Encl 2 Statement of Work.pdf

Statement of Work (SOW) For

Foreign Military Sales (FMS) Partner Country F100-PW-220/-220E/-229/-229EEP Engine Modules

Contract Number:

PR Number: Tinker-

FD2030-23-30034

Date: 03 AUG 2023 Version 7

Preparing Organization:

AFLCMC/LPSID

Tinker AFB, OK 73145-3030

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

Dissemination of this document is controlled under DoD Directive 5230.25

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TABLE OF CONTENTS Page

SECTION I

1.2 DATA

1.3 SECURITY

1.4 QUALITY

1.5 DELIVERY SCHEDULE

1.6 CONDEMNATION & REMANUFACTURE

1.7 HANDLING

1.8 INVENTORY

1.9 GOVERNMENT PROPERTY

1.10 PRESERVATION

1.11 RECEIPT/HANDLING OF PQDR EXHIBITS

SECTION II

2 APPLICABLE DOCUMENTS

2.1 APPLICABLE TECHNICAL ORDERS

2.2 APPLICABLE DIRECTIVES

2.3 APPLICABLE DOCUMENTS

SECTION III

3 WORK REQUIREMENTS

3.1 GENERAL WORK REQUIREMENTS

3.2 SPECIFIC WORK REQUIREMENTS

APPENDIX 1

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 MODULES APPLICABLE TO THIS REQUIREMENT AND APPLICABLE T.O.S

(TECHNICAL ORDERS)

APPENDIX 5

A5.1 PERFORMANCE METRICS PLAN

Metrics shall be monitored by DLA and USAF (or collectively as “Government”) and the

Contractor throughout the life of the contract. Performance will be reported by the Contractor on a monthly cadence and validated by USAF

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SECTION I

DESCRIPTION OF REMANUFACTURE

1 SCOPE: This Statement of Work (SOW) establishes the minimum work requirements to operate F100-PW-220/-220E/-229/-229EEP Modules to next scheduled depot interval, as listed in Appendix Four, by National Stock Number (NSN) and Part Number (P/N), in support of Foreign Military Sales (FMS) partner countries, and USAF modules on a contingency basis.

Modules received by the Contractor, as set forth in this contract shall be remanufactured in accordance with (IAW) the requirements in this SOW and the contract. The contractor shall provide management of the module induction plan and schedule to meet customer needs based on LPSI Program Office guidance and requirements in the SOW and the contract. This is an FMS requirement with the option to induct USAF modules (priced transactionally as required).

This requirement will include the use of a Regional Depot Network (RDN) consisting of depot facilities in Contiguous United States (CONUS) and Outside Contiguous United States (OCONUS), with European Command (EUCOM) designated as the first depot location within OCONUS. Throughout this document, the phrase “end item” is defined as an engine module.

1.1 REGIONAL DEPOT NETWORK

1.1.1 The contractor shall operate an RDN through coordination and administration of activities, task, and resources for two or more remanufacture depot facilities to efficiently meet customer demand. This will include supervision and training of staff for overseeing core operations within the RDN to optimize output. Requirements as spelled out in this SOW will encompass all module data from each depot with annotation of facility A (CONUS location) or B (OCONUS location) clearly identified. Prime Contractor Management maintains compliance oversight of all policy and procedures listed in this SOW.

1.1.1.1 Sub-contracted OCONUS Phased-in Minimum Induction Requirement

1.1.1.1.1 Year Four (Option 1): (1) Scheduled 220 Core; (1) 220 Fan; (1) 220 LPT.

1.1.1.1.2 Year Five (Option 1): (2) Scheduled 220 Core; (2) 220 Fan; (2) 220 LPT.

1.1.1.1.3 Year Six (Option 1): (2) Scheduled 220 Core; (2) 220 Fan; (2) 220 LPT;

(1) 229 Core; (1) 229 Fan; (1) 229 LPT.

1.1.1.1.4 Year Seven-Ten (Option 2): TBD before Option 2 awards utilizing historical data from contract basic and option 1 period of performance usage.

1.1.1.2 Sub-contracted OCONUS Induction rate subject for increase based off provided data

FD2030-23-30034 Page 4 of 36 as spelled out in SOW Section 1.1.1.4 Data to meet customer demand.

1.1.1.3 Sub-contracted OCONUS Induction Decrease

1.1.1.3.1 Request for a decrease in the contractual monthly induction rate requires the submission of justification to LPSI Program Office on memo with official letter head from prime contractor.

1.1.1.4 Sub-contracted OCONUS Priority Modules

1.1.1.4.1 The LPSID Program Office retains the ability to submit priority placement of modules during induction planning. Request will list Country, module serial number, and if module is planned for Schedule/Unscheduled remanufacture.

Priority request will not exceed facility capacity.

