PWS.pdf

PERFORMANCE WORK STATEMENT (PWS)

For

F100-PW-220/220E Augmentor Spray Manifold Assemblies

FILE NUMBER: PR# FD20301901835-00

REV. 0

DATE: 4 March 2019

PREPARING ORGANIZATION:

AFLCMC/LPSEA2

TINKER AFB OK 73145-3030

Warning –this document contains technical data whose export is restricted by the arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App 2401, et seq. violation of these export-control laws is subject to severe criminal penalties.

Dissemination of this document is controlled under DoD Directive 5230.25

PR FD20301901835-00 Page 2 of 35

TABLE OF CONTENTS Page

SECTION I

1.1 DATA

1.2 SECURITY

1.3 QUALITY

1.4 DELIVERY SCHEDULES

1.5 CONDEMNATION AND OVERHAUL

1.6 HANDLING

1.7 INVENTORY

1.8 PRESERVATION

1.9 RECEIPT/HANDLING OF PQDR EXHIBITS

1.10 GENERAL WORK REQUIREMENTS

1.11 SPECIFIC WORK REQUIREMENTS

1.12 APPLICABLE TECHNICAL ORDERS

1.13 APPLICABLE DIRECTIVES

1.14 APPLICABLE DOCUMENTS

1.15 MISSION ESSENTIAL SERVICES ………..…………………………………………………………………………………….….15

1.16 SAFETY AND HEALTH…………………………………………………………………………………………………………………..15

SECTION II

2.1 SERVICE SUMMARY REQUIREMENTS

2.2 CONTRACTOR PERFORMANCE EVALUATION

SECTION III

3.1 GOVERNMENT PROPERTY

APPENDIX 1

A1.1 ACRONYMS

APPENDIX 2

A2.1 NOTES

APPENDIX 3

A3.1 PRODUCT VERIFICATION AUDIT PROCEDURES

A3.2 TERMS EXPLAINED

A3.3 RESPONSIBILITIES

A3.4 AUDIT PROCEDURES

A3.5 AUDIT RESULTS

APPENDIX 4

CAV CFM REPORTING REQUIREMENTS…………

PR FD20301901835-00 Page 3 of 35

SECTION I

DESCRIPTION OF SERVICES

This PWS establishes the minimum work requirements to return F100-PW-220/220E Augmentor Spray Manifold Assemblies listed below by National Stock Numbers (NSN) and Part Numbers (P/N) to a serviceable but not like new condition. F100-PW-220/220E Augmentor Spray Manifold Assemblies received by the contractor, as set forth in this contract shall be overhauled, modified, tested, prepared for storage and shipped in accordance with (IAW) the requirements in this PWS and the contract.

NOUN PART NUMBER NSN APPLICABLE

TO

NO. 4 Augmentor Spray Manifold Assemblies

INPUT 4085199 2915-01-471-3480 6J28-2-3

INPUT 4073225 2915-01-334-7068 6J28-2-3

INPUT 4073225U 2915-01-344-7068 6J28-2-3

INPUT 4089329 2915-01-659-5074 6J28-2-3

OUTPUT 4089329 2915-01-659-5074 6J28-2-3

Contractor employees shall identify themselves as contractor personnel by introducing themselves or being introduced as contractor personnel and displaying distinguishing badges or other visible identification for meetings with Government personnel. In addition, contractor personnel shall appropriately identify themselves as contractor employees in telephone conversations and in formal and informal correspondence.

PR FD20301901835-00 Page 4 of 35

1.1 DATA

1.1.1 Reporting Requirements

1.1.1.1 Product Quality Deficiency Report (PQDR – SF 368): The contractor shall prepare a PQDR on all design and quality control (material) deficiencies found IAW the procedures of TO 00-35D-54. Applicable portions of TO 00-35D-54 relative to quality defects will apply. The contractor shall hold exhibits of reported deficient items pending disposition from the ACO representative. Report preparation, distribution, holding and tagging of exhibits shall be IAW TO 00-35D-54. The contractor shall furnish an information copy of the SF 368 to USAF F100 Engineering Source Authority listed in TO 2J-F100-13-1, WP 600 00.

1.1.1.2 TO System Publication Improvement Report (AFTO Form 22): The contractor shall prepare a PIR when an error or improvement changes the meaning of the instructions or information contained in technical directives and will prevent the adequate performance intended. The contractor shall accomplish a PIR IAW TO 00-5-1 and submit one copy to AFLCMC/ENR. Minor discrepancies of non- technical nature such as improper sequence of pages, typographical errors, transportation errors, misspelled words, etc., shall not be reported. The contractor shall report omissions of pertinent technical data, correction of overhaul procedures in TOs, or desired changes to TO data shall likewise use the AFTO Form 22.

1.1.1.3 Teardown Deficiency Report (TDR): A TDR shall be accomplished on any

PQDR exhibit received for investigation. The report shall be completed IAW the procedures established on DD Form 1423 as set forth in the contract.

1.1.2 Other Records, Forms and Reports

1.1.2.1 The contractor shall make available to the appropriate ACO representative the required information to enable him to review and/or verify monthly production status reports on end items and to enable him to complete his records or to complete such other reports as may be required.

1.1.2.2 CAV AF End Item Production Report (End Item Activity Report): The report shall be completed IAW the procedures established on DD Form 1423, as set forth in the contract and the Appendix 2.

1.1.2.3 CEMS Reporting: N/A Note: The -220/220E Augmentor Spray Manifold

Assemblies are not serialized tracked parts, and therefore, CEMS reporting is not required in this contract.

PR FD20301901835-00 Page 5 of 35

1.1.2.4 Completed DD Form 1574 Serviceable Tags are required IAW MIL-STD- 129R, paragraph 5.2.21.a.

1.1.2.5 The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via a secure data collection site. The contractor is required to completely fill in all required data fields at https://www.ecmra.dmdc.osd.mil.

1.1.2.5.1 Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar.

Contractors may direct questions to the CMRA help desk.

1.1.3 Technical Data

1.1.3.1 TOs listed in this specification are the basic directives to be used in accomplishing the overhaul requirements of the contract.

