SOW - Draft.pdf

File No: FD2030-19-02199

STATEMENT OF WORK (SOW)

F108 -200 Low Pressure Turbine Union of Assemblies

MODULE #13/15 (Navy)

PURCHASE REQUEST NUMBER: FD2030-19-02199

REV. 0

PREPARATION DATE: 10 Jun 2019

PREPARING ORGANIZATION:

421st Supply Chain Management Squadron (SCMS)/GUMBA

Air Force Sustainment Center (AFSC)

And

Navy E-6B ISSC Propulsion Engineering Team Technical Element (Navy Code 4.4.3.3)

Tinker AFB OK 73145-3031

TABLE OF CONTENTS Page

TABLE OF CONTENTS 1

SECTION I

1.0 SCOPE 2

1.1 Introduction 2

1.2 SOW Updates 2

1.3 Subcontractor and Vendor Management 2

1.4 Transition and Relocation Plan 2

1.5 Contractor Relocation 3

1.6 Safety 3

1.7 General Services and Material 3

1.8 Receiving 3

1.9 Disassembly 4

1.10 Remanufacture 4

1.11 Remanufacture Procedures 4

1.12 Remanufacture Deviations 5

1.13 Designated Engineering representative (DER) Processes and Procedures 5

1.14 Parts Not Listed in the Illustrated Parts Catalogue (IPC) 5

1.15 Condemnation of Tracked Items 5

1.16 Replacement Quality 6

1.17 Schedule 6

1.18 Special Instructions Concerning the Navy CFM56-2A Module 6

1.19 Re-installation of Life Limited Parts (LLP) 7

1.20 FAA Form 8130-3 7

1.21 Delivery Quality 7

1.22 Quality System and Quality Assurance Plan 8

1.23 Deficiency Report (DR) Investigation 8

1.24 Condemnation of Assets 8

1.25 Packaging and Handling 8

1.26 Preservation 8

1.27 Item Unique Identification (IUID) 8

1.28 Shipping and Transportation 9

1.29 Reporting 9

1.30 Contractor Manpower Reporting 10

1.31 Document Storage 10

1.32 Contractor Identification to Government Employees 10

1.33 Mission Essential Services 10

SECTION II

2.0 GOVERNMENT PROPERTY 11

2.1 Government Furnished Material (GFM) 11

2.2 Government Furnished Property (GRP) 11

ENCLOSURE 1

3.0 Statement of Work 12

APPENDIX A

ACRONYMS 14

APPENDIX B

CAV AF Reporting 15

SECTION I

1.0 SCOPE

1.1 Introduction: This Statement of Work (SOW) defines the tasks and performance requirements for the remanufacturing of the F108-200 (CFM56-2A) Low Pressure Turbine Union of Assemblies Module 13/15 that applies to the following National Stock Numbers (NSN) and Part Numbers (P/N):

LOW PRESSURE ROTOR AND FRAME ASSEMBLY MODULE #13/15

F108-200 (CFM56-2A)

Input P/N Output P/N Input NSN Output NSN____

305-482-301-0- 305-482-301-0-2A 2840-01-484-3913PN 2840-01-484-3913PN

305-482-301-0-2A 305-482-301-0-2A 2840-01-484-3913PN 2840-01-484-3913PN

305-482-302-0 305-482-302-0-2A 2840-01-484-3913PN 2840-01-484-3913PN

305-482-302-0-2A 305-482-302-0-2A 2840-01-484-3913PN 2840-01-484-3913PN

305-482-303-0 305-482-303-0-2A 2840-01-484-3913PN 2840-01-484-3913PN

305-482-303-0-2A 305-482-303-0-2A 2840-01-484-3913PN 2840-01-484-3913PN

The instructions provided herein are brief, concise statements providing general requirements for remanufacturing of the F108-200 Module 13/15 which will have accumulated approximately 15,000 to 23,000 Engine Operating Hours. The Contractor shall perform remanufacture of engine components at a Federal Aviation Administration Part 145 facility rated for CFM56-2A engine remanufacture/refurbishment. Contractor shall possess all necessary F108-200 Module 13/15 remanufacture capabilities to include possession of the appropriate technical data, documents and license agreements. The Contractor is responsible for delivering a quality remanufactured product with the constraints of the established delivery schedule.

1.2 SOW Updates: The Contractor shall provide updates and change recommendations concerning this SOW to the Procurement Contracting Officer (PCO) in writing (email is acceptable), but the Government shall maintain the SOW during the performance of this contract.

1.3 Subcontractor and Vendor Management: The Contractor shall maintain a system for the management of subcontractors and vendors IAW the provisions of this contract. The Contractor shall ensure that the subcontractor(s)/vendor(s) data, designs, and deliverables meet all F108-200 Module 13/15 engineering and technical requirements and shall fulfill the requirements of this contract. The Government personnel shall be provided the opportunity to attend all subcontractor reviews and other problem solving reviews as observers.

1.4 Transition and Relocation Plan: The Contractor shall maintain and execute a transition plan detailing a ramp-up/ramp-down process that will not impact on-going remanufacturing processes and scheduled deliveries. This plan shall include description of strategies, facilities, equipment, tooling, manpower, and skills that will be employed to execute transition from roll-out to full operational status.

