critical characteristic. Notification must include a description of the suspected nonconformance, contract number, part number, and affected serial number or lot numbers, as applicable.

1.8. Packaging/Handling/Shipping/Transportation

1.8.1. Packaging/Handling

The Contractor shall package items according to Special Packaging Instructions (SPIs) by obtaining access to the Special Packaging Instructions Retrieval and Exchange

System (SPIRES) website and IAW T.O. 00-85-20. The Contractor shall obtain a DD

Form 2875 access and PKI CAC card access to SPIRES system to ensure that they are using the latest SPI references. SPI website link is found at https://spires.wpafb.af.mil/.

The Contractor shall place a serviceable tag, DD Form 1574, inside the package along with the assembly as well as outside the package.

Additionally, the Contractor shall refer to Attachment N – Supplemental Packaging

Information.

In the event the Contractor discovers packaging discrepancies, the Contractor shall follow the process prescribed in SPIRES SPIs. If the USAF or Defense Logistics

Agency (DLA) cannot resolve a packaging discrepancy in a timely manner (30 business days), the Contractor may elect to package the asset IAW best commercial practices. In the event the Contractor elects to use commercial best practices, the Government’s O&A funding will not be utilized, and the Government will not incur any charge for packaging.

The Contractor shall store consolidated repairable inventory (CRI) hardware in serviceable SPI containers, unless received in unserviceable condition. Prior to installing an end item in the shipping container and/or storage device, the Contractor shall thoroughly inspect it to ensure that the container, trailer, stand and other associated equipment are clean, complete and free from structural and mechanical damage and all attaching points are complete and secure. The Contractor shall not destroy reusable shipping containers. For Engine trailers and MISTR containers, the Contractor shall determine repair procedures or condemnation actions IAW 35E20-3-1-103 and other pertinent T.O.s. The Contractor shall include the cost of container or engine trailer repair as part of each end item repair price if trailer or container is generated with the end item CLIN. Only irreparable or beyond economic repair containers or metal SPI containers are to be routed to MRB, or suitable location due to size. Containers of material not within the re-utilization program are to be scrapped in place.

1.8.1.1 Container Repair for Containers Only

Containers repaired at the CLIN level should be repaired IAW technical manual 35E20-

3-1-103 as identified in Tech Order 2J-T56-53 which outlines the specific requirements to return the container to serviceable condition. CLIN level container repairs are for the container only without the end item. Containers that are outside technical order limits or over 75% of the BER shall be sent to MRB for further evaluation.

1.8.2. Shipping

https://spires.wpafb.af.mil/

Upon completion of repair of USAF and USN end items, the Contractor shall ship assets

IAW the delivery order. Should exception shipping instructions be required, the PMS will provide the Contractor shipping instructions via e-mail and courtesy copy DCMA

QAR. The Contractor shall ship serviceable items within one (1) working day after receiving shipping instructions. For the FMS assets, the repairable assets are picked up at the Contractor’s facility by the country’s freight forwarder or equivalent. Upon completion of repair of the end items, the Contractor shall notify DCMA for the inspection and the acceptance. Contractor will notify the freight forwarder or equivalent noted in the delivery order (DO) who will arrange transportation of the end items.

1.8.3. Transportation

The Contractor shall use the Government Transportation Accounting Code identified in the contract for transportation costs. The Contractor shall have all appropriate shipping and export licenses as required to meet the requirements within the contract to ship T56 end items. For the FMS assets, the Contractor will notify the freight forwarder or equivalent noted in the DO to coordinate all transportation arrangements upon repair/overhaul completion of the end items

1.9. Material Management

1.9.1. Consolidated Reparable Inventory (CRI)

The Contractor shall maintain a consolidated reparable inventory (CRI). The Contractor shall report asset receipt and induction into Commercial Asset Visibility Air Force

(CAVAF) IAW Appendix B. The Contractor shall also report material receipt IAW

CDRL A00D.