1.1.3.2 TO illustrated parts breakdowns (IPBs) listed in this PWS shall be used in the part replacement requirements of the contract. Replacement parts shall conform to the configurations stipulated in the applicable TO IPB as supplemented by other applicable directives and instructions in this PWS. Part replacement shall be confined to those parts determined to be required to produce a serviceable end item.

1.1.3.3 Directives listed in paragraphs 1.11, 1.12, 1.13 & 1.14 and instructions provided throughout this PWS shall be adhered to, thus obtaining the highest possible quality of workmanship and to maintain acceptable quality standards.

1.1.3.4 Instructions listed in this PWS as “Changes” or “Revisions” to a TO represent publication changes to the Technical Order System and shall be complied with.

The sub-paragraphs contain the location of changes as designated and the deletion, change or addition of technical information to be accomplished.

1.1.3.5 In the event of a conflict between the instructions in this PWS and the applicable technical directive, the following order of override precedence applies (descending order): 1) this PWS, 2) the end item TO, 3) other technical directives.

1.2 SECURITY

https://www.ecmra.dmdc.osd.mil/

PR FD20301901835-00 Page 6 of 35

1.2.1 Contractor’s Security Controls: Equipment and materials covered by this PWS are not classified.

1.3 QUALITY

1.3.1 The contractor shall provide and utilize an inspection/quality system IAW ISO - 9001.

1.3.2 The contractor shall investigate, take corrective action if necessary, and reply to user initiated PQDR forwarded to them by the ACO. This applies to all PQDRs submitted against products overhauled by the contractor and/or their subcontractor or vendors. Sufficient priority shall be given to PQDR investigation to allow timely corrective action and to meet requirements of TO 00-35D-54 and the CDRL.

1.3.3 No defective parts shall be delivered to the Government.

1.3.4 The contractor shall allow quality assurance reviews by DCMA representative at the site of repair for each end item generated under the terms of this contract.

1.4 DELIVERY SCHEDULES

1.4.1 The delivery schedules shall be IAW the contract delivery schedules.

1.5 CONDEMNATION AND OVERHAUL

1.5.1 Contractor’s Scrap Procedures: The contractor shall prepare and submit to the

Government Property Administrator (GPA) for approval, a written plan that sets forth procedures for handling scrap materials. These procedures shall include the requirements stipulated in the Federal Acquisition Regulation (FAR) 45.1, titled “General”. Disposition of condemned parts containing critical alloys and/or precious metals shall by IAW TO 00-25-113, 00-25-153-F100-ENG and FAR 45.6 titled “Reporting, Reutilization, and Disposal”.

1.5.2 Condemnation: The contractor without written approval of the ACO or his representative shall not condemn End Items.

1.5.2.1 End Items determined by the contractor and verified by the ACO to be beyond economical overhaul shall be disposed of as directed by the ACO in writing.

1.5.2.2 Parts, which have been condemned as a result of NDI methods, other inspection methods, or for other reasons, shall be mutilated to the extent necessary to ensure that purchasers of scrap are unable to overhaul the item for possible resale or reuse. All documents and tags pertinent to such condemned parts authorized for transfer to disposal shall bear a certificate to the effect that all required mutilation has been accomplished and meets DEMIL directive requirements.

PR FD20301901835-00 Page 7 of 35

1.5.2.3 The serial number and part number of any life-limited item, which is condemned, must be transmitted to F100 Engineering Source Authority listed in TO 2J-F100-13-1, WP 600 00.

1.5.3 Overhaul: End Items determined to be beyond repair shall not be overhauled by the contractor unless authorized in writing by the ACO.

1.6 HANDLING

1.6.1 The contractor shall have physical custody of end items and parts received at their facility and shall be responsible for their constant care during such custody.

1.6.1.1 CEMS Reporting: Note: The F100-PW-220/220E Augmentor Spray Manifold

Assemblies are not a serialized tracked part, and therefore, CEMS reporting is not required in this contract.

1.7 INVENTORY

1.7.1 Each end item shall be inspected by the contractor upon receipt to determine its condition and to ensure that its item identification corresponds to that shown on the contract schedule. Non-conforming end items shall be reported to the appropriate ACO representative.

1.8 PRESERVATION

1.8.1 Preservation inspection of end items is not required upon receipt. Adequacy of preservation will be determined when the item is placed in work and if found deficient shall be reported to the appropriate ACO representative.

1.8.2 All Government assets shall be stored in an enclosed and covered area and shall be adequately protected against loss by fire, theft, and physical damage by the elements. Government owned items and parts shall not be co-mingled with non- Government owned property.

1.9 RECEIPT/HANDLING OF PQDR EXHIBITS

1.9.1 Any exhibit received for the purpose of an investigation into the cause of a material or a quality deficiency shall be kept separated from normal overhaul assets until the investigation is completed. The contractor shall provide the exhibit receipt date through the ACO with the F100 Engineering Source Authority listed in TO 2J-

F100-53-1, WP 600 00.

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1.10 GENERAL WORK REQUIREMENTS

1.10.1 The instructions for the overhaul of items stipulated in this PWS shall be performed IAW the applicable T.O.s and the below exceptions.

1.10.1.1 The contractor is authorized to inspect per part drawing and part QAD (Quality

Assurance Document).

1.10.2 The contractor shall use protective equipment to protect items from damage as they are processed through the plant. Special protection shall be placed over the machined surfaces of end items.

1.10.3 The contractor shall inspect the various disassembled components or part of the end item to determine if further overhaul is needed. Subsequent overhaul shall be accomplished IAW the applicable portion of the applicable overhaul technical order and supplementary instructions specified herein.

1.10.4 The contractor shall rework all reparable parts so that they are capable of meeting the serviceable requirements of this PWS.

1.10.5 The contractor shall continue to use all parts and assemblies determined serviceable and appropriate as a result of inspections and checks, except as specified in this

PWS.

1.10.6 The contractor shall replace condemned parts of the end item with like serviceable parts that are listed in the applicable technical order IPB unless otherwise specified in or within this PWS.

