PWS_TobiDuct_F100_PW_229.pdf

PERFORMANCE WORK STATEMENT (PWS)

For

F100-PW-229 1st Stage Turbine Stator Support (TOBI) Modification and Airflow Validation

FILE NUMBER: PR # FD2030-24-31852

REV. 0

DATE: 14 March 2024

PREPARING ORGANIZATION:

AFLCMC/LPSID

TINKER AFB OK 73145-3030

FD2030-24-31852 Page 2 of 22

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 SAFETY AND HEALTH

1.11 GENERAL WORK REQUIREMENTS

1.12 SPECIFIC WORK REQUIREMENTS

1.13 APPLICABLE TECHNICAL ORDERS

1.14 APPLICABLE DIRECTIVES

1.15 APPLICABLE DOCUMENTS

1.16 MISSION ESSENTIAL SERVICES

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

FD2030-24-31852 Page 3 of 22

SECTION I

DESCRIPTION OF SERVICES

This PWS establishes the minimum work requirements to return F100-PW-229 1st Stage Turbine Stator Support (TOBI) listed below by National Stock Numbers (NSN) and Part Numbers (P/N) to a serviceable but not like new condition. This is a modification by salvage layout (SL) 278883.

The purpose of the TOBI is to support the 1st Stage High Pressure Turbine (HPT) Vanes and direct airflow towards the HPT. F100-PW-229 1st Stage Turbine Stator Support 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.

TOBI

Modification

Part Number NSN Tech Order

INPUT 4083970 2840-01-450-2337 2J-F100-54

OUTPUT 4088557 2840-01-580-7061 2J-F100-54

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.

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1.1 DATA

1.1.1 Reporting Requirements

1.1.1.1 Monthly Production Report A0001: 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 will be prepared for the month during which the contract assets are received. Reports will continue to be forwarded until all end items are repaired. The last report will be annotated “Final Report”. Negative reports are required.

1.1.1.2 Product Quality Deficiency Report A0002(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 Administrative Contracting Officer (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 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 (CDRL A0001) and to enable him to complete his records or to complete such other reports as may be required.

1.1.2.2 Comprehensive Engine Management System (CEMS) Reporting: N/A

Note: FMS customers do not have access to CEMS and therefore, CEMS reporting is not required in this contract.

1.1.2.3 Completed DD Form 1574 Serviceable Tags are required IAW MIL-STD- 129P, 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 http://www.ecmra.mil.

1.1.2.5.1 Reporting inputs will be for the labor executed during the period of http://www.ecmra.mil/

FD2030-20-36477 Page 5 of 22 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) salvage layout (SL) 278883 3) the end item TO, 4) 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 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

FD2030-20-36477 Page 6 of 22 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 A0002.

1.3.3 No defective parts shall be delivered to the Government.

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 Nondestructive Inspection

(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.

1.5.2.3 The serial number and part number of any life-limited item, which is condemned, must be transmitted to the F100 Engineering Source Authority listed in TO 2J-F100-53-1, 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.

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1.6.1.1 CEMS Reporting: NA

Note: FMS customers do not have access to CEMS 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.

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. The contractor shall notify the Contracting Officer, 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

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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

1.10.2 If requested by the Contracting Officer, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Contracting Officer.

1.11 GENERAL WORK REQUIREMENTS

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

1.11.1.1 The contractor shall accomplish the required modification per salvage layout (SL) 278883.

FD2030-20-36477 Page 9 of 22

1.11.2 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.

1.11.3 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.

1.11.4 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.

1.11.5 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.

1.11.6 Fit and tolerance limits shall be IAW applicable overhaul TO processes and procedures unless otherwise specified.

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

1.12 SPECIFIC WORK REQUIREMENTS

1.12.1 Removal

1.12.1.1 Not Applicable.

1.12.2 Disassembly

1.12.2.1 Not Applicable.

1.12.3 Cleaning

1.12.3.1 The contractor shall ensure that cleaning and preserving materials meet the requirements specified in TO 2J-F100-53-1 or TO 2-1-111 and that such materials are properly used during application.

1.12.4 Inspection

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1.12.4.1 Inspection of the F100-PW-229 1st Stage Turbine Stator Support shall be accomplished IAW SL278883 and TO 2J-F100-9.

1.12.5 Corrosion Control

1.12.5.1 The corrosion control of F100-PW-229 1st Stage Turbine Stator Support during overhaul and storage shall be accomplished IAW TO 2J-F100-53-1 or TO 2-1- 111 whichever is applicable.

1.12.6 Modification and Overhaul

1.12.6.1 Modification and Overhaul of F100-PW-229 1st Stage Turbine Stator Support shall be accomplished IAW SL278883.

1.12.6.2 The contractor shall identify all overhauled F100-PW-229 1st Stage Turbine Stator Support with the contractor’s CAGE IAW MIL-STD-130N.

1.12.7 Installation

1.12.7.1 Not applicable.

1.12.8 Test and Government Acceptance

1.12.8.1 Inspect, test, and check each overhauled item IAW SL278883.

1.12.8.2 The Government shall accomplish acceptance.

1.12.9 Product Verification Audit (PVA)

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

1.12.9.2 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.