Maximum acceptable turnaround time, from receipt of an incoming module 13/15 to shipment of same asset is 60 days.

1.5 Contractor Relocation: The Contractor shall coordinate the relocation schedule with the PCO to ensure no conflicts exist. In the event of a relocation, the Contractor shall continue to provide support for the F108-200 Module 13/15 at the new location IAW this contract. The Contractor shall be responsible for the security of F108-200 Module 13/15 areas/equipment during relocation.

1.6 Safety: The Contractor shall maintain and execute a safety program using MIL-STD-882E, AFI 91- 202 and AFI 91-204 as guides. The Contractor shall comply with all safety provisions and technical specifications listed in CFM56 Engine Shop Maintenance Manual (CMM). All Contractor personnel and technicians shall comply with system safety principles during all levels of remanufacturing.

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 PCO within eight (8) hours of any damage to Government Furnished Property (GFP) where the dollar value exceeds $500,000.00 and within two workdays, for any damage to GFP less than $500,000.00 during the execution of the contract.

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

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

b. Date, Time and exact location of accident/incident

c. Brief Narrative of accident/incident (Events leading to accident/incident)

d. Cause of accident/incident, if known

e. Estimated cost of accident/incident (material and labor to remanufacture/replace)

f. Nomenclature of equipment and personnel involved in accident/incident

g. Corrective actions (taken or proposed)

h. Other pertinent information

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

1.7 General Services and Material: The Contactor shall provide all materials for the remanufacture processes required to execute this contract, except for the Government furnished modules sent to the Contractor for remanufacture.

1.8 Receiving: The Contractor shall perform a visual inspection upon receipt of incoming modules for any shipping or packaging damage. The Contractor shall report all received F108-201 Module 13/15 that are misidentified, misdirected, incomplete or missing parts to the PCO in writing (email is acceptable) for disposition instructions. In addition, Contractor shall perform a visual inspection of incoming modules to be remanufactured to determine condition using CFM56 Engine Shop Maintenance Manual (CMM) 72- 54-XX and 72-56-XX.

The contractor shall report in accordance with CDRL A005 any F108-200 Module 13/15 that are misidentified, misdirected, incomplete or missing parts to the PCO in writing (email is acceptable) for disposition instructions. The Contractor shall not destroy reusable shipping containers, and will reuse them for return shipment. In the event that a shipping container is no longer usable, the contractor will contact the PCO for disposition instructions. In addition, the contractor shall submit Shipping Discrepancy Reports (SDRs) IAW Contractor Data Requirements List (CDRL) A005 (SOW Para 1.29 Reporting) for such shipments as described above via the Department of Defense (DoD) web-based application WebSDR, located at: https://www.transactionservices.dla.mil/daashome/websdr.asp .

https://www.transactionservices.dla.mil/daashome/websdr.asp

This system of reporting an SDR has been developed in compliance with DoD Management (DoDM) regulation 4140.1-V1 and Defense Logistics Management (DLM) regulation 4000.25-M Supply Standards and Procedures, which requires automated SDR processing and IAW Contractor Asset Visibility for the Air Force (CAV AF) Reporting SOW Para 1.30.3 and 1.30.4.

The Prime Packaging Specialist may authorize exceptions to these requirements.

1.9 Disassembly: The contractor shall disassemble each F108-200 Module 13/15 to the full extent necessary to comply with all component/piece-part cleaning and inspection requirements specified in the CFM-56-2A Engine Shop Manual (ESM).

1.10 Remanufacture: After disassembly, cleaning, and inspection of the modules IAW paragraph 1.9, Contractor shall provide any required replacement components/piece-parts, perform all applicable processes, inspections, reassembly, adjustments, calibrations, testing and operational checks, necessary to return a like new Module 13/15 IAW with this SOW. All applicable CFM56-2A Engine Shop Manual (ESM) tasks and Service Bulletin/ Airworthiness Directive Requirements shall be complied with. The Contractor shall remanufacture the F108-200 Module 13/15 as follows:

1.11 Remanufacture Procedures: Low Pressure Turbine (LPT) Rotor and Frame Assembly and component parts shall be remanufactured IAW the procedures outlined in the CFM56-2A ESM 72-54-00 through 72-54-20 and 72-56-00 through 72-56-10. This also includes Standard Practice Manual CFMI-

TP-SP.2.

Replacement Life Limited Parts (LLP) shall be new and unused from USAF and/or Navy approved sources or remanufactured from Government inventory. New and unused non-LLP shall be from Navy approved vendors, Government inventory, or OEM approved vendors. Non-LLP used serviceable commercial components shall be from used commercial inventories acquired originally from an Air Force or OEM approved vendors. The Contractor shall not acquire non-LLP used commercial parts from supplier sources that have been subject to any violation, penalty, or disciplinary actions leading to FAA disapproval of its aircraft, engine maintenance or operations. The Contractor shall provide FAA Form 8130-3 documentation for each used component in a module at time of module delivery.

1.11.1 Level of Inspection: Component parts removed from rotor and frame assembly shall be inspected to piece part requirements outlined for that specific part in accordance with CFM56-2A

ESM.

