PWS.pdf

PERFORMANCE WORK STATEMENT

(PWS) For

F100-PW-220/229 Electro-Hydraulic Servo- Valve (EHSV) Kit

PR # FD2030-23-32203

DATE: 17 May 2023

PREPARING ORGANIZATION:

AFLCMC/LPSIB

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

TABLE OF CONTENTS Page

SECTION I

1.1 DATA

1.2 SECURITY

1.3 QUALITY

1.4 DELIVERY SCHEDULES

1.5 CONDEMNATION, REPAIR, 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 SAFETY

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

FD2030-23-32203

FD2030-23-32203 Page 4 of 22

SECTION I

DESCRIPTION OF

SERVICES

This PWS establishes the minimum work requirements for a Foreign Military Sales requirement to return F100-PW220/229 Electro- Hydraulic Servo-Valve kits listed below by National Stock Number (NSN) and Part Number (P/N) to a serviceable, like new condition. F100-PW-220/229 Electro-Hydraulic Servo-Valve Kits received by the contractor, as set forth in this contract shall be repaired, overhauled, modified, tested, prepared for storage and shipped in accordance with (IAW) the requirements in this PWS and the contract.

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 written correspondence.

NOUN PART NUMBER NSN APPLICABLE T.O.

Seg EHSV Kit 351018/20105080-101 2915-01-222-6311

Proprietary Technical Data

Core EHSV Kit 351008/20105040-101 2915-01-224-0746 Duct EHSV Kit 351009/20105030-101 2915-01-224-0747

RCVV EHSV Kit 351005/20105070-101 2915-01-224-0753 CENC EHSV Kit 351015/20105090-101 2915-01-226-1047 MFC EHSV Kit 351044/20105100-101 2915-01-244-5400

1.1 DATA

1.1.1 Engineering Source Authority

1.1.1.1 F100 Engineering Program Office, AFLCMC/LPSBE, Tinker AFB, OK

• W. Lance McCaughan, AFLCMC/LPSBE, william.mccaughan@us.af.mil

• Shai Cunningham, AFLCMC/LPSBE, shai.cunningham@us.af.mil

1.1.2 Reporting Requirements

1.1.2.1 Monthly Production Report CDRL A001: The contractor shall prepare and furnish a monthly cumulative status report for all items that have been placed on contract. The report shall be prepared as of the last working day of each month and forwarded by e-mail no later than the 5th working day of the following month. The initial report shall be prepared for the month during which the contract assets are received. Reports shall continue to be forwarded until all end items are repaired. The last report shall be annotated “Final Report”. Negative reports are required.

1.1.2.2 Product Quality Deficiency Report (PQDR – SF 368): CDRL A002: 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 mailto:william.mccaughan@us.af.mil mailto:shai.cunningham@us.af.mil mailto:am@us.af.mil

FD2030-23-32203 Page 5 of 22 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-F100-53-1, WP 600 00.

1.1.2.3 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 remanufacture procedures in TOs, or desired changes to TO data shall likewise use the AFTO Form 22.

1.1.2.4 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.

1.1.3 Other Records, Forms and Reports

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

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

1.1.3.3 Specific reporting requirements will be reflected in the attached CDRLs (listed below).

A001: Monthly Status/ Production Report of FMS R/R DI-PSSS-80368A A002: Deficiency Report DI-PSSS-81535B

1.1.4 Technical Data

1.1.4.1 TOs listed in this specification or OEM technical documents and specifications are the basic directives to be used in accomplishing the repair/overhaul requirements of the contract.

1.1.4.2 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

FD2030-23-32203 Page 6 of 22 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.

1.1.4.3 Directives listed in paragraphs 1.10, 1.11, 1.12, & 1.13 and instructions provided throughout this PWS shall be adhered to. Thus obtaining the highest possible quality of workmanship and to maintain acceptable quality standards.

1.1.4.4 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.

1.1.4.5 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

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 a written 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/PCO. This applies to all PQDRs submitted against products repaired/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.

1.4 DELIVERY SCHEDULES

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

1.5 CONDEMNATION, REPAIR, 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 be IAW TO 00-25-113, 00-25- 113-F100-ENG and FAR 45.6 titled “Reporting, Reutilization, and Disposal”.

1.5.2 Condemnation: The Contractor shall not condemn End Items without written approval of the ACO/PCO.

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1.5.2.1 End Items will be determined by the Contractor and in writing verified by the

ACO/PCO to be beyond economical repair/overhaul through disposition instructions from the ACO.

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 repair/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.