1.10.7 When overhaul kits are available for the overhaul of an end item, such kits shall be used IAW the applicable technical order and changes thereto or the specific instructions contained in this PWS.

1.10.8 Where the contractor is directed to hold an item for Air Force Life Cycle

Management Center disposition by any cited publication herein or be any statement made within this PWS, such items shall be reported to the ACO through the GPA for disposition.

1.10.9 Overhaul, to the maximum extent, is desired when such overhaul is economically feasible. The contractor is encouraged to submit new or improved overhaul procedures to the Government whenever practical. Procedures may be submitted on an AFTO Form 22 as specified in this PWS or by any other means authorized under this contract. This does not preclude the contractor’s submission of overhaul procedures, which are not economically feasible, when such overhauls are advantageous to the Government.

PR FD20301901835-00 Page 9 of 35

1.10.10 All of the contractor’s operators of special processes, such as X-ray, radiography machines, Fluorescent Penetrate and Magnetic Particle Inspection Equipment, as well as welders and moralizers, shall be qualified and certified for operation IAW applicable military specifications when listed in the PWS.

1.10.11 Fit and tolerance limits shall be IAW applicable overhaul TO/contractor’s processes and procedures unless otherwise specified.

1.10.12 Fluids, oil, greases and compounds shall conform to and be used as directed in the overhaul TO and instructions contained in this PWS.

1.11 SPECIFIC WORK REQUIREMENTS

1.11.1 Removal

1.11.1.1 Not Applicable.

1.11.2 Disassembly

1.11.2.1 Disassemble F100-PW-220/220E Augmentor Spray Manifold Assemblies to the extent necessary to accomplish thorough internal cleaning and complete inspection of all parts to accomplish the work IAW TO 6J28-2-3.

1.11.3 Cleaning

1.11.3.1 F100-PW-220/220E Augmentor Spray Manifold Assemblies shall be cleaned

IAW TO 2J-F100-13-5, WP 304 00, TO 2-1-111, and TO 6J28-2-3 as applicable.

1.11.3.2 The contractor shall ensure that cleaning and preserving materials meet the requirements specified in TO 2J-F100-13-1, TO 2-1-111, or TO 6J28-2-3 and that such materials are properly used during application.

1.11.4 Inspection

1.11.4.1 Inspection of F100-PW-220/220E Augmentor Spray Manifold Assemblies shall be accomplished IAW TO 6J28-2-3.

1.11.5 Corrosion Control

1.11.5.1 The corrosion control of F100-PW-220/220E Augmentor Spray Manifold

Assemblies during overhaul and storage shall be accomplished IAW TO 2-1- 111and TO 6J28-2-3 whichever is applicable.

1.11.6 Modification and Overhaul

PR FD20301901835-00 Page 10 of 35

1.11.6.1 Modification and Overhaul of F100-PW-220/220E Augmentor Spray Manifold Assemblies shall be accomplished IAW TO 6J28-2-3.

1.11.6.2 The contractor shall identify all overhauled F100-PW-220/220E Augmentor Spray

Manifold Assemblies with the contractor’s CAGE IAW MIL-STD-130N.

1.11.7 Installation

1.11.7.1 Not applicable.

1.11.8 Test and Government Acceptance

1.11.8.1 Inspect, test, and check each overhauled item IAW TO 2-1-111and TO 6J28-2-3.

1.11.8.2 The Government shall accomplish acceptance.

1.11.9 Product Verification Audit (PVA)

1.11.9.1 Overhauled items shall be subject to PVA if requested by the government.

1.11.9.2 To perform PVA, the government shall be permitted to select at random such quantities of items as may be necessary to determine quality of workmanship and materials.

1.11.9.3 After notification by the ACO that a PVA is required, the contractor shall follow the procedures of Appendix 3 - Product Verification Audit Procedures.

1.11.10 Technical Publication Compliance

1.11.10.1 Compliance with all TOs, Directives, Government Specifications, Drawings, etc., listed herein is mandatory, unless otherwise specified in this PWS, when:

1.11.10.1.1 They have not been previously accomplished

1.11.10.1.2 They are pertinent to the end item.

1.11.10.1.3 They prescribe Air Force Policies, use of materials and procedures for overhaul.

1.11.10.2 For solicitation purposes, the contractor may contact USAF F100 Engineering Source Authority for instructions for viewing or purchasing technical data required for maintenance of this contract. Upon contract award, the contractor shall establish and maintain a TO distribution account IAW TO 00-5-1; and be placed on initial distribution for one copy each of the TOs and TCTOs listed in this PWS. The contractor shall contact the TOMA office at AFLCMC.

mailto:AFLCMC.%20LPSAA.TOMA@us.af.mil

PR FD20301901835-00 Page 11 of 35

LPSAA.TOMA@us.af.mil within five (5) working days after contract award for guidance in obtaining a TODO account. Once the contractor’s TODO account is in operation, the contractor shall maintain all TOs and TCTOs and other technical directives listed in the PWS in an updated and current status IAW TO 00-5-1. The contractor is required to comply with the latest dated TO; TCTO and other technical directives issued and will be contractually covered during the time the work is accomplished. For example, an item already in work will continue to be worked under the existing contractual scope of work until such time that the latest TO revisions can be negotiated as to price and scheduled incorporation. The contractor shall submit a monthly review of changes to TOs, TCTOs, and other applicable directives received during that period. However, if a change is received that has a cost impact greater than 10% and/or is critical to safety of flight, the contractor shall notify the ACO within ten (10) calendar days of receipt of that change and also shall provide the cost impact with his backup data. The contractor shall not begin working with new publication until authorization has been granted by the ACO/PCO.

1.11.10.3 Copies of other Air Force publications required in the performance of work outlined in this PWS will be requisitioned through the ACO. Submit requests to appropriate ACO representative for review. TO 00-5-1 provides an explanation of the Technical Order System and for pertinent distribution, requisition and storage information.