1.11.1.1 Air Seals: Repair 001, LPT rotating air seals (72-54-06), Repair 0001, LPT inner stationary air seals (72-54-09) and Repair 001, LPT outer stationary seals (72-54-12) are to be accomplished 100% to restore seals to unworn condition.

1.11.1.2 LPT Blades: LPT stage 1 blades shall be inspected to “post-remanufacture requirements” (in-lieu of serviceable requirements) those that fail this inspection shall be remanufactured. Stage 2 thru 4 blades shall be inspected to serviceable requirements and reworked as necessary. Blades beyond remanufacture limits shall be replaced with new blades from OEM approved sources or fully overhauled blades from other Navy assets. Used Commercial Stock shall not be used for LPT blade replacement.

1.11.1.2.1 Three evenly spaced “cutter blades” shall be incorporated in each of stages 1 thru 3 IAW Service Bulletin SB 72-0228.

1.11.1.2.2 All blades used must meet the following pre-twist angle requirements:

Stage 1 min = 1.82 deg: max = 2.32 deg Stage 2 min = 2.55 deg; max = 3.05 deg Stage 3 min = 3.50 deg; max = 4.00 deg Stage 4 min = 4.70 deg; max = 5.20 deg

1.11.1.3 Module Inspection: In addition to the component piece part inspections all Modules returned to the Government shall meet the inspection criteria established in T.O. Reference CFM56-2A Engine Shop Manual Task 72-00-54-200-001 D “Low Pressure Turbine Rotor/Stator Module Inspection” specifically with respect to:

1) Circumferential looseness of blades at tip-shrouds.

2) Pre-twist gaps such that adjacent interlocks do not touch.

3) Shingled or unlatched blade tip-shrouds.

1.11.1.4 Adjusting Sleeve Considerations: The Turbine Frame Assembly is matched with the Low Pressure Turbine Rotor Assembly through No. 5 bearing adjusting sleeve. The replacement of Turbine Frame or of the No. 5 bearing support cannot be done without rework of the adjusting sleeve per CFM56-2A, ESM 72-00-03 (Refer to caution in 72-00-56-20 turbine frame removal) after removal and disassembly of the Module. During removal the parts must be identified and match marked for inspection and installation operations.

1.11.1.5 HPT Rear Turbine Frame Cleaning and NDI Inspection: CFM65-2A Program has a history of Rear Turbine Frame cracks. To address this issue perform NDI inspection of Rear Turbine Frame IAW SOW E6-PN-318A-10 found in Enclosure 1. Equivalent contractor cleaning process acceptable.

1.12 Remanufacture Deviations: Prior to Contractor’s deviations in remanufacturing of Module 13/15 or component parts, the Contractor shall obtain written approval for deviations from the PCO as outlined in ESM 72-54-00 thru 72-54-020 and 72-56-00 thru 72-56-010, or Service Bulletin authorized modifications. Requests for Deviations (RFD) will be sent to the PCO from the contractor, and a Navy Propulsion Engineering will review the request. If the deviation is approved the Contractor will receive a signed RFD from the PCO.

1.13 Designated Engineering Representative (DER) Processes and Procedures: Prior to Contractor’s use in the remanufacturing of Module 13/15 or component parts, the Contractor shall obtain written approval from the PCO for all DER processes and procedures (email is acceptable).

1.14 Parts Not Listed in the Illustrated Parts Catalogue (IPC): The Contractor shall identify the use and/or reuse of any part not listed specifically in the CFM56-2A Illustrated Parts Catalog (IPC) to the PCO (email is acceptable) for Navy Propulsion Engineering authorization.

1.15 Condemnation of Tracked Items: Tracked Parts/Components that have a remaining life of less than 5100 Maj Cycles (Navy Build Policy – para 1.19) require disposition from Navy Propulsion Engineer. The Navy may elect to use components that are within a few hundred cycles of meeting the

Build Policy requirements. In such instances the Navy will provide written authorization to use the affected item.

1.16 Replacement Quality: The Contractor shall ensure that materials, parts and accessories used for replacement items are equal or superior to the original and are interchangeable without alteration.

1.17 Schedule: Any changes to contractual milestones shall be made only with Program Office coordination and written approval of the PCO (email is acceptable).

Production or delivery problems which have developed, or are developing, and have the potential to stop, interrupt or impact the production or delivery of contract end items will be reported to the Program Management Office via the PCO within 1 business day.

1.18 Special Instructions Concerning the Navy CFM56-2A Module: In the following are special instructions concerning the CFM56-2A modules.

1.18.1 Service Bulletins: Contractor shall comply with the latest version of the following CFM56-

2A Service Bulletins (SB). SB compliance shall be recorded on DD Form 1574 (Serviceable Tag- Material) and on FAA Form 8130-3 that accompany the assets back to supply.

• SB 72-0228: Introduction of 3 New Blades with Hardened Teeth for Each Set of Stages 1, 2 and 3 LPT Blades.