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 Repair: End items determined to be beyond economical repair shall not be repaired/overhauled by the contractor unless authorized in writing by the ACO/PCO.

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.

1.7 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/PCO 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/PCO 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 repair assets until the investigation is completed. The contractor shall provide the exhibit receipt date through

FD2030-23-32203 Page 8 of 22 the ACO/PCO with the F100 Engineering Source Authority listed in TO 2J-F100-13-1, WP 600 00.

1.10 GENERAL WORK REQUIREMENTS

1.10.1 The instructions for the repair of items stipulated in this PWS shall be performed IAW the applicable TOs or OEM technical documents and specifications, and the below exceptions.

1.10.1.1 The contractor is authorized to process and inspect per part drawing and part

QAD (Quality Assurance Document). If the part has been re-identified and there is no QAD for the current part number, the part’s previously applicable QAD can be used.

1.10.1.2 The contractor is authorized to use its own tooling, which is similar to OEM (Original Equipment Manufacturer) tooling.

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 repair is needed. Subsequent repair 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 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 OC-ALC disposition by any cited publication herein or by any statement made within this PWS, such items shall be reported to the ACO/PCO through the GPA for disposition.

1.10.9 Repair, to the maximum extent, is desired when such repair is economically feasible.

The contractor is encouraged to submit new or improved repair procedures to the

FD2030-23-32203 Page 9 of 22

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 repair procedures, which are not economically feasible, when such repairs are advantageous to the Government.

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 Parker commercial processes.

1.10.11 Fit and tolerance limits shall be IAW applicable overhaul TO or Parker OEM documents and specifications. Where contractor’s processes and procedures conflict, contractor can submit, in writing, a request for deviation to PCO/Government Engineer.

1.10.12 Fluids, oil, greases and compounds shall conform to and be used as directed in the overhaul TO or Parker OEM documents and specifications 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 Not Applicable.

1.11.3 Cleaning

1.11.3.1 Specific work requirements are proprietary. Complete this requirement in accordance with OEM requirements.

1.11.4 Inspection

1.11.4.1 Specific work requirements are proprietary. Complete this requirement in accordance with OEM requirements.

1.11.5 Repair

1.11.5.1 Specific work requirements are proprietary. Complete this requirement in accordance with OEM requirements.

1.11.5.2 The contractor shall identify all remanufactured F100-PW-220/229 ElectroHydraulic Servo-Valve kits with the contractor’s CAGE IAW MIL-

STD130N.

FD2030-23-32203 Page 10 of 22

1.11.5.3 The contractor shall be required, upon completion of the work performed, whether it be a modification or overhaul to the extent necessary (On Condition Maintenance) or any combination of the above, report the work performed, using a Form 95 or Certificate of Conformance (COC) for data reporting purposes only (as required in Para. 1.1.3.2 above).

1.11.5.4 The contractor shall also be required, upon completion of the work performed, to modify the overhauled asset to comply with any outstanding Engineering Change Proposals (ECP), or equivalent, to bring the asset to the latest approved configuration.

1.11.6 Installation

1.11.6.1 Not applicable.

1.11.7 Test And Government Acceptance

1.11.7.1 Inspect, test and check each remanufactured item IAW OEM requirements.

1.11.7.2 The Government shall accomplish acceptance.

1.11.8 Product Verification Audit (PVA)

1.11.8.1 Product verification has been accomplished under Tinker Enterprise Contract FA8109-18-

D-0004

1.11.9 Technical Publication Compliance

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

1.11.9.1.1 They have not been previously accomplished.

1.11.9.1.2 They are pertinent to the end item.

1.11.9.2 They prescribe Air Force Policies, use of materials and procedures for repair.

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

1.11.9.3 In the event a follow on to this contract is awarded, 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.

FD2030-23-32203 Page 11 of 22

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 or latest Parker OEM documents and specifications.

TECH ORDER REVISION CG

NUMBER DATE NO SHORT TITLE

00-5-1 30 Aug 22 0 AF TECH ORDER SYSTEM

00-5-15

31 Mar 22

TIME COMPLIANCE TECH

ORDER SYSTEM

00-20-1 26 SEP 22 0

PREV MAINT PROG

00-20-2 22 JUL 21 0

MAINT DATA COLLECTION SYS

00-20-3 17 DEC 21 0

MAINT PROC OF REP PROP

00-25-113 15 SEP 13 0

CRITICAL ALLOY AND

PRECIOUS METAL

00-25-113-F100-

ENG

1 MAY 19 0

CRITICAL ALLOY AND

PRECIOUS METAL

00-35D-54 15 AUG 22 0

MATERIAL DEF REPORT &

INVEST SYSTEM

33B-1-1 01 JUL 22 0

NONDESTRUCTIVE INSP.