1.1.1.4.2 The contractor has 14 calendar days to submit a rebuttal of priority placement modules to the LPSI Program Office. A rebuttal requires justification that discloses details of constraint for consideration.

1.1.1.4.3 Consideration of Total Cost to the Customer

Per the table below, the Contractor must consider the total cost to the customer, along with priority of need, when determining the fleet management of where modules will be inducted into Facility A (CONUS) or Facility B (OCONUS).

Cost of Transportation Remanufacture Cost Value Added TAX (Sipping to CONUS)

CONUS

$ XXX See Appendix X for cost $ XXX

OCONUS

$ XXX

1.2 DATA

1.2.1 Reporting Requirements

1.2.1.1 Contractor employees shall identify themselves as Contractor personnel by introducing themselves or by 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.

1.2.1.2 Product Quality Deficiency Report (PQDR – SF 368): The Contractor shall prepare a PQDR response on all design and quality control (material) deficiencies

FD2030-23-30034 Page 5 of 36 found in accordance with (IAW) the procedures of TO 00-35D-54. Applicable portions of TO 00-35D-54 relative to quality defects shall 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 T.O. 2J-F100-13-1, WP 600 00. (CDRL A001)

1.2.1.3 Technical Manual (TM) Change Recommendation and Reply (AFTO Form 22):

Contractor shall prepare an AFTO 22 for Recommended Changes (RC) 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 an AFTO 22 IAW TO 00-5-1 and submit one copy of the RC to Cognizant Engineering Authority (CEA). 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 procedures in TO’s, or desired changes to T.O. data using the AFTO Form 22. (CDRL A002)

FD2030-23-30034 Page 6 of 36

1.2.1.4 Teardown Deficiency Report (TDR): CAT I and II material deficiency report (MDR) Teardown Deficiency Report (TDR) will be authorized using a Statement of Work (SOW) through the PCO. SOW shall be used for pricing request from the Contractor and response shall be sent to the PCO within 7 business days from discovery of material deficiency. CAT I and CAT II MDRs shall be inducted for TDR upon receipt of exhibit and approved funding. Using TO 00-35D-54 as a reference, final CAT I MDR TDRs shall be submitted to the PCO NLT 45 working days after exhibit induction and authorization. Final CAT II MDR TDRs shall be submitted to the PCO NLT 90 calendar days after exhibit induction and authorization. The Contractor shall investigate exhibit to disclose failure mode(s).

If failed components require additional lab analysis, Contractor may use independent agencies for analytical evaluation. Contractor may request support from Cognizant Engineering Authority (CEA) for additional guidance and disposition via PCO. TDR may be written in Contractor format. The Contractor shall input the TDR to JDRS. (CDRL A003)

1.2.1.5 Maintenance Reporting: Contractor shall enter significant maintenance actions during remanufacture on AFTO Form 95 or Contractor equivalent, in accordance with Section 9 Technical Order (T.O.) 00-20-01, “Significant Historical Data”.

Copy of AFTO Form 95 or Contractor equivalent shall be packaged with each part.

(CDRL A004)

1.2.1.6 Supply Discrepancy Report (SDR)/Report of Discrepancy (ROD): Contractor shall submit a SF-364 (Standard Form) IAW T.O. 00-35D-54 upon discovery of discrepancies for items of supply received for overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damage or improperly packaged shipment. (CDRL A005)

1.2.1.7 The Contractor shall submit a Government Property Physical Inventory Count or

Custodial Balance Report: The Contractor shall submit a Government Property Physical Inventory Count or Custodial Balance Report to the LPSI Program Office bi-annually. This report enables the Government to track each country's bond room and Material Review Board holding area material at the contractor facility. Identify all assets stored in the bondroom. Include NSN, PN, SN, Noun, Qty, Unit of Issue, Dae Received, and Condition Code. (CDRL A006)

1.2.2 Other Records, Forms and Reports

1.2.2.1 Engine Management System/Engine Management Maintenance System

Reporting: For FMS assets maintained in the US by United States Government (USG) personnel, the status of all serialized life limited parts must be known at all times. The Contractor shall report this status to the appropriate engine management system: Comprehensive Engine Management System (CEMS) or Engine Management and Tracking System (EMATS) or Jet Engine Maintenance Management Application (JEMMA) as deemed appropriate through PCO IAW T.O. 00-25-254-1. The Contractor shall direct any questions regarding the reporting requirements through the ACO. (CDRL A007)

FD2030-23-30034 Page 7 of 36

1.2.2.2 Contractor shall include completed DD Form 1574 Serviceable Tags as required

IAW MIL-STD-129P, paragraph 5.2.21.a with completed modules. In addition, a FAR 52.246-15 compliant Certificate of Conformity, CoC, is required at the module level. The Contractor shall retain vendor CoC as part of the module remanufacture records and shall provide to the DCMA QAR for review upon request. The end item CoC shall be sent with the module.

