PWS_Rev5_20Mar2024.pdf

PERFORMANCE WORK STATEMENT (PWS)

For

F100-PW-229 Augmentor Fuel Control (AFC) and Augmentor Fuel Pump (AFP)

FILE NUMBER: PR # FD2030-24-00247

REV. 5

DATE: 20 March 2024

PREPARING ORGANIZATION:

AFLCMC/LPSAAC

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 52.30.

FD2030-24-00247 Page 2 of 37

TABLE OF CONTENTS Page

Contents

SECTION I

1.1 DATA

1.2 SECURITY

1.3 QUALITY

1.4 DELIVERY SCHEDULES

1.5 CONDEMNATION AND REPAIR

1.6 HANDLING

1.7 INVENTORY

1.8 PRESERVATION

1.9 RECEIPT/HANDLING OF PQDR EXHIBITS

1.10 SAFETY AND HEALTH…………………………………………………………………………………………………………………..7

1.11 ITEM UNIQUE IDENTIFICATION (IUID)…………………………………………………………………………………………8

1.12 GENERAL WORK REQUIREMENTS

1.13 SPECIFIC WORK REQUIREMENTS

1.14 APPICABLE TECHNICAL ORDERS

1.15 Surge………………………………………………………………………………………………………………………………………14

1.16 APPLICABLE DOCUMENTS

1.17 MISSION ESSENTIAL SERVICES

SECTION II

2.1 SERVICE SUMMARY REQUIREMENTS

2.2 CONTRACTOR PERFORMANCE EVALUATION .............................................................................. E18

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

A4.1 CAV CFM REPORTING REQUIREMENTS

A4.2 SCRM Supply Chain Risk Management…………………………………………………………34

FD2030-24-00247 Page 3 of 37

SECTION I

DESCRIPTION OF

SERVICES

This PWS establishes the minimum work requirements to return F100-PW-229 AFC and AFP listed below by National Stock Number (NSN) and Part Number (P/N) to a serviceable but not like new condition. F100-PW-229 AFC and AFP received by the contractor, as set forth in this contract shall be overhauled/repaired, 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

REPAIR T.O.

Fuel Control Augmentor (AFC) 790100 2915-01-310-2141 6J3-2-36-3 6J3-2-36-4

6J3-2-36-503 Pump – Fuel Augmentor (AFP) 792840 2915-01-309-7888 6J10-2-18-3

6J10-2-18-4

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 Technical Order (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.

1.1.1.2 TO System Publication Improvement Report (PIR): The contractor shall prepare a PIR, utilizing the AFTO Form 22, 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/LPSZB. 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 overhauls procedures in TO’s, or desired changes to TO data shall

FD2030-24-00247 Page 4 of 37 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 Administrative

Contracting Officer (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 Commercial Asset Visibility Air Force (CAVAF) 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 B.

1.1.2.3 Note: The F100-PW-229 AFC and AFP are serialized tracked parts, and therefore, CEMS reporting is required in this contract. CEMS Reporting: The status of all serialized life limited parts must be known at all times. This status is to be reported to CEMS IAW T.O. 00-25-254-1 as required by DD Form 1423. Any questions regarding the reporting requirements are to be directed through the ACO.

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

1.1.2.5 Contractor Manpower Reporting: 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 in the Service Contract Report (SCR) at www.SAM.gov

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 year Contractors may direct questions to the SAM.gov service desk (https://www.fsd.gov/fsd-gov/home.do).".

1.1.2.5.2 Reporting Period: Contractors are required to input data by 31 October of each year.

1.1.2.5.3 Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.

1.1.2.5.4 User Guide: Data for Air Force service requirements must be input at www.sam.gov. A quick start user guide is available at on the SAM.gov https://www.fsd.gov/fsd-gov/home.do)

FD2030-24-00247 Page 5 of 37 website at https://www.fsd.gov/sys_attachment.do?sys_id=95849fed1be769100ca 4a97ae54bcbba

1.1.3 Technical Data

1.1.3.1 TO’s listed in this specification are the basic directives to be used in accomplishing the overhaul or on-condition maintenance (OCM) requirements of the contract.

1.1.3.2 TO Illustrated Parts Breakdowns (IPB’s) 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 beyond economical repair unless otherwise specified.