1.11.10.4 In the event a follow-on contract is awarded to this contract, the “Package

File” at the contract facility as of the end of the previous contract will be applicable to the follow-on contract and will be updated through amendments to the new PWS of the new contract. This procedure will ensure continuity of the publication data from one contract to another.

1.11.11 Initial Production Evaluation (IPE)

1.11.11.1 Repaired and Overhauled items shall be subject to an IPE if the contractor has not overhauled or repaired these items successfully within the last three years.

1.11.11.2 The IPE will be composed of two parts, a Site Visit and then a Repair Demonstration. The contractor will have a 45 day period from contract award to complete the Site Visit. After the site visit the DCMA QAR will have 10 calendar days to complete the site visit Survey and perform an exit briefing with the contractor and the IPE Team. If necessary the contractor shall have 30 calendar days from the Site Visit exit briefing to correct any critical or major deficiencies. Upon approval of the Site Visit Survey by the ESA the contractor will be notified in writing by the ACO. After notification of a successful Site Visit Survey by the ACO the contractor will have a 75 day period to perform the Repair Demonstration part of the IPE. Upon completion of the Repair Demonstration and submission of the Repair Demonstration Report the ESA mailto:AFLCMC.%20LPSAA.TOMA@us.af.mil

PR FD20301901835-00 Page 12 of 35 will have 30 calendar days to review the report. If necessary the contractor will have 30 calendar days to correct any critical or major deficiencies after the ESA review of the Repair Demonstration Report. Upon a successful Repair Demonstration and approval of the Repair Demonstration Report by the ESA the PCO will notify the contractor of the results. At this time the ESA will provide a letter to show that the contractor has been unconditionally approved to repair the contract items.

1.11.11.3 Repair and Overhaul of production items will not commence until the contractor has successfully passed the IPE and received the unconditional approval letter from the ESA. If the contractor cannot pass the Site Visit or the Repair Demonstration in the time periods allotted this constitutes contract cancellation.

1.11.11.4 To perform IPE, the government shall be permitted to select at random such quantities of items as may be necessary to determine quality of workmanship and materials. The ESA may waive parts of the IPE as it deems appropriate.

1.11.11.5 To perform the IPE, the contractor will follow the procedures of Appendix 4 –

Initial Production Evaluation (IPE) Procedures.

1.12 APPLICABLE TECHNICAL ORDERS

This is a preliminary list of Technical Orders. The contractor is responsible for ensuring they are using the latest edition.

TECH ORDER BASIC CG CHANGE

NUMBER DATE NO DATE SHORT TITLE

00-5-1-WA-1 14 JUN 16 AF TECH ORDER SYSTEM

00-5-15-WA-1 22 SEP 14 14 Feb 16 TIME COMPLIANCE TECH

ORDER SYSTEM

00-20-1-WA-1 11 JUL 16 PREV MAINT PROG

00-20-2-WA-1 15 MAR 16 MAINT DATA COLLECTION SYS

00-20-3-WA-1 15 AUG 15 MAINT PROC OF REPARABLE

PROP

PR FD20301901835-00 Page 13 of 35

00-25-113-F100—

ENG-WA-1

1 AUG 88 51 15 Mar 17 CRITICAL ALLOY AND

PRECIOUS METAL

00-35D-54-WA-1 1 SEP 15 MATERIAL DEF REPORT &

INVEST SYSTEM

33B-1-1-WA-1 1 OCT 16 NONDESTRUCTIVE INSP.

METHODS

2-1-111-WA-1 15 FEB 90 70 1 Apr 18 STAND MAINT PROCEDURES

2J-F100-9-WA-1 1 NOV 95 63 15 Dec 17 NONDESTRUCTIVE INSPECTION

2J-F100-94-WA-1 1 MAY 92 63 1 Apr 18 IPB SUPPORT EQUIPMENT

2J-F100-13-1-WA-1 15 Jan 19 MAINT INSTR-DEPOT

2J-F100-13-2-WA-1 15 Jan 19 MAINT INSTR – DEPOT OCM

2J-F100-13-5-WA-1 15 Jan 19 MAINT INSTR – DEPOT ENGINE

6J28-2-3-WA-1 15 APR 16 OVERHAUL INSTRUCTIONS

WITH IPB AUGMENTOR SPRAY

MANIFOLD

33B-1-1-WA-1 NON-DESTRUCTIVE INSP

METHODS, BASIC THEORY

2J-F100-24-WA-1 15 Jan 19 IPB F100-PW-220/220E

33D4-6-731-1 15 JAN 95 1 30 MAY 97 OPERATION & MAINT FLOW

MODULE, MANIFOLD

1.13 APPLICABLE DIRECTIVES

AIR FORCE

INSTRUCTION

CHANGE DATE

TITLE

AFI 21-101 21 MAY 15 MAINT MGMT OF

AIRCRAFT

AFI 21-118 21 NOV 14 IMP AERO EQUIP

RELIABILITY &

MAINTAINABILITY

AFI 61-204 DISSEMINATING

SCIENTIFICAND

TECHNICAL INFORMATION

PR FD20301901835-00 Page 14 of 35

MILITARY STANDARDS CHANGE DATE TITLE

MIL-STD-129P 18 FEB 14 U.S. MILITARY MARKING

FOR SHIPMENT AND

STORAGE

MIL-STD-130N 16 NOV 12 ID MARKING OF U.S.