1.2.2.3 Status Report for the Contractor Receipt/Shipment of Material: The Contractor shall prepare and furnish a monthly cumulative status report for all items that have been received for remanufacture Tab 1 will include, but not limited to, applicable country, item part number, national stock number, serial number, nomenclature, date received, document number, date input into work, exhibit line item number, forecast completion date, production gate status, ship date of serviceable asset, turn-around time, each depot capacity, part supportability assessment with constraints. Report is to be furnished in DPAS rating order for CONUS depot.

Tab 2 will reflect same requirement as Tab 1 for OCONUS. Tab 3 the Contractor shall prepare and provide a monthly induction plan and schedule to meet customer needs at the CONUS and OCONUS depot facilities based on LPSI Program Office guidance and requirements in this SOW and contract. This report will include a proposed schedule of inductions for 12 months by module with FMS country of origin. (CDRL A008)

1.2.3 Technical Data

1.2.3.1 The Contractor shall use T.O.’s listed in this specification as the basic directives in accomplishing the remanufacture requirements of the contract.

1.2.3.2 The Contractor shall use T.O. illustrated parts breakdowns (IPB’s) listed in this SOW in the completion of 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 SOW. Part replacement shall be confined to those parts determined to be required to produce a serviceable end item.

1.2.3.3 The Contractor shall adhere to directives and instructions provided throughout this

SOW.

1.2.3.4 Instructions listed in this SOW as “Changes” or “Revisions” to a T.O. represent publication changes to the Technical Order System and the Contractor shall comply with such. The sub-paragraphs contain the location of changes as designated and the deletion, change or addition of technical information to be accomplished.

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

FD2030-23-30034 Page 8 of 36

1.2.3.6 Contractor is not authorized to replace non-condemned reparable parts with new material without PCO approval. When requesting PCO approval, P&W will provide the following information to the PCO; Country, Contract and Delivery Order number, Module Serial Number, Engine TMS, Nomenclature, Part number, New Part Price, Estimated Repair Price, Required Quantity, Historical Scrap Rate, Estimated Repair Availability Date and Additional Remarks. If approved by the PCO, the reparable part shall be documented, tagged and placed in the country’s bond room.

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1.3 SECURITY

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

1.4 QUALITY

1.4.1 ISO Quality Management: Contractor shall have in place and maintain a quality management system in compliance with International Organization for Standardization (ISO) 9001:2015/AS9100 or equivalent quality systems – Model for quality assurance in production, installation, and servicing. The quality system procedures, planning, and other documentation and data that comprise the quality system shall be made available to the Government for review upon request. The Government will, at their discretion, perform any inspections, verifications, and evaluations to ascertain conformance to the ISO 9001:2015/AS9100 requirements and the adequacy of implementing procedures. Contractor is responsible for maintaining its quality management systems and/or registration that complies with the requirements of ISO 9001:2015/AS9100 or equivalent and shall provide the Government access to ISO audits as the Government deems necessary.

1.4.2 Product Audits: The Contractor shall support product audits, at the determination of the

Government on remanufactured components. The Government may select at random such quantities of End Items and/or components therein as may be necessary to determine quality of workmanship and materials.

1.4.3 The Contractor shall investigate, take corrective action if necessary, and reply to user initiated PQDRs as directed by the ACO. This applies to all PQDRs submitted against products remanufactured by the Contractor and/or their subcontractor or vendors.

Sufficient priority shall be given to PQDR investigation to allow corrective action to be accomplished within the timeframe directed by the Procurement Contracting Officer (PCO) in order to meet requirements of T.O. 00-35D-54.

1.4.4 The Contractor shall not deliver defective parts to the Government.

1.5 DELIVERY SCHEDULE

1.5.1 The Contractor shall deliver requirements as specified within individual Delivery

Order schedules.

1.6 CONDEMNATION & REMANUFACTURE

1.6.1 Contractor’s Scrap Procedures: The Contractor shall prepare 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 T.O. 00-25-113, 00-25-113-F100-ENG and FAR 45.6 titled

FD2030-23-30034 Page 10 of 36

“Reporting, Reutilization, and Disposal”.

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

1.6.2.1 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.

1.6.2.2 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 remanufacture 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.

1.6.2.3 For modules maintained by USG and tracked in CEMS, the serial number and part number of any life-limited item, which is condemned, must be transmitted to F100 Engineering Source Authority listed in T.O. 2J-F100-13-1 or T.O. 2J-F100-53-1, WP 600 00.

1.6.3 Remanufacture: End Items determined to be beyond economical repair shall not be remanufactured by the Contractor unless authorized in writing by the ACO. All work will stop for authorization to proceed from the ACO except for parts and components in work at repair vendors which may continue to be processed.