• SB 72-0338: Re-identification of Low Pressure Turbine (LPT) Conical Supports and LPT

Stub shafts (Air Directive 96-18-16)

• SB 72-0356: Anti-Rotation lock replacement rework/re-identification of Stage 2 and 3

Stationary Air Seal Segments

• SB 72-0372: Re-identification of conical supports

• SB 72-0144: Increase in height of the Abradable Honeycomb on Stage 1 Outer Stationary

Air Seal

• SB 72-0541: Turbine Frame (72-56-00) Rework of the Old LPT Frame Assy to permit the removal of the Oil Supply Tube Elbow Assy on wing

• SB 72-0602: Replacement of suspect Stage 1 LPT blades 301-330-114-0 and 301-330-115-0

NOTE: Currently the above mentioned Service Bulletins require compliance. Should, in the future, additional Service Bulletin(s) be released and required to return a Module 14 to like new condition they will be addressed on a case by case basis and may be incorporated in this SOW via contract modification.

1.18.2 If it has not already been done, re-identify the remanufactured/reconditioned Module 13/15

Assembly by adding “-2A” to the assembly part number to read 305-482-301-0-2A, 305-482-302-0- 2A or 305-482-303-0-2A depending on the original P/N of the unit. Permanently mark assembly using CFM International authorized method or equivalent with a -2A after the assembly part number in the location allowed by the blueprint.

1.18.3 The CFM56-2A assets will be shipped with a statement on the FAA 8130-3 Form required in paragraph 1.20 that states that the Source of Repair (SOR) complied or did not comply with the service bulletins of this paragraph. It is understood that some service bulletins may not apply. If a service bulletin was not applicable, this is to be stated on the serviceable tag or FAA document.

1.18.4 The contractor shall use non-life-limited Navy CFM56-2A assets, to include Navy CFM56- 2A assets that can be remanufactured within a 30 day time frame. When a Module 13/15 cannot be remanufactured within a 30 day time frame, the contractor shall inform the PCO and request a stated additional amount of time to complete the remanufacture. If Navy assets are not available to replace those that have been condemned, and the only assets available are commercial assets; commercial assets may be used provided that they have not undergone more than one remanufacture cycle and have received Navy approval. (This paragraph does not apply to LPT blades of paragraph 1.11.1.2)

1.18.5 Special Measurements: Measure and record the following Module 13 features on DD Form 1574 (Serviceable Tag-Material) and on the FAA Form 8130-3 that accompany the assets back to supply:

1) LPT Case diameter D: 34.476-34.484 (serviceable) or 34.4803-34.4838 (remanufactured)

2) LPT 1st Stage Shroud Support (un-installed) diameter B: 34.653-34.665 (serviceable) or

34.6614-34.665 (remanufactured) and diameter C: 34.468-34.480 (serviceable) no remanufacture.

3) LPT 1st Stage Shroud Support diameter B while installed on the LPT case.

1.19 Re-installation of Life Limited Parts (LLP): The Contractor shall ensure all LLPs that were removed for a required inspection are assembled back into the same rotor. The Contractor shall check records to ensure specified life cycles have not been exceeded and part must have 5100 cycles (Build Policy) remaining to max life limit for the CFM56-2A components. When a part exceeds max life cycle limit or has insufficient life cycles remaining, the Contractor shall ensure the replacement part selected for that rotor shall have equal or greater life cycles remaining than all other component parts in that rotor assembly.

A LLP removed from a Navy F108-200/CFM56-2A assembly will not be replaced with a component/part that has operated in any configuration other than a Navy F108-200/CFM56-2A engine. LLP parts will not be co-mingled with or replaced by repaired/reconditioned commercial parts from any other sources or fleets.

NOTE: Due to the substantial cost of life limited components the remanufacture CLINs will be set forth in a way to establish separate pricing for those unexpected and rarely replaced items on an “as needed” basis. The parts included at this time are the Stage 1 Blades, Stage 1 Disk, Stage 2 Disk, Stage 3 Disk and Stage 4 Disk. Should the replacement of these items be required, the Contractor will email the Contracting Officer, the PMS and the Navy Logistician prior to performing any work. The Contracting Officer will provide the Contractor approval/non-approval to complete the requested action.

1.20 FAA Form 8130-3: The Contractor shall provide a completed FAA Form 8130-3, Airworthiness Approval Tag and/or Certificate of Conformance, with each assembly or component part that has been remanufactured with the intent of approval for returning these assemblies or component parts. In item 13 (remarks), list the status of each of the CFM56-2A Service Bulletins identified in this SOW. (Example:

CFM56-2A, SB 72-338 complied with or CFM56-2A, SB 727-338 not required).

1.21 Delivery Quality: The contractor shall ensure that materials, parts and accessories used in remanufactured components are restored to a like new condition.

1.22 Quality System and Quality Assurance Plan: The Contractor shall maintain a system that adheres to the requirements of International Standard Organization (ISO) 9001.2000/ANSI/ASQC Q92 or AS9100, Quality Systems Model for Quality Assurance in Design/Development, Production, Installation, and Servicing and supplement requirements imposed by this contract. The Contractor shall develop and implement procedures to properly maintain measuring and test equipment IAW ANSI/NCSL Z540-1.

The quality system will include a clear and complete set of work documents for all maintenance required by this contract. The Contractor’s quality program shall be designed to promptly detect and correct conditions adverse to quality.

1.23 Deficiency Report (DR) Investigation: At the Government’s request, the Contractor shall investigate and submit findings to include root causes and a corrective action against all deficiency reports submitted to the Contractor for items remanufactured by this contact which are reported to be defective.