MILITARY PROP

INTERNATIONAL ORGANIZATION FOR STANDARIZATION (ISO)

ISO - 9001 15 SEP 15 QUALITY MGMT SYSTEMS –

REQUIREMENTS – 3RD EDITION

ISO - 10012 MEASUREMENT

MANAGEMENT SYSTEMS –

REQUIREMENTS for

DEPARTMENT OF DEFENSE (DoD)

JOINT AERONAUTICAL 4 AUG 05 EXHIBIT H: UNIVERSAL

LOGISTICS COMMANDERS/ VENDOR SITE SURVEY

AVIATION CRITICAL SAFETY CHECKLIST

1.14 APPLICABLE DOCUMENTS

1.14.1 LPF-QR-001: BASIC TECHNICAL DATA REQUIREMENTS FOR

FRACTURE CRITICAL AND DURABILITY CRITICAL PARTS

1.14.2 LPF-QR-002: CONDITIONS OF WAIVER FOR FRACTURE CRITICAL

AND DURABILITY CRITICAL PARTS

1.14.3 LPF-QAR-001: GENERAL QUALITY ASSURANCE DOCUMENTS FOR F100

ENGINE FC/DC BREAKOUT COMPONENTS

1.14.4 LPF-QAR-002: CHANGE PROCEDURES FOR PROCESS

CONTROL DOCUMENTS

1.14.5 LPF-QAR-004: GENERAL QUALITY ASSURANCE REQUIREMENTS FOR

F100 ENGINE COMPONENTS

1.14.6 LPF-QAR-005: QUALITY LETTER OF INSTRUCTION FOR F100-

100/200/220/220E AUGMENTOR SPRAYRING MANIFOLD ASSEMBLIES

PR FD20301901835-00 Page 15 of 35

1.14.7 LPF-QAR-006: LPFR QUALITY ASSURANCE REQUIREMENTS

FOR PRODUCT VERIFICATION AUDIT (PVA) TEST PLANS AND

REPORTS

1.14.8 LPF-QPR-004: LPFR QUALITY PLAN REQUIREMENTS FOR

WELDED ASSEMBLIES

1.14.9 LPF-QPR-007: LPFR QUALITY PLAN REQUIREMENTS FOR

PLASMA SPRAYED COATINGS

1.14.10 LPF-QPR-009: LPFR QUALITY PLAN REQUIREMENTS FOR

VACUUM BRAZED ASSEMBLIES

1.14.11 LPF-QPR-016: LPFR QUALITY PLAN REQUIREMENTS FOR

DURABILITY CRITICAL PARTS

1.14.12 LPF-QPR-018: LPFR QUALITY PLAN REQUIREMENTS

FOR NONDESTRUCTIVE INSPECTION

1.14.13 EI FOR RQR-1: GENERIC ENGINEERING INSTRUCTIONS

FOR OVERHAUL OF F100 PARTS IN RQR-1

1.15 MISSION ESSENTIAL SERVICES N/A- Note: Not required in this contract.

1.16 SAFETY AND HEALTH

1.16.1 While performing work under this contract the contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. The contractor shall notify the Government Representative (GR), within eight (8) hours of any damage to government property where the dollar value exceeds $500,000.00 during the execution of the contract.

1.16.1.1 Mishap notifications shall contain, as a minimum, the following information:

1.16.1.1.1 Contract, Contract Number, Name and Title of Person(s) Reporting

1.16.1.1.2 Date, Time and exact location of accident/incident

1.16.1.1.3 Brief Narrative of accident/incident, if known

1.16.1.1.4 Cause of accident/incident, if known

1.16.1.1.5 Estimated cost of accident/incident (material and labor to repair/replace)

1.16.1.1.6 Nomenclature of equipment and personnel involved in accident/incident

1.16.1.1.7 Corrective actions (taken or proposed)

PR FD20301901835-00 Page 16 of 35

1.17.1.1.8 Other pertinent information

1.16.1.2 If requested by designated GR, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office.

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SECTION II

SERVICE SUMMARY

The contractor service requirements are summarized into performance objectives that relate directly to the mission essential items. The performance threshold describes the minimum acceptable levels of service for each requirement. The contractor shall be aware that the absence contract requirement from the service summary does not detract from its enforceability nor limit the rights or remedies of the government under any other provision of the contract. The government will use the surveillance methods contained in the Surveillance Plan to evaluate the Contractor’s performance for the performance objectives listed below. In the event the performance objective is not met, the Contractor will be given a reasonable time after notification to correct the unacceptable performance, if such correction is possible. The Contractor shall immediately take corrective action in accordance with the performance threshold(s). In cases where the Contractor fails to implement corrective action, the PCO will take appropriate measures.

NOTE: For those requirements listed in Section II, Service Summary, the Surveillance Plan will follow the methods of surveillance specified in the Surveillance Plan. The Surveillance Plan is authorization for the Government’s PCO to participate in the administration of this contract.

2.1 SERVICE SUMMARY REQUIREMENTS

2.1.1 The contractor shall ensure the performance objectives and performance thresholds identified in table 2-1 of this PWS are achieved as follows:

Table 2-1

Performance Objective

Reference Paragraph

Performance Threshold

SS-1 Quality: PWS # 1.3.3 No defective parts shall be delivered to the Government.

SS-2 Delivery Performance:

PWS # 1.4.1 The contractor shall meet the delivery schedule

2.2 CONTRACTOR PERFORMANCE EVALUATION

2.2.1 The contractor shall be aware that the evaluation of performance will occur when the Program Manager evaluates the services of the contractor to determine whether or not it meets the performance measures of the contract.

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2.2.1.1 SS-1: The contractor’s failure to meet the requirements for this item shall result in the possibility of a poor rating under the Contractor Performance Assessment Review (CPAR) and remedies as allowed under Federal Acquisition Regulation (FAR) 52.246-4 Inspection of Services-Fixed Price.

2.2.1.2 SS-2: The contractor’s failure to meet this requirement shall result in a negative CPAR rating and remedies as allowed under FAR 52.246-4 Inspection of Services- Fixed Price.

PR FD20301901835-00 Page 19 of 35

SECTION III

GOVERNMENT

PROPERTY

3.1 GOVERNMENT PROPERTY

3.1.1 Contractor shall furnish all material, support equipment, tools, test equipment and services. Government Furnish Material shall not be provided.