1.1.3.3 Directives listed in paragraphs 1.12. 1.13, 1.14, 1.15 & 1.16 and instructions provided throughout this PWS should 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

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 management system (QMS) IAW ISO 9001 or AS9110, and AFI 63-138 Chapter 6

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/repaired 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.

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1.3.3 No defective parts shall be delivered to the Government.

1.3.4 The Contractor’s accepted Quality Management System (QMS) plan effectively controls quality, meets the PWS quality requirements, and does not deviate from the Contractor’s accepted QMS. To receive a satisfactory rating, the Defect Correction Rate, which identifies if COR/contractor identified non-conformities should be corrected within the contractor’s self-imposed “get-well” dates.

1.4 DELIVERY SCHEDULES

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

1.4.2 DoD FEDMall is prohibited for use by non-DoD entities. The contractor shall ensure they have viable sources of supply to enable them to meet the government’s delivery schedules.

1.5 CONDEMNATION AND REPAIR

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, 00-25-113-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 repair 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 repair 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-

53-1, WP 600 00.

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1.5.3 Overhaul: End Items determined to be beyond economical repair & overhaul shall not be repaired & 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 Note: The F100-PW-229 AFP and AFC are serialized tracked parts, and therefore, CEMS reporting is required in this contract. The receipt and status of all serialized components or accessories, which are tracked in CEMS, must be reported IAW Para 1.1.2.3 of the PWS.

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 repair 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.

1.10 SAFETY AND HEALTH

1.10.1 While performing work under this contract the contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health.

FD2030-24-00247 Page 8 of 37

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.

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

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

1.10.1.1.2 Date, Time and exact location of accident/incident

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

1.10.1.1.4 Cause of accident/incident, if known

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

1.10.1.1.6 Nomenclature of equipment and personnel involved in accident/incident

1.10.1.1.7 Corrective actions (taken or proposed)

1.10.1.1.8 Other pertinent information

If requested by the 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

1.11 ITEM UNIQUE IDENTIFICATION (IUID)

1.11.1 Repair contracts that result in the delivery of tangible personal property to the Government shall follow the latest DoD instructions to install IUID compliant marks in accordance with policy as stated in DFARS 211.274. IUID requirements for the J85 MISTR components have not been identified at this time. When directed by the PCO, the contractor shall follow the latest DoD instructions to install IUID compliant marks.

TOs and drawings shall be complied with for any component where direction is currently called out in the TO or drawings.

1.12 GENERAL WORK REQUIREMENTS

1.12.1 The instructions for the overhaul or OCM of items stipulated in this PWS shall be performed IAW the applicable TO’s and the below exceptions.

1.12.1.1 The contractor is authorized to use its own tooling, which is similar to OEM

(Original Equipment Manufacturer) tooling.

1.12.1.2 The contractor is authorized to inspect per part drawing and part QAD (Quality Assurance Document).

FD2030-24-00247 Page 9 of 37

1.12.2 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.

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

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

1.12.5 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.

1.12.6 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.

1.12.7 When overhaul or OCM kits are available for the overhaul or OCM 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.

1.12.8 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 through the GPA for disposition.

1.12.9 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.

1.12.10 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 inspectors, shall be qualified and certified for operation IAW applicable military specifications when listed in the PWS.

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

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

1.13 SPECIFIC WORK REQUIREMENTS

FD2030-24-00247 Page 10 of 37

1.13.1 Disassembly

1.13.1.1 Disassemble F100-PW-229 AFC to the extent necessary to accomplish thorough internal cleaning and complete inspection of all parts to accomplish the work IAW

TO 6J3-2-36-3.

1.13.1.2 Disassemble F100-PW-229 AFP to the extent necessary to accomplish thorough internal cleaning and complete inspection of all parts to accomplish the work IAW

TO 6J10-2-18-3.

1.13.2 Cleaning

1.13.2.1 F100-PW-229 AFC shall be cleaned IAW TO 6J3-2-36-3.

1.13.2.2 F100-PW-229 AFP shall be cleaned IAW TO 6J10-2-18-3.

1.13.2.3 The contractor shall ensure that cleaning and preserving materials meet the requirements specified in IAW TO 6J3-2-36-3, TO 6J10-2-18-3, and TO 2-1-111 and that such materials are properly used during application.