METHODS

2-1-111 15 APR 23 0

STAND MAINT PROCEDURES

2J-F100-9 01 APR 23 0

NONDESTRUCTIVE INSPECTION

2J-F100- 54 01 FEB 23 0

IPB

2J-F100-94 01 FEB 23 0

IPB SUPPORT EQUIPMENT

2J-F100- 53-1 01 APR 22 0

MAINT INSTR-DEPOT

2J-F100- 53-2 15 APR 23 0

MAINT INSTR – DEPOT OCM

FD2030-23-32203 Page 12 of 22

1.13 APPLICABLE DIRECTIVES

MILITARY STANDARDS CHANGE DATE TITLE

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

SHIPMENT AND STORAGE

MIL-STD-130N 17 DEC 07 ID MARKING OF U.S. MILITARY

PROP.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO - 9001 23 SEP 15 QUALITY MANAGEMENT

SYSTEMS – REQUIREMENTS –

THIRD EDITION

1.14 SAFETY AND HEALTH

1.14.1 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 and within two workdays, for any damage to government property less than $500,000.00 during the execution of the contract.

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

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

1.14.1.1.2 Date, Time and exact location of accident/incident

1.14.1.1.3 Brief Narrative of accident/incident (Events leading to accident/incident)

1.14.1.1.4 Cause of accident/incident, if known

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

1.14.1.1.6 Nomenclature of equipment and personnel involved in accident/incident

1.14.1.1.7 Corrective actions (taken or proposed)

1.14.1.1.8 Other pertinent information

Continuation of Essential Department of Defense (DoD) Contractor Services During Crisis: This requirement has been determined not to be essential and does not require continued support during a crisis as defined in DFARS 252.237-7023.

FD2030-23-32203 Page 13 of 22

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: Contractor shall provide and utilize an inspection/quality system IAW ISO

- 9001. The contractor shall investigate, take corrective action if necessary, and reply to user initiated PQDR forwarded to them by the

ACO/PCO.

PWS # 1.3,

1.3.1 1.3.2

No defective parts shall be delivered to the Government. Contractor shall provide a written quality system to the COR with no more than one error.

FD2030-23-32203 Page 14 of 22

SS-2 Delivery Performance:

1.4.1 The delivery

schedules shall be IAW the contract delivery schedules

PWS # 1.4, 1.4.1 The contractor shall meet the delivery schedule. Zero errors

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.

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.

FD2030-23-32203 Page 15 of 22

SECTION III

GOVERNMENT PROPERTY

GOVERNMENT PROPERTY

3.1 Contractor shall furnish all material, support equipment, tools, test equipment and services.

Government Furnish Material (GFM) shall not be provided.

APPENDIX 1

A1.1 ACRONYMS

ACO Administrative Contracting Officer AFLCMC Air Force Life Cycle Management Center AFMC Air Force Material Command ALC Air Logistics Center BER Beyond Economical Repair CAGE Contractor and Government Entity CAO Contract Administration Office CDRL Contract Data Requirement List CEMS Comprehensive Engine Management System DCMA Defense Contract Management Agency DOD Department of Defense DR Deficiency Report EC Engineering Change ESA Engineering Source Authority FAR Federal Acquisition Regulation GFM Government Furnished Material GFP Government Furnished Property GPA Government Property Administrator IAW In Accordance With IPB Illustrated Parts Breakdown MRB Material Review Board NDI Nondestructive Inspection NSN National Stock Number OC-ALC Oklahoma City Air Logistics Center OEM Original Equipment Manufacturer PCO Procurement Contracting Officer PIR Publication Improvement Report PM Program Manager

PN Part Number

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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 SDR Supply Deficiency Report SL: Salvage Layout SR Service Repair TO Technical Order USAF United States Air Force WP Work Package

APPENDIX 2

A2.1 NOTES

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.

APPENDIX 3

A3.1 PRODUCT 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 repair 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 a repaired item and contractor compliance to contractual requirements as well as the adequacy of the Government's contractually stipulated requirements.

FD2030-23-32203 Page 17 of 22

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 repair 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

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

FD2030-23-32203 Page 18 of 22 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

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.

FD2030-23-32203 Page 19 of 22

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/PCO 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 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 ALC 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.

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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 will 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 repair 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.

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 repair 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 ALC 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.

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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

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

ALC 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."

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