PR FD20301901835-00 Page 20 of 35

APPENDIX 1

A1.1 A C R O N Y M S

ACO Administrative Contracting Officer AFLCMC Air Force Life Cycle Maintenance Center AFMC Air Force Material Command ALC Air Logistics Center CAGE Contractor and Government Entity CAO Contract Administration Office CEMS Comprehensive Engine Management System DOD Department of Defense EC Engineering Change ESA Engineering Source Authority (AFLCMC/LPSAAB) FAR Federal Acquisition Regulation GFM Government Furnished Material GFP Government Furnished Property GPA Government Property Administrator IAW In Accordance With IPE Initial Production Evaluation IPB Illustrated Parts Breakdown MRB Material Review Board NDI Nondestructive Inspection OEM Original Equipment Manufacturer PCO Procurement Contracting Officer PIR Publication Improvement Report PQDR Product Quality Deficiency Report PVA Product Verification Audit PWS Performance Work Statement QAD Quality Assurance Document QAR Quality Assurance Representative QCD Quality Control Deficiency SAR Source Approval Request SL Salvage Layout SR Service Remanufacture TO Technical Order USAF United States Air Force WP Work Package

PR FD20301901835-00 Page 21 of 35

APPENDIX 2

A2.1 N O T E S

A2.1.1 The contractor is authorized to establish and convene a Material Review Board (MRB) to evaluate and determine disposition on non-conforming material or parts.

Board members shall consist of representatives from the Contractor’s Quality Production Control, Engineering (Industrial, Product Support or Design) and the Government QAR. The MRB shall be convened when the contractor identifies non-conformance of material or parts during and after assembly. The MRB is not authorized to violate any TO limit. When MRB action is required on material or parts during and after assembly, the contractor shall provide information, to include part number, serial number and statement of non-conformance and corrective action taken, to AFLCMC/LPSAA via email within (5) working days after approval of the

MRB.

PR FD20301901835-00 Page 22 of 35

APPENDIX 3

A3.1 P R O D U C T VERIFICATION AUDIT PROCEDURES

A3.1.1 This attachment contains procedures and instructions for contractual accomplishment of Product Verification Audits (PVAs). This attachment does not supersede instructions contained in the contract overhaul work requirements or other contractual provisions. In instances of conflict, the latter applies. The contractual issuance of this attachment and performance of PVAs does not relieve the contractor of the responsibility for maintaining a Quality Control System that will assure productions of items that conform to contractual requirements. PVAs are management tools used to independently evaluate and validate the conformance of an overhauled item and contractor compliance to contractual requirements as well as the adequacy of the Government's contractually stipulated requirements.

A3.2 TERMS EXPLAINED

A3.2.1 PVA. The physical examination, functional testing and complete disassembly of an item to determine conformance to contractual requirements as well as adequacy of the contractual requirements which may require in excess of the original contractor overhaul effort. The audit includes correction of defects, reassembly, retesting, repackaging, remarking, update of records and correction of contractual requirements as required.

A3.2.2 Cognizant Quality Assurance Element. The DOD contract administration service element having direct responsibility for implementing the Government Quality Assurance Program at the contractor's plant.

A3.2.3 Overhaul Work Requirement. Any contract instrument, TO, drawing, specification or directive which contains instructions and requirements for overhaul and rehabilitation of a reparable/unserviceable item.

A3.2.4 Procedural Deficiency. A deficiency which is noted during the audit and which results from either:

A3.2.4.1 Failure by contractor to establish processes/procedures in conformity with contractual requirements; or, A3.2.4.2 Failure by contractor to follow established processes or procedures.

A3.3 RESPONSIBILITIES

A3.3.1 The Contractor shall:

A3.3.1.1 Perform audit functions under the surveillance of the cognizant DOD CAO and

PR FD20301901835-00 Page 23 of 35

Air Force Life Cycle Maintenance Center (AFLCMC) representative(s).

A3.3.1.2 Provide technical personnel, tooling, measuring/test equipment, work areas, forms and clerical assistance, as required, to perform the PVA.

A3.3.2 The Cognizant DOD QAR shall:

A3.3.2.1 Be designated as audit team chairman, unless otherwise directed by the Procuring

Contracting Officer (PCO).

A3.3.2.2 Schedule the product verification audit and select the item(s) to be audited.

A3.3.2.3 Notify the PCO and the contractor when the PVA will begin. Notification shall be provided at least 15 working days prior to the audit date. Scheduled audits may be waived by the PCO on a case-by-case basis.

A3.4 AUDIT PROCEDURES

A3.4.1 Classifying Defects. Defects observed in the audited item(s) will be classified according to the following:

A3.4.1.1 Category I - Critical Defect. Defect that judgment and experience indicates likely to result in hazardous/unsafe conditions for individuals using, maintaining or depending upon the product; or a defect that judgment and experience indicates is likely to prevent performance of the tactical function of a major end item such as an aircraft, engine communication system, surveillance system or major part thereof. Critical defects are furthered identified as follows:

A3.4.1.1.1 Category IA - Defect attributable to the contractor's failure to comply with contractual requirements.

A3.4.1.1.2 Category IB - Defect not attributable to contractor's failure to comply with contractual requirements such as a design deficiency, inadequate or omitted requirement or defective Government Furnished Property (GFP).

A3.4.1.2 Category II - Major Defect. Defect other than critical that is likely to result in failure or reduce materially the usability of unit or product for its intended purpose. Major defects are further identified as follows:

A3.4.1.2.1 Category IIA - Defect attributable to the contractor's failure to comply with

PR FD20301901835-00 Page 24 of 35

A3.4.1.2.2 Category IIB - Defect not attributable to contractor's failure to comply with contractual requirements such as a design deficiency, inadequate or omitted requirements or defective GFP.

A3.4.1.3 Category III - Minor Defect. Defect that is not likely to reduce materially the usability of the unit or product for its intended purposes or is a departure from established standards having little bearing on the effective use or operation of the unit. Minor defects are further identified as follows:

A3.4.1.3.1 Category IIIA - Defect attributable to the contractor's failure to comply with

A3.4.1.3.2 Category IIIB - Defect not attributable to the contractor.

A3.4.1.4 Category IV - Defect caused during accomplishment of the audit disassembly or inspection process which would not have occurred had the contractor exercised proper care of the audit item, i.e., improper handling, improper disassembly technique.

A3.4.1.5 Procedural Defect – Reference paragraph A3.2.4.