1.6.4 Serviceable Military Assets (SMA): The contractor may propose the use of Serviceable Military Assets (SMA) on a case-by-case basis per module. SMA shall not be utilized until negotiations are complete. Repairable Parts removed and replaced by a PCO Approved SMA part will be placed in the country bond room until repaired asset is needed on another module belonging to the same country.

1.6.4.1 SMA proposals shall utilize the following methodology:

1.6.4.1.1 XX% of current MESP list prices, part must have 50% total Life remaining to be eligible for XX% of current MESP list prices. Below 50% Life remaining pricing must be reviewed AFLCMC/LPSIA Customer Representative for applicability.

1.6.4.1.2 For SMA not on the MESP, the contractor shall submit the SMA proposal using the unpriced Material methodology defined in the contract for the base price and part must have 50% total Life remaining to be eligible for XX% of current MESP list prices. Below 50% Life remaining pricing must be reviewed AFLCMC/LPSIA Customer Representative for applicability.

1.7 HANDLING

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1.7.1 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. The receipt and status of all serialized components or accessories, which are tracked in CEMS must be reported IAW Para 1.2.2.1 of the SOW.

1.8 INVENTORY

1.8.1 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.

1.9 GOVERNMENT PROPERTY

1.9.1 Contractor shall furnish all material, support equipment, tools, test equipment and services. Government Furnished Material shall be identified as an attachment to the contract. The PCO will be notified of any parts received directly from the countries.

1.10 PRESERVATION

1.10.1 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.

1.10.2 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. Best Estimated Quantities indicate that it would not be practicable to co-mingle module components.

1.11 RECEIPT/HANDLING OF PQDR EXHIBITS

1.11.1 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 remanufacture 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 T.O. 2J-F100- 13-1 or T.O. 2J-F100-53-1, WP 600 00.

FD2030-23-30034 Page 12 of 36

SECTION II

2 APPLICABLE DOCUMENTS

2.1 APPLICABLE TECHNICAL ORDERS

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

TECH ORDER BASIC CG CHANGE

NUMBER DATE NO DATE SHORT TITLE

00-5-1 01 JAN 14 0 25 JAN 21 AF TECH ORDER SYSTEM

00-5-2 01 APR 01 0 TECH ORDER DIST SYSTEM

00-5-15-WA-1 15 MAY 14 0 31 MAR 22 TIME COMPLIANCE TECH

ORDER SYSTEM

00-20-1 15 JUN 11 21 JUN 21 PREV MAINT PROG

00-20-2 01 NOV 12 22 JUL 21 MAINT DATA COLLECTION

SYS

00-20-3 01 NOV 08 1 17 DEC 21 MAINT PROC OF

REPARABLE PROP

00-25-113 30 APR 95 0 15 SEP 13 CONSERVATION AND

SEGREGATION OF

CRITICAL ALLOYS AND

PRECIOUS METAL

BEARING AND SCRAP

00-25-113-F100-

ENG

1 AUG 88 48 01 MAY 19 CRITICAL ALLOY AND

PRECIOUS METAL PARTS

LIST

00-25-254-1 15 AUG 01 12 01 FEB 22 SYS MANUAL

COMPREHENSIVE ENGINE

MGT. SYS. (CEMS)

00-35D-54 1 JUL 04 15 APR 21 MATERIAL DEF REPORT &

INVEST SYSTEM

FD2030-23-30034 Page 13 of 36

2-1-111 15 FEB 90 58 01 JUN 22 STAND MAINT

PROCEDURES

2J-F100-9 1 NOV 95 52 01 AUG 22 NONDESTRUCTIVE

INSPECTION

2J-F100-94 1 MAY 92 53 01 AUG 22 I.P.B. SUPPORT

EQUIPMENT

2J-F100-13-1 1 FEB 07 10 01 AUG 22 MAINT INSTR-DEPOT

2J-F100-13-2 1 FEB 07 10 01 AUG 22 MAINT INSTR – DEPOT

OCM

2J-F100-13-3 1 FEB 07 7 01 AUG 21 SUPPORT EQPT- NUM TOOL

2J-F100-13-5 1 FEB 07 10 01 AUG 21 MAINT INSTR-DEPOT

ENGINE

2J-F100-13-6 1 FEB 07 10 01 JUN 22 FAN 220/E MODULES

2J-F100-13-7 1 FEB 07 10 01 AUG 22 CORE 220/E MODULES

2J-F100-13-8 1 FEB 07 01 AUG 21 REAR COMP DRIVE

TURBINE 220/E

2J-F100-13-8-1 1 FEB 07 6 01 APR 22 REAR COMP DRIVE

TURBINE 220/E

2J-F100-13-9 1 FEB 07 9 01 AUG 22 FAN DRIVE TURB

220/E MODULE

2J-F100-13-11 1 FEB 07 10 01 AUG 22 GEAR BOX 220/E MODULE

2J-F100-24 31 MAR 08 27 01 AUG 21 IPB 220/E ENGINES

2J-F100-54 15 APR 09 7 01 AUG 22 IPB -229 ENGINES

2J-F100-53-1 15 FEB 07 9 01 APR 22 INTRO & GEN INFO -229

ENG

2J-F100-53-2 15 FEB 07 9 01 AUG 22 OCM -229 ENG MODULES

2J-F100-53-3 15 FEB 07 6 01 FEB 22 SPT EQPT & NUM TOOL

LIST -229

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2J-F100-53-4 15 FEB 07 7 01 AUG 22 ENG ACCESS & RIG