Each DR will be processed IAW Technical Order (T.O.) 00-35D-54, USAF Material Deficiency Reporting System, in a timely manner to meet suspense dates assigned by the action agency. Reference

CDRL A004.

1.24 Condemnation of Assets: Condemnation of F108–200 Module 13/15 components that are classified as high-cost (all LLP components plus the turbine frame and turbine case) that do not meet inspection and/or remanufacture limits, shall be coordinated with Navy engineering prior to actual condemnation. All high-cost components that receive approval for condemnation as well as all other lower-cost components shall be condemned at the contractor’s facility. The contractor shall provide the government quantities by P/N, NSN and S/N of condemned F108-200 13/15s and annotate on Contract Depot Maintenance (CDM) Production Report CDRL A002 DD Form 1423.

1.24.1 Condemned Asset Reporting: Condemned F108-200 Module 13/15 component parts shall be reported via CDRLs Form 413, Monthly Production Report and Commercial Asset Visibility for Air Force (CAV AF). Condemnations shall be reported to 421 SCMS/GUMBA, Air Force Global Logistics Support Center (AFGLSC) to establish usage rates and cost planning.

1.25 Packaging and Handling: The Contractor shall properly package the F108-200 Module 13/15 IAW Air Force Material Command (AFMC) Form 158, Packaging Requirements. The Contractor shall place a serviceable tag, Department of Defense (DD) Form 1574 inside the package along with the assembly as well as another completed DD Form 1574 to the outside of the package.

In addition, all marking and labeling of unit and shipping containers shall be IAW Mil-STD-12R, Department of Defense Standard Practice, Military Marking for Shipment and Storage. Use additional guidance for preparation and shipment IAW T.O. 00-20-1, 00-20-3, MIL-STD-2073-1, MIL-STD-129, AFPAM 24-237 and AFMAN 24-206. This contract does not allow for commercial packaging.

1.26 Preservation: The contractor shall not destroy reusable shipping containers, and will reuse them for return shipment. In the event that a shipping container is no longer usable, the contractor will contact the PCO for disposition instructions. Units shall be packed IAW with T.O. 00-85B-3.

1.27 Item Unique Identification (IUID): The contractor shall follow the latest DoD instructions to install IUID compliant marks. TOs and drawings will be complied with for any component where direction is currently called out in the TO or drawings. Unless otherwise directed, the following Number Structure will be used as the IUID, in the order specified, in accordance with UII Construct #2 specified in MIL-STD-130N Table IV “UII construct business rules and supplemental data”. This number shall be incorporated into the box label, affixed or attached to the exterior of the item packaging, and shall not be affixed or attached to the part itself.

Issuing Agency Code (IAC), Enterprise Identifier (CAGE Code, DUNs number or DODAAC), Original Part Number and Serial Number.

1.28 Shipping and Transportation: Contractor shall meet the delivery schedule as outlined in the contract. The contractor shall ship or transport applicable assets as appropriate in order to have the assets available to support the customer’s operational requirements and IAW the contract. The contractor shall not destroy reusable shipping containers and will reuse them for return shipment.

1.29 Reporting: The Contractor shall meet the delivery schedule of up to 1 F108-200 Mod 13/15’s every 60 days after receipt of asset(s). Contractor shall provide completed FAA Form 8130-3 (Airworthiness Approval Tag) and/or Certificate of Conformance documentation with each F108-200 Module 13/15 and its component parts that have been remanufactured with the intent of returning these assemblies or component parts to like new condition. This documentation shall have part number, serial number, work accomplished, Service Bulletins complied with on serviceable tag, DD Form 1574. The Contractor shall ensure that all reporting as specified under the following CDRLs is accomplished:

A001: Commercial Asset Visibility Air Force (CAVAF) End Item Reporting A002: Contract Depot Maintenance (CDM) Production Report A003: Comprehensive Engine Management System (CEMS) Reporting A004: Deficiency Report A005: Shipping and Packaging Discrepancy Report (Supply Discrepancy Report (SDR)) A006: Government Property Inventory Report

A001: CAVAF End Item Reporting CDRL – Contractor shall input the data IAW CAV AF and shall not be waived. For CAVAF reporting, the Contractor shall submit Discrepancy Reports (SDRs) when required and IAW CDRL DD Form 1423-1and SOW 1.30.4.

A002: Contract Depot Maintenance (CDM) Production Report CDRL – Data IAW the CDM report shall not be waived. The report format Source: https://assist.dla.mil – Downloaded: 2016- 04—12T17:42Z (sample form attached to CDRL). Data totals shall be as of the end of each month. Contractor’s format with the same data elements as found on the CDM report may be accepted if approved through the PCO and IAW CDRL DD Form 1423-1.

A003: CEMS Reporting CDRL – Each Serial Number F108-200 Module 13/15 assembly is loaded into Comprehensive Engine Management System (CEMS) system and all part number changes must have documentation accomplished. The point of contact for verification of part numbers and serial numbers for the Navy NSN: 2840-01-484-3913PN (CII: HG108E0/HG108G0) is Steven Gastineau, Equipment Specialist, (405) 734-494, AFLCMC/GKGBAA email: steven.gastineau@us.af.mil

A004: Deficiency Reporting (DR) CDRL – The Deficiency Reporting (DR) is initiated on the occurrence when deficient government assets are received by the contractor. Contractor shall refer to T.O. 00-35D-54. Contractor shall process Deficiency Reports when required IAW paragraph

1.22 of this SOW.