1.13.3 Inspection

1.13.3.1 Inspection of F100-PW-229 AFC shall be accomplished IAW TO 6J3-2-36-3.

1.13.3.2 Inspection of F100-PW-229 AFP shall be accomplished IAW TO 6J10-2-18-3.

1.13.4 Corrosion Control

1.13.4.1 The corrosion control of F100-PW-229 AFC during overhaul or OCM and storage shall be accomplished IAW TO 6J3-2-36-3 or TO 2-1-111 whichever is applicable.

1.13.4.2 The corrosion control of F100-PW-229 AFP during overhaul or OCM and storage shall be accomplished IAW TO 6J10-2-18-3 or TO 2-1-111 whichever is applicable.

1.13.5 Overhaul

1.13.5.1 Overhaul of F100-PW-229 AFC shall be accomplished IAW TO 6J3-2-36-3.

1.13.5.2 Overhaul of F100-PW-229 AFP shall be accomplished IAW TO 6J10-2-18-3.

1.13.5.3 The contractor shall identify all overhauled F100-PW-229 AFC and AFP with the contractor’s CAGE IAW MIL-STD-130N.

1.13.5.4 Overhaul or OCM

FD2030-24-00247 Page 11 of 37

1.13.5.4.1 For the following item, disposition will depend on the life limit or Maximum Operating Hours (MOH) remaining. OCM may be performed on any item that has at least 25% of the MOH remaining. Overhaul shall be performed on any item that has less than 25% of the MOH remaining. Overhaul may be performed if during the initial receiving inspection overhaul is determined to be more practical. Items shall be condemned if the Time Since New exceeds 19,500 hours.

Nomenclature NSN P/N Life limit MOH Aug Fuel Pump 2915-01-309-7888 792840 20,000 10,000

1.13.5.4.2 The following item shall be repaired as necessary to return them to serviceable condition. For the following item, disposition will depend on the life limit or MOH remaining. OCM may be performed on any item that has at least 1000 hours time remaining. Overhaul should not be performed due to design limitations of the cast housing. If the Time Since New exceeds 19,500 hours, contact the Production Management Specialist for further guidance.

Nomenclature NSN P/N Life limit MOH Aug Fuel Control 2915-01-310-2141 790100 20,000 20,000

1.13.5.4.3 If you have any questions regarding whether to overhaul or OCM, please provide the Production Management Specialist with the following: Component Item Identifier (CII), part number, serial number, Time-Since-New, Time- Since-OCM, Time-Since Overhauled and Time Remaining Percentage.

1.13.5.4.4 The contractor shall be required to modify the overhauled asset to comply with any outstanding Engineering Change (EC) to bring the asset to the latest approved configuration per TOs identified below.

1.13.6 Installation

1.13.6.1 Not Applicable

1.13.7 Test And Government Acceptance

1.13.7.1 Inspect, test and check each overhauled F100-PW-229 AFC IAW TO 6J3-2-36-3.

1.13.7.2 Inspect, test and check each overhauled F100-PW-229 AFP IAW TO 6J10-2-18-3.

1.13.7.3 The Government shall accomplish acceptance.

1.13.8 Product Verification Audit(PVA)

1.13.8.1 Repaired items shall be subject to PVA if requested by the government.

1.13.8.2 To perform PVA, the government shall be permitted to select at random such

FD2030-24-00247 Page 12 of 37 quantities of items as may be necessary to determine quality of workmanship and materials.

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

1.13.9 Technical Publication Compliance

1.13.9.1 Compliance with all TO’s, Directives, Government Specifications, Drawings, etc., listed herein is mandatory, unless otherwise specified in this PWS, when:

1.13.9.1.1 They have not been previously accomplished

1.13.9.1.2 They are pertinent to the end item.

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

1.13.9.2 For solicitation purposes, the contractor may contact USAF F100 Engineering Source Authority listed in TO 2J-F100-13-1, WP 600 00, 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 00-5-2; and be placed on initial distribution for one copy each of the TO’s and TCTO’s listed in this PWS. The contractor shall contact AFCLMC/LPSZB TOMA, 405-739-8498 within five (5) working days after contract award for guidance in obtaining a Technical Order Distribution Office (TODO) account. Once the contractor’s TODO account is in operation, the contractor shall maintain all TO’s and TCTO’s and other technical directives listed in the PWS in an updated and current status IAW TO 00-5-1 and TO 00-5-

2. 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 TO’s, TCTO’s, 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.