PROCEDURES -229

2J-F100-53-5 15 FEB 07 9 01 APR 22 DEPOT MAINT INSTR-229

ENG MODULES

2J-F100-53-6 15 FEB 07 9 01 AUG 22 INLET FAN -229 MODULES

2J-F100-53-7 15 FEB 07 9 01 AUG 22 CORE -229 ENG MODULES

2J-F100-53-8 15 FEB 07 9 01 AUG 22 REAR COMP DRIVE -229

MODULES

2J-F100-53-9 15 FEB 07 9 01 AUG 22 FAN DRIVE TURBINE 229

MODULES

2J-F100-53-11 15 FEB 07 9 01 DEC 21 GEAR BOX 229 MODULES

33B-1-1 15 FEB 14 0 01 JUL 22 NON-DESTRUCTIVE INSP.

METHODS

7J4-2-50-3 01 MAR 14 0 15 MAY 22 OIL PUMP OVERHAUL

35E20-3-1-103 01 MAR 07 0 01 MAR 22 METAL CONTAINERS

35E20-3-33-1 01 MAY 08 0 01 AUG 22 FIBERGLASS CONTAINERS

42B-1-1 13 AUG 12 15 JUN 19 QUAL CONTROL FUEL &

LUBS

42B5-1-2 15 MAY 06 15 JUN 22 USE & HANDLING GAS

CYLINDERS

42C2-1-7 28 FEB 06 01 JAN 20 PROCESS INSTR METAL

TREATMENTS

42E1-1-1 30 JUL 07 15 APR 22 AEROSPACE HOSE ASSY

42E1-1-2 15 DEC 02 ID, USE & DISP HYD PK &

GASKETS

44B-1-15 28 FEB 92 6 28 JUL 18 ANTI-FRICTION BEARINGS

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2.2 APPLICABLE DIRECTIVES

AIR FORCE

INSTRUCTION

CHANGE DATE TITLE

AFI 21-118

02 OCT 03

IMP AERO EQUIP RELIABILITY &

MAINTAINABILITY

MILITARY STANDARDS CHANGE DATE TITLE

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

SHIPMENT AND STORAGE

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

PROP.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO – 9001:2015 15 SEP 15 QUALITY MANAGEMENT

SYSTEMS – REQUIREMENTS –

FIFTH EDITION

2.3 APPLICABLE DOCUMENTS

2.3.1 LPF-QAR-001: “GENERAL QUALITY ASSURANCE DOCUMENTS FOR F100

ENGINE FC/DC BREAKOUT COMPONENTS”

2.3.2 LPF-QAR-002: “CHANGE PROCEDURES FOR PROCESS ORDERS”

2.3.3 LPF-QAR-004: “LPFR QUALITY ASSURANCE REQUIREMENTS FOR F100

ENGINE COMPONENTS”

2.3.4 LPF-QAR-006: “LPFR QUALITY ASSURANCE REQUIREMENTS FOR

PRODUCT VERIFICATION AUDIT (PVA) TEST PLANS AND REPORTS

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2.3.5 LPF-QPR-007: “LPFR QUALITY PLAN REQUIREMENTS FOR PLASMA

SPRAYED COATINGS”

2.3.6 LPF-QPR-016: “LPFR QUALITY PLAN REQUIREMENTS FOR DURABILITY

CRITICAL PARTS

2.3.7 LPF-QPR-018: “LPFR QUALITY PLAN REQUIREMENTS FOR

NONDESTRUCTIVE INSPECTION”

2.3.8 LPF-QR-001: “BASIC TECHNICAL DATA REQUIREMENTS FOR FRACTURE

CRITICAL AND DURABILITY CRITICAL PARTS”

2.3.9 LPF-QR-002: “CONDITIONS OF WAIVER FOR FRACTURE CRITICAL AND

DURABILITY CRITICAL PARTS”

2.3.10 EI FOR RQR-1: “GENERIC ENGINEERING INSTRUCTIONS FOR

REMANUFACTURE OF F100 PARTS IN RQR-1”

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SECTION III

3 WORK REQUIREMENTS

3.1 GENERAL WORK REQUIREMENTS

The Contractor shall remanufacture, modify, prepare for storage and ship received reparable End Items, returning them to a serviceable condition capable of operating to the next scheduled depot interval, in accordance with (IAW) the requirements of this SOW and the contract.