1.9.2. Segregation of Material

The Contractor shall ensure that USAF, USN and FMS components and individual parts within the MISTR components received are kept segregated during storage and the process of overhaul. NOTE: This does not require a separate repair line for each service.

1.9.2.1. Parts Integrity

The Contractor shall maintain integrity of matched parts IAW applicable technical directives. The Contractor shall not cannibalize or inter-mix parts between customers

(USAF and USN) without prior approval from Air Force Sustainment Center (AFSC).

Approvals will be made via either PCOL, or email sent from PCO to the Contractor and

ACO. For FMS assets, the Contractor shall not cannibalize or inter-mix parts between

FMS customers, USAF or USN.

1.9.3. Contractor Furnished Material (CFM)

The Contractor may use the DLA as their source of supply for consumable items. The

Contractor shall procure new and unused parts only. Parts must be procured from

Government approved sources, the Original Equipment Manufacturer (OEM), or OEM authorized parts distributers. For each occurrence that the Contractor buys around DLA, the Contractor shall submit a Demand Data Exchange (DDE) to DLA for the parts to only be procured by DLA.

1.9.4. CFM Forecasting

The Contractor shall be responsible for forecasting CFM requirements to DLA and other parts supply vendors. The Government will provide annual BEQs for all CLINs to assist with the CFM forecasting (para 1.1.2). The Contractor shall obtain access to DLA forecasting systems to input Data Demand Exchange (DDE) actions to provide demand planning requirements. The Contractor shall report CFM usage IAW CDRL A00N.

1.10. Mission Essential Services

Mission Essential Services are not applicable to this PWS.

1.11. Reporting Requirements

The Contractor shall prepare and submit accurate CDRLs to include reconciliation with

CAVAF reporting with timely and factual data to the system in a timely manner as specified within each CDRL. Contractor shall report all delays related to production with each CDRL. The Contractor shall not submit more than one document late per quarter and no document shall be received later than five (5) working days. The Contractor shall not submit reports that require more than two corrections per report per quarter. The

Contractor shall also accomplish reporting on Small Business IAW CDRL A00R and via the ESRS Small Business Database reporting procedures. It is important to note that the

SB CDRL A00R reporting and the ESRS database reporting are different.

The Contractor shall accomplish reporting on CDRLs A0AA and A0AB for Safety Alert

Report and Responses respectively.

Commercial Asset Visibility Air Force (CAV AF) is the USG official reporting system of record, to allow the Government to maintain asset visibility throughout the repair cycle at a Commercial Repair Facility. Contractor shall ensure asset record in CAV AF is an accurate reflection of physical asset on hand at all times.

1.11.1. Programs, Databases & Websites

The Contractor shall obtain and maintain, at a minimum, the accounts identified below to access programs, databases & websites. The Contractor shall obtain a Public Key

Infrastructure (PKI) certificate when necessary for access and PKI security clearances as required for any systems, databases, and websites.

a. Joint Deficiency Reporting System (JDRS)

b. Commercial Asset Visibility Air Force (CAVAF)

c. Web Based Commercial Asset Visibility Air Force (WebCAV or CAV AF)

d. D042 Comprehensive Engine Management System (CEMS)

e. Enhanced Technical Information Management System (ETIMS)

f. Web-based SDR system

g. Plant Clearance Automated Reutilization Screening System (PCARSS)

h. Electronic Data Access (EDA)- Accessed through Procurement Integrated

Enterprise Environment (PIEE)

i. Wide Area Workflow (WAWF)- Accessed through Procurement Integrated

Enterprise Environment (PIEE)

j. FedMall Commerce- Accessed through Procurement Integrated Enterprise

Environment (PIEE)

k. DLA Forecasting Systems

l. Navy Aircraft Engine Management System (AEMS)

m. P-700 Common Naval Packaging (CNP)

n. Air Force Equipment Management System (AFEMS)

o. Contractor Performance Assessment…