1.13.9.3 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 and TO 00-5-2 are provided in explanation of the TO System and for pertinent distribution, requisition and storage information.

1.13.9.4 In the event of a follow-on to this contract is awarded, the “Package File” at the

FD2030-24-00247 Page 13 of 37 contract facility as of the end of the previous contract shall 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.

1.14 APPICABLE TECHNICAL ORDERS

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

TECH ORDER CHANGE

NUMBER DATE SHORT TITLE

00-5-1

11 SEP 23

AIR FORCE TECHNICAL ORDER SYSTEM

00-5-2 01 APR 01 TECHNICAL ORDER DISTRIBUTION SYSTEM

00-5-15 28 JUL 23 TIME COMPLIANCE TECH ORDER (TCTO)

SYSTEM

00-20-1 26 SEP 22 PREVENTIVE MAINTENANCE PROGRAM

00-20-2 23 AUG 23 MAINTENANCE DATA COLLECTION SYSTEM

00-20-3 17 DEC 21 MAINTENANCE PROCESSING OF REPARABLE

PROPERTY AND THE REPAIR CYCLE ASSET

CONTROL SYSTEM

00-25-113 15 SEP 13 CRITICAL ALLOY AND PRECIOUS METAL

00-25-113-F100-

ENG

15 MAR 17 CRITICAL ALLOYS AND PRECIOUS METALS

PARTS LIST F100 ENGINE

00-25-254-1 1 FEB 22 COMPREHENSIVE ENGINE MANAGEMENT

SYSTEM (CEMS) PROCEDURES

00-35D-54 15 AUG 22 USAF DEFICIENCY REPORTING,

INVESTIGATION, AND RESOLUTION

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2-1-111 01 AUG 23 STANDARD MAINTENANCE PROCEDURES

6J3-2-36-3 01 MAY 20 OVERHAUL INSTRUCTIONS AFC ASSEMBLY NO.

791000, MODEL JFC136-1

6J3-2-36-4 01 APR 14 ILLUSTRATED PARTS BREAKDOWN AFC NO.

790100, MODEL JFC136-1

6J-2-36-503 13 JUN 19 REPLACEMENT OF SELECTED AFC HYDRAULIC

HOUSING AND SEQUENCE PISTON ASSEMBLY, PN

801038-1, F100-PW-229 ENGINE, F-15F-16 ARICRACT

6J10-2-18-3 01 AUG 15 OVERHAUL INSTRUCTIONS AFP ASSEMBLY NO.

79240, MODEL TPC24-2

6J10-2-18-4 15 FEB 14 ILLUSTRATED PARTS BREAKDOWN AFP

ASSEMBLY NO. 792840, MODEL TPC24-2

33B-1-1 01 JUL 22 NONDESTRUCTIVE INSPECTION METHODS, BASIC

THEORY

1.15 SURGE

1.15.1 In the event that the DoD experiences an unplanned spike or sudden increase in demand, due to major theater warfare or national emergency (also known as surge, reference DFARS 217.208-70 and DFARS 252.217-7001) and invokes surge: The contractor is willing to work to meet and sustain this demand for quantity levels above and beyond normal peacetime requirements. The contractor is required to provide the Government a surge plan. A CDRL and DID are associated with the surge requirement. After being notified of the surge demand in writing, the contractor may see additional orders and/or will see the priority status elevated on current orders. The contractor may do one or more of the following to fill the demand:

1.15.2 The contractor will maintain level of safety stock of components to draw from to perform additional repairs.

1.15.3 Add additional shifts to increase production within the contractor and with suppliers.

1.15.4 The contractor will work with the various manufacturing sites and their supply chain to expedite production. The contractor will be notified in advance of, and be given the opportunity to negotiate; any expedite charges that might apply at the time of surge.