3.1.1 The instructions for the remanufacture of items stipulated in this SOW shall be performed IAW the applicable T.O.’s and the below exceptions.

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

3.1.2 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.

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

3.1.4 The Contractor shall rework all reparable parts so that they are capable of meeting the serviceable requirements of this SOW. The Contractor shall notify the PCO for the AFLCMC/LPSIA F100 International Engine Management Program Office Technical Program Manager coordination if a repair is not available to be managed on a case by case basis.

3.1.5 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 SOW.

3.1.6 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 SOW.

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

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

3.1.9 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 metalizers, shall be qualified and certified for operation IAW applicable military specifications when listed in the SOW.

3.1.10 Fit and tolerance limits shall be IAW applicable TO/Contractor’s processes and procedures unless otherwise specified.

3.1.11 Fluids, oil, greases and compounds shall conform to and be used as directed in the applicable T.O. and instructions contained in this SOW.

3.2 SPECIFIC WORK REQUIREMENTS

3.2.1 Receiving

3.2.1.1 The Contractor shall perform receiving inspection and removal of Module from shipping container IAW Technical Orders (TOs) 35E20-3-1-103 and 35E20-3-33-1.

3.2.1.2 The Contractor shall perform inspection, repair and storage of shipping container and attachments/accessories IAW TOs 35E20-3-1-103 and 35E20-3-33-1.

3.2.2 Disassembly

3.2.2.1 Disassemble F100-PW-229 Modules per required work packages in module specific 53 series depot T.O.

3.2.2.2 Disassemble F100-PW-220 Modules per work packages in module specific 13 series depot T.O.

3.2.3 Cleaning

3.2.3.1 F100-PW-229 Modules shall be cleaned IAW work packages in module specific

53 series depot T.O.

3.2.3.2 F100-PW-220 Modules shall be cleaned IAW module specific 13 series depot T.O.

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3.2.3.3 The Contractor shall ensure that cleaning and preserving materials meet the requirements specified in T.O. 2J-F100-13-1, T.O. 2J-F100-13-2, T.O. 2J-F100- 53-1, T.O. 2J-F100-53-2, or T.O. 2-1-111, and that such materials are properly used during application.

3.2.4 Inspection

3.2.4.1 Inspection of F100-PW-229 Modules and assemblies shall be accomplished

IAW module specific 53 series depot T.O.

3.2.4.2 Inspection of F100-PW-220 Modules and assemblies shall be accomplished IAW module specific 13 series depot T.O.

3.2.5 Corrosion Control

3.2.5.1 The corrosion control of F100-PW-220/-229 Modules during remanufacture and storage shall be accomplished IAW T.O. 2-1-111.

3.2.6 Remanufacture

3.2.6.1 Modules - Scheduled

3.2.6.1.1 Remanufacture of F100-PW-229 Module and assemblies returned for scheduled maintenance shall be accomplished IAW module specific 53 series depot T.O in order to perform scheduled depot visit maintenance and Time Compliance Technical Order (TCTO) requirements.

3.2.6.1.2 Remanufacture of F100-PW-220 Module and assemblies returned for scheduled maintenance shall be accomplished IAW module specific 13 series depot T.O in order to perform scheduled depot visit maintenance and Time Compliance Technical Order (TCTO) requirements.

3.2.6.2 Modules - Unscheduled

3.2.6.2.1 The Contractor shall disassemble modules only to the extent necessary to be inducted for unscheduled maintenance IAW applicable model TO 2J-F100-13 or 53 series WP in order to perform required maintenance to restore to the module to a serviceable condition and to comply with any applicable TCTOs.

3.2.6.3 The Contractor shall identify all remanufactured F100-PW-220/-220E/- 229/-

229EEP Modules with the Contractor’s CAGE IAW MIL-STD-130N on the module data plate.

3.2.6.4 Core Modules – Mismatched

3.2.6.4.1 When core modules are received that have high pressure turbine (HPT)

FD2030-23-30034 Page 20 of 36 modules with differing maintenance requirements (i.e. scheduled core, unscheduled HPT), work for each module type will be performed according to the requirements specific to the part as specified in sections 3.2.4.2 and 3.2.6.1.2.

3.2.6.5 Component Remanufacture

3.2.6.5.1 The Contractor shall inspect components IAW applicable TO 2J-F100-13 or

2J-F100-53 series WPs depending on model type.

3.2.7 Installation

3.2.7.1 Not applicable.

3.2.8 Test And Government Acceptance

3.2.8.1 Inspect, test, and check each remanufactured item IAW applicable depot T.O.

3.2.8.2 The Government will accomplish acceptance.

3.2.9 Assembly and Preservation

3.2.9.1 The Contractor shall assemble modules undergoing scheduled or unscheduled depot level support IAW applicable model T.O. 2J-F100-13 or T.O. 2J-F100-53 series WPs before return shipment to customer IAW the Government’s required delivery schedule.