A005: Shipping and Packaging Discrepancy Report (Supply Discrepancy Report (SDR)) CDRL –

This report enables the contractor to notify the government when freight contents do not agree https://assist.dla.mil/ with shipping documents and IAW CDRL DD Form 1423-1. In addition, the contractor shall submit Supply Discrepancy Reports (SDRs) when required IAW SOW. Contractor shall process SDRs when required IAW paragraph 1.22 and 1.30.4 of this SOW.

A006: Government Property Inventory Report CDRL – This shall not be waived. This report enables the contractor to a 100% inventory listing of Government Property (i.e., both Government Furnished Property (GFP) and Contractor Acquired Property (CAP)) in the contractor’s possession (to include subcontractors) by contract IAW CDRL 1423-1.

1.30 Contractor Manpower Reporting: Contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the United State Air Force via electronic Contractor Manpower Reporting Application (eCMRA) a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

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 CMRA help desk.

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.

User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for government personnel and contractors are available at the Army CMRA link at http://www.ecmra.mil.

1.31 Document Storage: All records and reports outlined in this SOW shall be prepared for each part and a copy kept on file by the Contractor for five (5) years. The Government Technical Representative reserves the right to request and view any records at any time.

1.32 Contractor Identification to Government Employees: 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."

1.33 Mission Essential Services: N/A

http://www.ecmra.mil/ http://www.ecmra.mil/

SECTION II

2.0 GOVERNMENT PROPERTY

2.1 Government Furnished Material (GFM): NONE. All parts and components required to accomplish the intent of the CMM, SOW or SBs shall be contractor furnished material. Contractor furnished material and parts used for replacement shall be parts specified in CMM 75-21-30 Illustrated Parts List (IPL), SBs or as written approval from the AFLCMC/LPSAB and/or AFLCMC/LPSBAA in writing through the PCO.

2.2 Government Furnished Property (GFP): All items to be remanufactured will be shipped to the contractor.

Enclosure 1

3.0 STATEMENT OF WORK

SOW Number: E6-PN-318-A10

Subject: HPT Rear Turbine Frame Cleaning and NDI Inspection

WUC: 27631F0

References: A) CFM Engine Shop Manual B) 79-007 76PMXG Cleaning/Blasting Process C) 97-003 76PMXG NDI Process Order D) 2J-F108-2-2-70-21-41 E) 2J-F108-2-2, Task 70-32-21-230-10

Cancellation: None

Background

1. This Rear Turbine Frame (RTF) NDI is required because the Navy CFM56-2A fleet has found 3 cracked RTFs with cracked struts and circumferential case cracks. This cleaning and inspection process at OC/ALC was prototyped with Navy Propulsion Engineer, OC/ALC Planner and OC/ALC Chemical Cleaning process Engineer involved with the effort.

2. This SOW is written assuming the F108-200 13/15 Module will be removed from the engine and the front engine assembly shop will send the RTF out for inspection. This process will be accomplished to all Navy engines when F108-200 Module 13/15 is removed for engine repair.

Detailed Instructions

1. Remove RTF/Sump Assembly from LPT Rotor Assembly (Module 13) IAW CFM56-2A Engine Shop Manual (ESM).

2. Remove the #5 Bearing, #5 Bearing Support, Forward Sump Assembly, the fairing from the struts and the asbestos lined tube brackets IAW CFM56-2A ESM. Hold these parts to install on frame upon return from inspection.

3. Clean RTF/Sump Assembly IAW F108-2-2-70-21-41 (Process A).

4. Pressure wash (HCP1) RTF/Sump Assembly and insure all tubes are rinsed out.

5. Manually flush all tubes and cavities.

6. Bake part at 275° F to remove moisture from internal cavities.

7. Prepare part for NDI inspection. Cover sump cavity and tubes with plastic prior to NDI to prevent as much NDI penetrant as possible form getting into internal cavities and passages.

8. FPI RTF IAW 2J-F108-2-2 Task 70-32-21-230-10 (Level 2 Sensitivity). Although all of turbine frame is to be inspected (except surfaces internal to the sump), areas of most interest are the struts near the weld seams and the outer case with in approximately ½ inch AFT of the FWD flange. No cracks are allowed.

9. Pressure wash (HPC1) RTF Assembly and insure all tubes are rinsed out.

10. Bake part at 275° F to remove moisture from internal cavities.

APPENDIX A

ACRONYMS

AF Air Force AFLCMC Air Force Life Cycle Management Center AFMC Air Force Materiel Command AFSC Air Force Sustainment Center CAVAF Commercial Asset Visibility Air Force CEMS Comprehensive Engine Management System CDRL Contract Data Requirements List CFMI CFM International CII Configured Item Identifier CMM Commercial Maintenance Manual CPP Counterfeit Prevention Plan DD Department of Defense DER Designated Engineering Representative DCMA Defense Contract Management Agency DR Deficiency Report FAA Federal Aviation Administration FAR Federal Acquisition Regulation IAW In Accordance With ISO International Standards Organization IUID Item Unique Identification LPP Life Limited Parts LPT Low Pressure Turbine NSN National Stock Number PCO Procurement Contracting Officer PCARSS Plant Clearance Automated Reutilization Screening System P/N Part Number SB Service Bulletin SCMS Supply Chain Management Squadron SDR Supply Discrepancy Report S/N Serial Number SOW Statement of Work SRAN Stock Record Account Number TO Technical Order USAF United States Air Force

APPENXIX B

CAVAF REPORTING REQUIREMENTS

CAVAF Reporting Requirements, v2, September 2018

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

Contractors are responsible for ensuring current User Guides are utilized by their CAV AF reporters.