Contractual requirements for production of this contract are addressed in Part I. The schedule and surge requirements will be on a best-effort basis.

1.15.5 Surge plans have four basic phases (assessment, execution, sustainment, and exit/termination) and the plan associated with the surged items requested need to address those phases. The Government will provide, in writing, the items on contract that are requested to be surged.

That will include the item, the quantity, and timeline with respect to delivery schedule with estimated termination dates when known.

1.15.6 Contractors will provide a plan that includes the identified surge items, how they are going to

FD2030-24-00247 Page 15 of 37 meet the requirement, timeline to implement the plan, ability to sustain the surge through termination, identify any limiting factors or supply chain risks that will impact current surge production and future requirements for identified items.

1.15 APPLICABLE DIRECTIVES

AIR FORCE

INSTRUCTIONS

CHANGE DATE TITLE

AFI 21-101 21 MAY 15 AIRCRAFT AND EQUIPMENT

MAINTENANCE MANAGEMENT

AFI 21-118 21 NOV 14 IMPROVING AEROSPACE

EQUIPMENT RELIABILITY &

MAINTAINABILITY

MILITARY STANDARDS CHANGE DATE TITLE

MIL-STD-129P 24 MAY 18 U.S. MILITARY MARKING FOR

SHIPMENT AND STORAGE, CHG 4

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

PROPERTY

ISO 9001 15 SEP 15 QUALITY MANAGEMENT

SYSTEMS – REQUIREMENTS -

FOURTH EDITION

DEPARTMENT OF DEFENSE (DoD)

JOINT AERONAUTICAL 4 AUG 05 EXHIBIT H: UNIVERSAL

LOGISTICS COMMANDERS/ VENDOR SITE SURVEY

AVIATION CRITICAL SAFETY CHECKLIST

1.16 APPLICABLE DOCUMENTS

1.16.1 FEDERAL ACQUISITION REGULATION - ISSUED MARCH 2005

1.16.2 LPF-QAR-002: CHANGE PROCEDURES FOR PROCESS ORDERS

1.16.3 LPF-QAR-004: LPFR QUALITY ASSURANCE REQUIREMENTS FOR

F100 ENGINE COMPONENTS

1.16.4 LPF-QAR-006: LPFR QUALITY ASSURANCE REQUIREMENTS FOR

PRODUCT VERIFICATION AUDIT (PVA) TEST PLANS AND

REPORTS

1.16.5 LPF-QPR-018: LPFR QUALITY PLAN REQUIREMENTS

FOR NONDESTRUCTIVE INSPECTION

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1.16.6 EI FOR RQR-1: GENERIC ENGINEERING INSTRUCTIONS FOR REPAIR

OF F100 PARTS IN RQR-1

1.17 MISSION ESSENTIAL SERVICES

1.17.1 The contractor shall prepare for the continuation of essential DoD services during crisis IAW Depart of Defense Instruction (DoDI) 3020.37. In a state of emergency, if the Government deems necessary, the contractor shall provide all services necessary to ensure mission accomplishment. On occasion, services may be required to support an activation, or exercise of contingency plans outside normal duty hours. IAW DoDI 3020.37, the contractor shall develop a contingency plan and furnish a copy to the PCO for those tasks identified as essential to provide reasonable assurance of continuation during crisis conditions.

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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 Quality Assurance Surveillance Plan (QASP) 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.

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

PERFORMANCE

THRESHOLD

SS-1. Quality of Service: Contractor conforms to overall TO requirements.

Contractor receives less than five (5) valid customer complaints per year. 100% Compliant

SS-2. Schedule: Contractor conforms to T.O. schedule.

Contractor performs tasks within their schedule 95% of the time. Provides notification to the Govt of schedule delay within 2 work-days. 100% Compliant

SS-3. Business Relations: Contractor interacts seamlessly with Government as well as internal/external customers. Contractor maintains a non-personal services relationship with the Government with continued awareness of Government/Contractor relationships.

Contractor receives less than five (5) valid customer complaints per year. 100% Compliant

SS-4. Cost Control: Contractor effectively forecasts, manages and controls task order cost.