3.2.9.2 Modules will be preserved IAW T.O. 2J-F100-13 or T.O. 2J-F100-53 series manuals.

3.2.10 Shipping

3.2.10.1 The Contractor shall install the module into serviceable module-shipping container for pick up by the designated Freight Forwarder.

3.2.10.2 The Contractor shall provide notification if a non-reparable shipping container is received and will request disposition instructions from ACO/PCO.

3.2.11 Parts Disposition

3.2.11.1 Disposition of condemned parts containing critical alloys and/or precious metals shall be IAW TO 00-25-113, 00-25-113-F100-ENG and DEFARS 245.607, entitled “Scrap” and input the Plant Clearance Automated Reutilization Screening System (PCARSS) in accordance with FAR 45.6.

3.2.11.2 The Contractor shall input serviceable parts removed from the modules that

FD2030-23-30034 Page 21 of 36 cannot be used for module upgrade/remanufacture into PCARSS in accordance with FAR 45.6. If disposition is not received within 90 days, the ACO should be notified.

3.2.11.3 The Contractor shall condemn parts that are beyond tech order limits.

3.2.11.4 The Contractor shall mutilate parts that have been condemned as result of failure to meet serviceability limits, or for other reasons, to the extent necessary to ensure that purchasers of scrap are unable to remanufacture the item for possible resale or reuse IAW Government Demilitarization regulation DFARS 245.7310-1.

3.2.11.5 The Contractor shall ensure that all documents and pertinent to such condemned parts authorized for the transfer to disposal have a certificate to the effect that all required mutilation has been accomplished.

3.2.11.6 The Contractor shall not condemn End Items (ERRC code “T” items) without written approval of the ACO or his/her representative.

3.2.11.7 The Contractor shall dispose of End Items (ERRC code “T” items) determined by the Contractor and verified by the ACO to be beyond economical repair when directed in writing by the PCO.

3.2.11.8 The Contractor shall obtain written PCO approval prior to incorporating a new component in place of a non-condemned reparable component.

3.2.11.9 The Contractor shall ensure that the appropriate engine management system;

CEMS, JEMMA, and EMATS, for tracked components’ historical records reflect the reasons for condemnation and the approving authority IAW TO 00-25-254-1, Chapter 4. Contractor Reporting.

3.2.11.10 Non-conforming configurable hardware shall be held for Contractor engineering evaluation. The Contractor shall use the DoD Request for Variance (RFV) form 1694or contractor equivalent to request AFLCMC/LPSIB disposition instructions for non-conforming hardware.

3.2.12 Product Verification Audit (PVA)

3.2.12.1 Remanufactured items shall be subject to PVA if requested by the Government.

3.2.12.2 To perform PVA, the Contractor shall permit the Government to select at random such quantities of items as may be necessary to determine quality of workmanship and materials.

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

3.2.13 Technical Publication Compliance

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3.2.13.1 Compliance with all T.O.’s, Directives, Government Specifications, Drawings, etc., listed herein is mandatory, unless otherwise specified in this SOW, when:

3.2.13.1.1 They have not been previously accomplished.

3.2.13.1.2 They are pertinent to the end item.

3.2.13.1.3 They prescribe Air Force Policies, use of materials and procedures for remanufacture.

3.2.13.2 Copies of T.O.’s and other Air Force publications required in the performance of work outlined in this SOW 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.

3.2.14 Technical Library Maintenance

3.2.14.1 The Prime Contractor shall maintain all TOs, TMs, TCTOs and other technical directives in an updated and current status IAW TO 00-5-1. If a conflict arises between the requirements of this SOW and the Technical Documents, the Contractor shall notify the PCO.

3.2.14.1.1 Review of Change: The Contractor shall review all updates to the TO’s, TM’s, TCTO’s and other directives within five business days of receipt unless otherwise approved by PCO. Safety of Flight changes shall be reviewed within one day of receipt.

3.2.14.1.2 Cost Impact of Changes: If the Contractor determines the changes will result in remanufacture cost change; the Contractor shall notify the PCO in writing of estimated cost impact within 30 calendar days for non-safety of flight changes and 15 days for safety of flight changes.

3.2.14.1.3 Implementation of Changes: The Contractor shall implement all no cost changes within 10 business days of review. Safety of Flight changes shall be implemented within one business day regardless of cost and notification shall be provided to the PCO that changes have been incorporated and defining any possible schedule impact. Non-safety of flight changes having cost or schedule impact shall not be implemented without PCO direction.