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

CAVAF FAMILIARIZATION TRAINING:

1. Familiarization training for CAV AF reporting will be requested by the contractor via the applicable ICP CAV AF system administrator (SA). For assistance, guidance or questions to specific contract transactions reporting requirements may be addressed to the CAV AF contract monitor (CM). ICP CAV AF (SA and/or CM) points of contact (See Contractor Responsibility Item #4).

CONTRACTOR RESPONSIBILITY:

1. Contractor CAV AF reporting requirements shall be accomplished daily and/or within one (1) business day of a maintenance action occurrence IAW the applicable CAV AF CDRL and CAV AF system, version

8.0.1 or higher. Accurate and timely reporting of maintenance transactions into CAV AF is critical to the management of repair/remanufacture requirements and the management of world-wide asset distribution. Contractor shall ensure asset record in CAV AF is an accurate reflection of physical assets on hand at all times. (NOTE: A valid PKI is required prior to accomplishing # 2 and #3 of contractor responsibilities)

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

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

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

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

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

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

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

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

c. Product Functionality Caution: To meet technical functionality requirements, this awareness product was developed to function with Windows operating systems (Window 7, VISTA, and XP), when configured correctly) using either the Internet Explorer (IE) or Firefox browsers. Users employing other operating systems or browser may experience difficulties and may not be able to complete the training or print the certificate of completion.

The Cyber Awareness Challenge course completion is a contractual requirement and the contractor must comply.

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

a. Tinker AFB, OK, call (405) 739-3229, or send email request to:

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

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

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

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

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

9. All NSNs identified as Nuclear Weapon Related Materiel (NWRM) shall require contractor CAV AF reporting for production management, to track and report NWRM end items in remanufacture with Serial Number identification within one (1) business day for asset visibility and serial number tracking. When receipted, Contractor’s reporter shall capture each NWRM asset’s Serial Number when reparable is received. Contractors shall follow all NWRM management requirements outlined in AFI 20-110, NWRM Management, to include, but not limited to packaging, marking, labeling, storage, transportation and receipt of all NWRM assets, with emphasis on Positive Inventory Control (PIC) and records management by the contractor and government to assure compliance. The successful application of these procedures requires the full cooperation of all personnel associated with the storage, shipping, transshipping and receiving of all NWRM assets.

SPECIFIC CAVAF CONTRACTOR TRANSACTIONAL REPORTING REQUIREMENTS:

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

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

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

b. Inventory Control Point Items – are identified as assets stored at contractor facility and are not repair/remanufacture end items or discrepancies items. Movement of assets from “Not-on-Contract” category shall be resolved using reversals of individual record control document numbers (RCDN) or may be accomplished utilizing a ‘bulk’ shipment action of RCDN.

NOTE: Contractor is responsible for all “Not-on-Contract” assets ensuring physical asset balances are reflected and CAV AF reporting actions occur within one (1) business day of occurrence.

2. CAV AF receipt or reporting actions will not be utilized for quality deficiency report (QDR) items, as there is a separate process and tracking mechanism for them.

3. All Contract Line Item Number (CLIN) assets shall be receipted in CAV AF under Receipt Type: On Contract (F). CAV AF generates an RCDN for each unit receipted and allows the reporter to assign a reference or serialization number for tracking purposes. Where no reference or serialization numbers are utilized, the oldest RCDNs (listed first) shall always be processed first. Any reversal actions shall be accomplished using the last RCDNs processed.

4. The “Complete Date” entered into CAV AF cannot be dated prior to the DD250 date entered in the same screen. Contractor will validate that the DD250 shipment number and date entered into CAVAF are accurate. This requirement is also applicable to Condition Code H (Condemned) only when specifically directed by the contract.

5. Proper usage of DD Form 1348-1A, Issue Release/Receipt Document in relation to CAV AF reporting requirements.

a. Receipt Actions: Contractor’s reporter will use government issued shipment document numbers for CAV AF end item receipt transaction reporting only in the absence of missing DD Form 1348-1A or shipment document number. Contractors are not authorized to generate pseudo shipment document numbers for receipt transactions because this creates disconnects in shipment tracking within government inventory systems.