A3.4.2 Scheduling/Frequency

A3.4.2.1 During the initial production phase, one of the first five items may be audited. The frequency for performing subsequent audits will be as specified in the schedule of the contract or by the PCO.

A3.4.2.2 The contractor may be directed by the PCO to extend or increase the frequency of the audits or to increase or decrease the scope thereof pursuant to the "changes" clause of the contract.

A3.4.2.3 Like or similar items may be grouped for audit purposes when the concurrence of the PCO or his designated representative has been obtained.

A3.4.3 Inspection and Test

A3.4.3.1 Audit candidates shall be randomly selected by the Cognizant DOD QAR from all items currently available. It shall be the responsibility of the ACO to assure that an adequate number of items from which a random selection can be made are on hand at the time of the audit. Selection, except as specified in paragraph A3.4.3.2 below, shall be made from items which have been accepted by the Government but have not been shipped.

A3.4.3.2 The first five items of the initial production phase shall be set aside after having been tendered by the contractor as in conformity with the contract and inspected

PR FD20301901835-00 Page 25 of 35 by the Government and not rejected for failure to comply with contractual requirements. Upon completing the testing and disassembly portion of the audit of the selected candidate and if no Category I or II defects are found during the audit, the other four items will be accepted by the Government. In any Category I or II defect is found in the audit candidate, the contractor shall satisfy the Government that such defect does not exist in the other four items prior to Government acceptance thereof. The audit candidate shall be accepted by the Government upon compliance with paragraph A3.4.4.6 below.

A3.4.3.3 The items selected for audit shall be inspected for adherence to preservation, packing, packaging and marking requirements prior to removal from the shipping container. A visual inspection and functional test shall be performed prior to disassembly.

A3.4.3.4 Disassembly shall be performed in a secure area accessible only to audit participants.

Normally, audit participation will be limited to specified contractor production and quality control personnel, the Cognizant DOD QAR and AFLCMC personnel.

A3.4.3.5 Visual inspection, dimensional checks (such as backlash, end clearance and running clearance) and non-destructive testing will be accomplished during and after disassembly IAW applicable technical directives. Audit findings will be recorded for comparison with contractual requirements and the contractor's production/inspection records. Measuring and test equipment shall be reviewed for current calibration prior to use.

A3.4.3.6 Applicable accessories and components will be functionally tested and inspected to contractual specifications. This action may require disassembly in excess of the original contractor effort as determined necessary by the Government.

A3.4.4 Corrective Actions

A3.4.4.1 In the event a critical or major defect is observed, Government acceptance of further production will be withheld until the Government has either inspected other items for the observed defect(s) or has received suitable evidence from the contractor that the cause of such defect(s) has been corrected and the defect does not exist in other items. In the case where there is a probability of such defect existing in previously shipped items, the contractor shall promptly advise the Government of the identity and destination of such previously shipped items.

A3.4.4.2 When Category IA, IIA or IIIA defects are found, the contractor shall implement measures in the overhaul process which will preclude recurrence.

A3.4.4.3 When Category IB, IIB or IIIB defects are found, actions will be taken as directed by the Government pursuant to the contract.

PR FD20301901835-00 Page 26 of 35

A3.4.4.4 When Category IV defects are noted, the contractor shall take those actions necessary to preclude recurrence.

A3.4.4.5 When Procedural Deficiencies are noted, the contractor shall take those actions necessary to correct the procedures or operations concerned.

A3.4.4.6 Upon completion of the audit, all defects attributable to failure to comply with contractual requirements or attributable to the performance of the PVA shall be corrected. All noted defects shall be corrected and the item assembled and functionally tested IAW applicable overhaul specifications including preservation, packing, packaging, marking and update of records.

A3.4.4.7 After the audit is completed, the DOD QAR shall conduct a critique attended by contractor personnel and AFLCMC representative(s). Findings, classifications and corrective actions shall be discussed and determination of defect cause(s) established (e.g. workmanship, tooling, technical requirements, etc.). The contractor shall take immediate action to correct and preclude recurrence of all defects or deficiencies attributable to failure to comply with contractual requirements, subject to the provisions of paragraph A3.5.1.10 below.

A3.5 AUDIT RESULTS

A3.5.1 The quality office of the CAO activity shall prepare and forward to the responsible PCO the finalized audit findings within 10 working days after completion of the audit. Finalized findings will contain the following information:

A3.5.1.1 Name and address of the contractor.

A3.5.1.2 Contract number.

A3.5.1.3 Descriptive noun, Federal Stock Number, part number and serial number of the item audited.

A3.5.1.4 Summary of total defects.

A3.5.1.4.1 Category IA

A3.5.1.4.2 Category IB

A3.5.1.4.3 Category

IIA A3.5.1.4.4 Category

IIB

PR FD20301901835-00 Page 27 of 35

A3.5.1.4.5 Category IIIA

A3.5.1.4.6 Category IIIB

A3.5.1.4.7 Category IV

A3.5.1.5 A complete listing of audit findings.

A3.5.1.6 A description of defects listed by category (commencing with critical). The defective item will be identified by part number and standard nomenclature.

A3.5.1.7 Cause(s) for each noted defect.

A3.5.1.8 Corrective action(s) taken on each classified defect attributable to failure to comply with contractual requirements, or a projected target date for completion when not otherwise immediately corrected.

A3.5.1.9 Procedural deficiencies noted and the corrective actions applied.

A3.5.1.10 The signature of the DOD QA participants, contractor management personnel and

AFLCMC representative(s). Non-concurrence with the findings shall be specifically annotated in the vicinity of the applicable signatures. Non- concurrence by the contractor as to the existence or classification of a defect or as to whether or not a defect is attributable to failure to comply with contractual requirements shall be subject to the procedures set forth in the clause entitled "Dispute."

A4.1 CAV CFM REPORTING REQUIREMENTS

The purpose of this attachment is to provide Contract Depot Maintenance (CDM) guidance for contractor technical responsibilities and reporting requirements of the Commercial Asset Visibility Air Force (CAVAF) system. CAVAF shall be the primary system of record for providing daily status of all Government owned assets located at contractor repair facilities. Reporting within CAV AF shall not be limited to end items subject to repair but are to include assets stored at a contractor Inventory Control Point (ICP). Any CAVAF system down-time will be identified on the CAVAF home page banner. Contractors are responsible for ensuring current User Guides are utilized by their CAVAF reporters. NOTE:

Contractor User’s Guide may be accessed from the CAVAF Homepage.