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

1.12.10 Technical Publication Compliance

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

1.12.10.1.1 They have not been previously accomplished

FD2030-20-36477 Page 11 of 22

1.12.10.1.2 They are pertinent to the end item.

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

1.12.10.2 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.

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) 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 or Procurement Contracting Officer

(PCO_.

1.12.10.3 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.

1.12.10.4 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.

1.13 APPLICABLE TECHNICAL ORDERS

This is a preliminary list of Technical Orders. The contractor is responsible for ensuring they mailto:AFLCMC.%20LPSAA.TOMA@us.af.mil mailto:AFLCMC.%20LPSAA.TOMA@us.af.mil

FD2030-20-36477 Page 12 of 22 are using the latest edition.

TECH ORDER BASIC CG LATEST

NUMBER DATE NO REVISION SHORT TITLE

00-5-1-WA-1

15 Aug 09

AF TECH ORDER SYSTEM

00-20-1-WA-1 1 SEP 10 PREV MAINT PROG

00-20-2-WA-1 1 SEP 10 MAINT DATA COLLECTION SYS

00-35D-54-WA-1 1 NOV 11 MATERIAL DEF REPORT &

INVEST SYSTEM

33B-1-1-WA-1 1 JAN 13 NONDESTRUCTIVE INSP.

METHODS

2-1-111-WA-1 15 FEB 90 STAND MAINT PROCEDURES

2J-F100-9-WA-1 1 NOV 95 NONDESTRUCTIVE INSPECTION

2J-F100-53-1-WA-1 1 FEB 07 MAINT INSTR-DEPOT

2J-F100-54-WA-1 31 MAR 08 IPB F100-PW-220/220E

1.14 APPLICABLE DIRECTIVES

AIR FORCE

INSTRUCTION LATEST REVISION TITLE

AFI 21-101 MAINT MGMT OF

AIRCRAFT

AFI 21-118 IMP AERO EQUIP

RELIABILITY &

MAINTAINABILITY

MILITARY STANDARDS LATEST REVISION TITLE

MIL-STD-129P U.S. MILITARY MARKING

FOR SHIPMENT AND

STORAGE

MIL-STD-130N ID MARKING OF U.S.

MILITARY PROP

FD2030-20-36477 Page 13 of 22

INTERNATIONAL ORGANIZATION FOR STANDARIZATION (ISO)

ISO - 9001 LATEST

REVISION

QUALITY MGMT SYSTEMS –

REQUIREMENTS – 3RD EDITION

DEPARTMENT OF DEFENSE (DoD)

JOINT AERONAUTICAL LATEST REVISION EXHIBIT H: UNIVERSAL

LOGISTICS COMMANDERS/ VENDOR SITE SURVEY

AVIATION CRITICAL SAFETY CHECKLIST

ITEM MANAGEMENT HANDBOOK

1.15 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-006: LPFR QUALITY ASSURANCE REQUIREMENTS

FOR PRODUCT VERIFICATION AUDIT (PVA) TEST PLANS AND

REPORTS

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

WELDED ASSEMBLIES

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

DURABILITY CRITICAL PARTS

1.14.9 LPF-QPR-018: LPFR QUALITY PLAN REQUIREMENTS

FOR NONDESTRUCTIVE INSPECTION

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

FD2030-20-36477 Page 14 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: PWS #s 1.3 No defective parts shall be delivered to the Government.

SS-2 Delivery Performance:

PWS # 1.4 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.

FD2030-20-36477 Page 15 of 22

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.

2.2.1.3 The Contractor shall allow quality assurance reviews to be conducted at the site of repair at the request of the Defense Contract Management Agency (DCMA) throughout the contract period.

2.2.1.4 The Contractor shall allow a quality acceptance review by the DCMA representative at the site of repair for each end item generated under the terms of this contract.

The Contractor shall comply with quality acceptance inspections of each end item IAW DCMA’s latest approved procedure. Quality acceptance will be performed by DCMA at the repair site for each end item generated under the terms of the contract. Quality acceptance documentation for each end-item shall be maintained by the Contractor as part of the item document package.

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.

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A1.1 ACRONY MS

APPENDIX 1

ACO Administrative Contracting Officer AFLCMC Air Force Life Cycle Management 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

FAR Federal Acquisition Regulation

GFP Government Furnished Property GPA Government Property Administrator IAW In Accordance With

IPB Illustrated Parts Breakdown MRB Material Review Board NDI Nondestructive Inspection

PCO Procurement Contracting Officer PIR Publication Improvement Report PQDR Product Quality Deficiency Report PVA Product Verification Audit PWS Performance Work Statement

QAR Quality Assurance Representative

SL Salvage Layout

TO Technical Order USAF United States Air Force WP Work Package

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APPENDIX 2

A2.1 NOTES

A2.1.1 The contractor shall 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 AFLCMC/LPSAA via email within (5) working days after approval of the MRB.

APPENDIX 3

A3.1 PR ODUC 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

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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 RES PONS IBI LITIES

A3.3.1 The Contractor shall:

A3.3.1.1 Perform audit functions under the surveillance of the cognizant DOD Contract Administration Office (CAO) and Air Force Life Cycle Management 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 A UDIT 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

FD2030-20-36477 Page 19 of 22 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 further 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.

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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 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

FD2030-20-36477 Page 21 of 22 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 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 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 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 A UDIT 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.

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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

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."