NOTE: If the DD Form 1348-1A is missing or no shipment document number is available, contractors are to immediately contact Production Management Specialist (PMS), who will acquire government issued shipment document number from the Inventory Management Specialist (IMS).

b. Shipping Actions: DD Form 1348-1A shall be used as the shipping document for shipment transactions of all end items. A DD Form 1348-1A is also applicable to all Consolidated Serviceable Inventory/Consolidated Reparable Inventory (CSI/CRI) assets regardless of tracking or reporting purposes. A Material Inspection and Receiving Report, DD Form 250 or Requisition and Invoice/Shipping Document, DD Form 1149 are not authorized as a shipment document, and shall not accompany any material shipments on repair/remanufacture contracts. CAVAF provides a DD Form 1348-1A in a Portable Document Format (PDF). DD Form 1348-1A shipping documents will be prepared for each NSN shipment from contractor’s facility, regardless of destination. The entire form, complete with bar coding, will be printed on a laser printer as specified under technical considerations. It is recommended the PDF be saved at the contractor’s facility prior to printing (note: The DD1348-1A forms are not saved/stored in CAV AF and cannot be reproduced by the system). The Contractor shall print three copies as required for shipping. Place one copy on the outside of the shipment container, one copy inside the shipment container, and retain the third copy for the contractor’s records. For end item shipments the DD Form 1348-1A shipment document number shall be comprised as one of the following actions:

i. Back to Depot Shipments:

(1) For a “single” unit NSN shipment, the default shipment document number will be the CAV

AF record control document number (RCDN) of item being shipped.

(2) For “multiple” quantity shipments, it is recommended the CAV AF RCDN of the lead item of the shipment be used as the shipment document number.

ii. Amended Shipping Instructions (ASI): Are used to divert material that is due-in from a contractor to a requisitioner. Government disposition instructions will provide a shipment document number to the contractor to be utilized for CAV AF shipment transaction reporting and the DD Form 1348-1A.

c. In the event CAV AF system is inoperable or is on a scheduled downtime:

i. The DD Form 1348-1A shall be manually completed and generated (printed) by contractor, using the AFPUBS website.

ii. When CAV AF is again operational, the contractor shall resume with transactional reporting actions in a timely and accurate manner, including completing a DD Form 1348-1A (printing not required if manual DD1348-1A PDF file utilized) and the shipment process in CAV AF.

6. Upon contract expiration and/or becoming production complete, the contractor will complete a 100% physical inventory inspection. Any assets remaining at the facility within 30-days must be noted in an email request to the contracting officer (CO) and PMS for disposition instructions by the government. If none is provided, assets are to be returned to the depot and reported within CAV AF, shipping to the following addresses according to each national stock number (NSN) inventory management location by source of supply (SOS) code:

a. FHZ – Tinker AFB, the ship for disposition address to SW3211:

TYPE/CODE: A SW3211

DEF DISTRIBUTION DEPOT OF OKLAHOMA

CEN REC 3301 F AVE

BLDG 506, DR 22

TINKER AFB, OK, 73145-8000

7. Systemic data problems created by contractor’s failure to report data accurately or in a timely manner are subject to immediate Program Management Review (PMR). Examples of documented system data problems include but are not limited to:

a. Timely reporting means compliance with 24 hour requirement for all contractor CAV AF reporting of maintenance transactions. Actual date information is required for all reporting actions.

Contractors are not authorized to report all receipt, induction, complete and ship transactions the same day to ‘catch-up’ due to periodic reporting. This affects government inventory management systems and balances creating D035 Stock Control Supply System (SCSS) controlled exceptions (associated with same day reporting issue).

b. Contractors not using government issued DD Form 1348-1A document numbers on CAV AF contractor reporting on end item receipt transactions. This creates a data variance disconnect with government inventory D035 Stock Control System (SCS). Contractors are required to use DD Form 1348-1A document numbers for end item receipt transactions.

NOTE: If the DD Form 1348-1A is missing or no shipment document number is available, contractors are to immediately contact Production Management Specialist (PMS) and acquire government issued shipment document number from Inventory Management Specialist (IMS).

c. Overages and shortages, for items which are part of this contract shall be reported by the contractor into CAV AF as received “On-Contract” with actual quantities received. Any items which are not part of this contract shall be receipted as “Not-on-Contract”, which represents misdirected or misidentified assets.

8. RCDNs are systemically generated in CAV AF and should not be duplicated or fabricated with a suffix for shipment document numbers. RCDN is comprised of the CAV AF Contractors DoDAAC, the Julian date the RCDN was produced, and a four digit serial number (begins with 0001 each day). This affects government inventory management systems D035 SCSS controlled exceptions.

DISCREPANCIES INCIDENT TO SHIPMENT:

1. There are transportation and item discrepancies, each having different reporting requirements. Detailed information for each report is in the pertinent service publications.

2. Discrepancies incident to shipment include misidentified items, variations in quantity, non-requisitioned items, lost or damaged parcel post, and items in dubious condition. These discrepancies shall be reported and resolved using the DoD web-based application WebSDR link is https://www2.transactionservices.dla.mil/websdr/home.asp This system of reporting a Supply Discrepancy Report (SDR), formerly called Report of Discrepancy (ROD), has been developed in compliance with DoD regulations 4140.1-Vol 6 and DLM 4000.25, Vol 2, Ch. 17 which requires automated SDR processing. In those situations where the SDR initiator is unable to gain access to the AF WebSDR, continued use of manual forms is permitted. A copy of the form will be forwarded through the CAO and Quality Assurance (QA) activity for corrective action.

3. Transportation discrepancies and item transaction discrepancies shall be coordinated with the DCMA Property Administrator and Administrative Contracting Officer (ACO) immediately upon discovery for corrective action…