CAVAF FAMILIARIZATION TRAINING:

1. Familiarization training for CAVAF reporting will be requested by the contractor via the applicable ICP CAVAF system administrator (SA). For assistance, guidance or questions to specific contract transactionsl

PR FD20301901835-00 Page 28 of 35 reporting requirements may be addressed to the CAV AF contract monitor (CM). ICP CAVAF (SA and/or CM) points of contact (See Contractor Responsibility Item #4).

CONTRACTOR RESPONSIBILITY:

1. Contractor CAVAF reporting requirements shall be accomplished daily and/or within one (1) business day of a maintenance action occurrence IAW the applicable CAVAF CDRL and CAVAF system, version 8.0.1 or higher. Accurate and timely reporting of maintenance transactions into CAVAF is critical to the management of repair requirements and the management of world-wide asset distribution. Contractor shall ensure asset record in CAVAF is an accurate reflection of physical assets on hand at all times.

2. Each CAVAF reporter shall submit a completed System Authorization Access Request, DD Form 2875, per instructions within 10 days after contract award date. All DD Form 2875(s) shall be digitally signed.

There “must be two CAVAF reporters” for the contractual reporting requirements to ensure there is no possibility of a lapse in reporting coverage.

3. User(s) shall complete initial DoD Information Assurance (IA) Cyberawareness Challenge training and submit a course completion certificate with the DD Form 2875. IA Cyberawareness Challenge course completion certification shall be accomplished annually. Users shall access IA training on the CyberAwareness Challenge website, under the Department of Defense Employees section, click hyperlink;

“Launch New CyberAwareness Challenge Department of Defense Version” using the following website:

http://iase.disa.eta/cyberchallenge/launchPage.htm

a. First time CAV AF users will email initial IA Cyberawareness Challenge course completion certificates, AF Form 4394, AF User Agreement Statement, and completed DD Form 2875 to point of contact at applicable ICP (see item #4).

b. All following annual course completion certificates shall be completed before lapse in certification occurs and will be emailed to respective ICP identified in paragraph 4a, 4b, and 4c below.

c. Product Functionality Caution: To meet technical functionality requirements, this awareness product was developed to function with Windows operating systems (Wingdow 7, VISTA, and XP), when configured correctly) using either the Internet Explorer (IE) or Firefox browsers. Users employing either OS or browser may experience difficulties and may not be able to complete the training or print the certificate of completion. They Cyberawareness Challenge course completion is a contractual requirement and the contractor must comply.

4. Reporters requiring the default password or password resets should contact their applicable ICP CAV AF System Administrator POC listed below:

http://iase.disa.eta/cyberchallenge/launchPage.htm

PR FD20301901835-00 Page 29 of 35

a. Robins AFB, GA, call (478) 327-6602 or 327-6603, or send email request to:

406scms.cav.af.ar@us.af.mil

b. Hill AFB, UT, call (801) 586-3736, or send email request to:

420scms.cdm@us.af.mil

c. Tinker AFB, OK, call (405) 622-7325 or (405) 736-7329, or send email request to:

420.scms.tinker.cdm.workflow@us.af.mil

5. To access the CAVAF system, contractor and subcontractor reporters shall follow “initial log-in procedures” as prescribed within the Contractors User’s Guide.

6. Contractor shall ensure accountability of all Government Furnished Property (GFP) within their Enterprise Resource Planning (ERP) or Commercial Off-the-Shelf (COTS) system, which must be reported accurately for same GFP records within CAVAF at all times.

7. Contractual Induction-at-Risk of end items is prohibited on all repair contracts.

8. Contract/Delivery Order Closure Disposition– Government will provide disposition instructions to contractor’s reporter. Contractor shall begin shipping assets within 10 days of receiving government disposition instructions and have completed all shipping actions 30 days thereafter. Contractor shall be fully responsible to ensure all corresponding CAVAF reporting actions associated with disposition occur within one (1) business day of related shipment action.

9. All NSNs identified as Nuclear Weapon Related Materiel (NWRM) shall require contractor CAVAF reporting for production management, to track and report NWRM end items in repair with Serial Number identification within one (1) business day for asset visibility and serial number tracking. When receipted, Contractor’s reporter shall capture each NWRM asset’s Serial Number when reparable is received.

Contractors shall follow all NWRM management requirements outlined in AFI 20-110, NWRM Management, to include, but not limited to packaging, marking, labeling, storage, transportation and receipt of all NWRM assets, with emphasis on Positive Inventory Control (PIC) and records management by the contractor and government to assure compliance. The successful application of these procedures requires the full cooperation of all personnel associated with the storage, shipping, transshipping and receiving of all NWRM assets.

SPECIFIC CAVAF CONTRACTOR TRANSACTIONAL REPORTING REQUIREMENTS:

1. “Not-on-Contract” (NOC) receipt transactions apply to assets which are associated to a contractor facility DoDAAC and not an active contract delivery order. Regardless of asset condition code status, Not-on-contract shall be used for the following reporting actions:

mailto:420scms.cdm@us.af.mil mailto:420.scms.tinker.cdm.workflow@us.af.mil

PR FD20301901835-00 Page 30 of 35

a. Discrepancy Items – Are identified as misrouted shipments, misidentified shipments, or damaged end items. Contractor’s reporter will verify resolution weekly to acquire resolution to discrepancy within 30-days of receipt transaction. The contractor shall comply with disposition instructions provided by the Government within 10-days and complete all associated reporting actions within same period. Contractor reporting actions shall be resolved using reversals of individual record control document numbers (RCDN) or may be accomplished utilizing a ‘bulk’ shipment action of RCDN.

b. Inventory Control Point Items – are identified as assets stored at contractor facility and are not repair end items or discrepancies items.