Contractor performs tasks within their estimated cost 95% of the time. Provides notification to the Govt of potential cost overrun within 2 work-weeks. 100% Compliant

SS-5. Management of Personnel:

Contractor selects, retains and replaces personnel when necessary.

Contractor meets all task requirements while selecting, retaining and replacing qualified personnel as needed. 100% Compliant

SS-6. Quality Product: Each F100 MFP/AFC identified as serviceable shall be delivered to the Government free of defects.

100% of AFC/AFPs delivered shall be defect free. 100% Compliant

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OBJECTIVE

THRESHOLD

SS-7. Delivery Performance: The Contractor shall meet the delivery schedule

100% of AFC/AFPs shall be delivered IAW the contractual delivery schedule. 100% Compliant

SS-8: QMS Metrics: The Contractor’s accepted QMS plan effectively controls quality, meets the PWS quality requirements, and does not deviate from the Contractor’s accepted QMS.

Defect Correction Rate: identifies if COR/contractor identified non-conformities are corrected within the contractor’s self-imposed “get-well” dates. 100% Compliant

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 may result 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 may result in a negative CPAR rating and remedies as allowed under FAR 52.246-4 Inspection of Services-Fixed Price.

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SECTION III

GOVERNMENT PROPERTY

3.1 GOVERNMENT PROPERTY

3.1.1 The use of Government Furnished Property (GFP) is anticipated for this acquisition. A listing of

GFP offered is located in Attachment 1 of this solicitation. Contractor shall furnish all other material, support equipment, tools, test equipment and services.

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APPENDIX 1

A1.1 ACRONYMS

ACO Administrative Contracting Officer AFC Augmentor Fuel Control AFMC Air Force Material Command AFP Augmentor Fuel Pump 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 FAR Federal Acquisition Regulation GFM Government Furnished Material GFP Government Furnished Property GPA Government Property Administrator IAW In Accordance With IPB Illustrated Parts Breakdown MOH Maximum Operating Hours MRB Material Review Board NDI Nondestructive Inspection OC-ALC Oklahoma City Air Logistics Center OCM On-Condition Maintenance 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 TCTO Time Compliance Technical Order TODO Technical Order Distribution Office QAD Quality Assurance Document QAR Quality Assurance Representative QCD Quality Control Deficiency SL Salvage Layout SR Service Repair TO Technical Order USAF United States Air Force WP Work Package

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APPENDIX 2

A2.1 NOTES

A2.1.1 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 Quality Assurance Representative (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 536 ACSS/GFEA via email within (5) working days after approval of the MRB.

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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/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 QMS 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/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 repair/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 Department of Defense (DoD) contract administration service element having direct responsibility for implementing the Government Quality Assurance Program at the contractor's plant.

A3.2.3 Repair and Overhaul Work Requirement. Any contract instrument, TO, drawing, specification or directive which contains instructions and requirements for repair/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 w i t h 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:

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A3.3.1.1 Perform audit functions under the surveillance of the cognizant DoD Contract Administration Office (CAO) and Air Logistics Center (ALC) 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 b e 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

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.

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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 2d.

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 c (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.

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The audit candidate shall be accepted by the Government upon compliance with paragraph 4d (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.

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 repair/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.

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

FD2030-24-00247 Page 26 of 37 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/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 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 5j 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

A3.5.1.4.5 Category IIIA

A3.5.1.4.6 Category IIIB

A3.5.1.4.7 Category IV

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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 Quality Assurance (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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APPENDIX 4

A4.1 CAVAF 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 CAV AF system. CAV AF is the mandated primary system of record for providing daily status of all Government owned assets located at contractor repair facilities. Reporting within CAV AF is not limited to end items subject to repair, but includes assets stored within a contractor Inventory Control Point (ICP). CAV AF system down-time will be identified on the CAV AF homepage banner. Contractors are responsible for ensuring the most current Contractor User Guides are utilized by their assigned reporters.

NOTE: Contractor User’s Guide can be accessed from the CAV AF homepage.

CAV AF FAMILIARIZATION TRAINING

1. Familiarization training for CAV AF reporting can be requested by the contractor via the applicable contracts ICP CAV AF system administrator (SA). Assistance, guidance, general questions or specific contract transactional reporting requirements can be addressed to the CAV AF contract monitor (CM).