3.2.15 Contractor Billing

3.2.15.1 The Contractor will bill for remanufactured and new components utilizing the

Price List in effect at the time on the module is inducted. If a component is not on the price list, the Contractor will submit a proposal for pricing to the ACO

FD2030-23-30034 Page 23 of 36

IAW methodology specified in the contract or as agreed upon with the ACO.

Final pricing for all module components must be submitted as soon as possible and in no case later than at the time of the module presentation for final acceptance.

3.2.15.2 The Contractor shall not bill for new component parts when components could be remanufactured unless approved by the PCO.

3.2.15.3 The contractor shall provide supporting documentation in their billing package including but not limited to:

3.2.15.3.1 Contractual Start Date: Effective date of delivery order, date of order funding, module receipt date, records receipt date, position of module in the capacity constraint log.

3.2.15.3.2 Contractual Stop Date: signed DD250 date from Quality Acceptance.

3.2.15.3.3

3.2.15.3.4 Hold Days Start Date(s) (if applicable): email(s) with each Additional

Funding Request with correct funding dollar calculations.

3.2.15.3.5 Hold Days Stop Date(s) (if applicable): Effective date of modification or signature date of modification.

FD2030-23-30034 Page 24 of 36

A1.1 ACRONYMS

APPENDIX 1

ACO Administrative Contracting Officer 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 EMATS Engine Management Tracking System ESA Engineering Source Authority FAR Federal Acquisition Regulation GFM Government Furnished Material GFP Government Furnished Property GPA Government Property Administrator IAW In Accordance With IPB Illustrated Parts Breakdown MRB Material Review Board NDI Nondestructive Inspection OC-ALC Oklahoma City Air Logistics Center OEM Original Equipment Manufacturer PCO Procurement Contracting Officer PIR Publication Improvement Report PQDR Product Quality Deficiency Report PVA Product Verification Audit QAD Quality Assurance Document QAR Quality Assurance Representative QCD Quality Control Deficiency SL Salvage Layout SR Service Remanufacture TO Technical Order USAF United States Air Force WP Work Package

FD2030-23-30034 Page 25 of 36

APPENDIX 2

A2.1 NOTES

A2.1.1 The Contractor is authorized to establish and convene a Material Review Board (MRB) to evaluate and determine disposition on non-conforming material or parts valued at or above $18,500. Board members shall consist of representatives from the Contractor's Quality Production Control, Engineering (Industrial, Product Support or Design) and the cognizant Government Contract Management Office representative. The MRB shall be convened when the Contractor identifies non- conforming material or parts, engine components that are cracked, worn or damaged beyond TO authority and requiring special engineering disposition for material and parts that are valued at or above 18,500. When MRB action is required on material or parts outside of TO limits the Contractor shall provide the part number, serial number and statement of non- conformance to include T.O. reference for non-conformance and recommended corrective action using a Deviation/Waiver submitted on a DoD Request for Variance (RFV) form 1694. A copy of this 1694 shall be provided to the local DCMA representative and the ALFCMC/LPSIA (IEMP) representative at the time of submission.

FD2030-23-30034 Page 26 of 36

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 remanufacture work requirements or other contractual provisions. In instances of conflict, the latter applies. The contractual issuance of this attachment and performance of PVAs does not relieve the Contractor of the responsibility for maintaining a Quality Control System that will assure productions of items that conform to contractual requirements. PVAs are management tools used to independently evaluate and validate the conformance of a remanufactured 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 remanufacture effort. The audit includes correction of defects, reassembly, retesting, repackaging, remarking, update of records and correction of contractual requirements.

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

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

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

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

A3.3 RESPONSIBILITIES

A3.3.1 The Contractor shall:

FD2030-23-30034 Page 27 of 36

A3.3.1.1 Perform audit functions under the surveillance of the cognizant DOD 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 by the Government, to perform the PVA.

A3.3.2 The cognizant DOD QAR reserves the right to:

A3.3.2.1 Be designated as audit team chairman, unless otherwise directed by the Procuring Contracting Officer (PCO).

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

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

A3.4 AUDIT PROCEDURES

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

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

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

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

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

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

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.

FD2030-23-30034 Page 28 of 36

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

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

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

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

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

A3.4.2 Scheduling/Frequency

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

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

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

A3.4.3 Inspection and Test

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

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

FD2030-23-30034 Page 29 of 36 or II defect is found in the audit candidate, the Contractor shall satisfy the Government that such defect does not exist in the other four items prior to Government acceptance thereof. The audit candidate shall be accepted by the Government upon compliance with paragraph A3.4.4.6 below.

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

A3.4.3.4 Disassembly shall be performed in a secure area accessible only to audit participants. Normally, audit participation will be limited to specified Contractor production and quality control personnel, the cognizant DOD QAR and ALC personnel.

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

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

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 remanufacture 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

FD2030-23-30034 Page 30 of 36 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.