Statement of Work 70Z03821QB2000007.pdf

STATEMENT OF WORK (SOW)

REPAIR MAIN ROTOR BLADE

70Z03821QB2000007

1.0 GENERAL

1.1 Background

The United States Coast Guard (USCG) currently operates a fleet of MH-65 helicopters. The MH-65 helicopter is primarily a Short Range Recovery (SRR) aircraft used by the USCG to perform search and rescue, law enforcement and homeland security missions. The USCG missions require frequent operation at lower altitudes and in salt-laden environments. These environments accelerate corrosion on airframe structures, engines and components of the aircraft.

2.0 SCOPE

2.1 The USCG requires test, evaluation, and repair of Main Rotor Blades, Part Number

(P/N) 366A11-0010-07 this component is used on the USCG MH-65 aircraft. Repair work shall be performed in accordance with (IAW) the Original Equipment

Manufacturer (OEM), Airbus Helicopters (ETS DEMARIGNANE) Aeroport Marseille

France, Marignane, France 13700 (Cage Code F0210) Component Maintenance Manual

(CMM) and this SOW.

The USCG does not have access to and cannot provide the CMM. Contractors must be able to obtain the CMM including updates, service bulletins or engineering changes directly from the OEM as distribution of this data is controlled by the OEM. If the

Contractor receives a component for which sufficient or proper repair procedures do not exist, the Contractor shall immediately notify the Contracting Officer in writing.

Disposition instructions will be provided via issuance of a modification to the purchase order.

The Contractor shall provide all labor, parts, tooling, test equipment and facilities necessary to repair the Main Rotor Blades IAW the OEM's CMM at firm fixed prices established in the schedule of supplies/services.

All components are flight critical. The Contractor must be approved by the OEM to repair the Main Rotor Blades and must have capabilities to incorporate any service bulletins or engineering changes. The Contractor must be Federal Aviation

Administration (FAA) Approved or European Aviation Safety Agency (EASA) approved to repair the Main Rotor Blades. Repair components shall be certified to be airworthy and suitable for installation on a USCG aircraft.

3.0 APPLICABLE DOCUMENTS

3.1 Industry Documents.

3.1.1 Industry documents consist of any OEM specifications and drawings which apply to Main Rotor Blades. Industry documents are not available from the USCG and must be obtained from the applicable OEM if so approved by the OEM.

3.2 Order of Precedence. In the event of conflicts between OEM specifications and procedures and USCG specifications and procedures, the order of precedence is as follows:

3.2.1 USCG specifications.

3.2.2 OEM specifications and procedures.

4.0 REQUIREMENTS

4.1 Certification. The Contractor shall be OEM and FAA certified or EASA approved certified to perform repairs on the Main Rotor Blades. The Contractor shall maintain

OEM certification and FAA certifications or EASA approval throughout the life of the contract for the components listed in the schedule of supplies/services and shall immediately provide written notification to the Contracting Officer of the loss of either certification

4.2 OEM Manuals and Data. The Contractor must have access to the OEM's CMM, including any updates and service bulletins issued during the life of the contract, to ensure main rotor blades are repaired, calibrated, balanced, tested and operating in accordance with the OEM's current specifications and procedures.

4.1.3 USCG Review of procedures. The USCG reserves the right to review and modify inspection, repair and test procedures to make them more suitable to the USCG environment. The Contractor shall advise the USCG within fifteen (15) working days of any OEM changes to repair procedures and any effect the change may have on the firm fixed repair price. Incorporation of any such change will be made by a modification to the contract in accordance with FAR 52.212-4(c).

5.0 MAJOR TASKS

5.1 Repair. Components shall be shipped by the USCG to the Contractor for repair via individually funded fixed price purchase order. The Contractor shall test and evaluate

(T&E) components and repair deficiencies in order to return the component to an airworthy and Ready For-Issue (RFI) condition. The Contractor shall replace missing or broken parts and the removal of any foreign matter or corrosion in accordance with the firm fixed repair prices established in the schedule of supplies/services. The Contractor shall certify all repaired components to be airworthy and suitable for installation on

USCG aircraft.

Components shipped to the Contractor will have a DD Form 1577-2, Unserviceable

(Reparable) Tag-Material attached that identifies the component's specific fault(s) rendering the component as non-ready-for-issue (non-RFI). The Contractor shall repair the component for the specific fault and correct deficiencies found during test and evaluation under the firm fixed repair prices established in the schedule of supplies/services. The Contractor shall package with each repaired component with a completed DD Form 1574 Serviceable Condition Code Tag, FAA Form 8130-3, Airworthiness Certification Tag and a Certificate of Conformance (COC) in its entirety.

5.2 Failure Data Report. The Contractor shall submit a failure data report (in numerical order, by P/N for each repaired main rotor blade. This report shall include National

Stock Number (NSN), Part Number (P/N), Serial Number (S/N), nomenclature, date of repair, Contract Number, line item numbers, description of the repaired failure, the

USCG reported failure, a listing of parts repaired, a listing of parts replaced, and the schematic location of parts that were replaced or repaired. The Contractor's in-house work order may be used to satisfy this requirement if the work order contains information requested above. This report shall be included with the packing slip, which shall be included with the repaired component when shipped.

6.0 MANDATORY ACTIONS

6.1 Static balance check. This check may be accomplished both before and after repair effort on all main rotor blades. MRV WC 62.10.00.805 applies.

6.2 Balances. The Contractor shall ensure that anytime the balance is adjusted for a repair, the spanwise and chordwise balances are within the manufacturer's tolerances and will be included in the firm fixed repair price.

6.3 Trim Tab Settings. The Contractor shall ensure, after the repair has been completed, that the manufacturer's trim tab setting on tabs 1 through 4 remain the same as indicated in the Significant Component History Report (SCHR) to ensure the blade will track properly. This task shall be included in the firm fixed repair price.

6.4 High visibility paint scheme. This task is to be performed on all main rotor blades and shall be included in the firm fixed repair price. (MM) Maintenance Manual WC

62.10.00.795 (C level repair) (Hi-vis paint)

6.5 Main rotor blade deflection checks. This check shall be performed only after known main rotor blade incidents and will be included in the firm fixed repair price.

Maintenance Repair Manual (MRM) WC62.10.00.604 (Deflection check following an incident) applies.

6.6 Serviceable Parts. Parts of a component found to be in a serviceable condition as a result of inspection and functional testing shall be reused. Parts found to be defective shall be replaced with parts meeting the manufacturer's specifications and drawings.

Replacement parts shall be factory new.

7.0 TEST AND EVALUATION (T&E) / NO FAULT FOUND (NFF) / BEYOND

ECONOMICAL REPAIR (BER) ITEMS

If, after T&E a component is determined to be NFF (found to meet manufacturer's minimum performance specifications and requires no parts or labor) or is determined to be BER the Contractor will be allowed only the firm fixed price. The Contractor shall notify the Contracting Officer in writing of the applicable material condition and identify the applicable line item number(s). The order and applicable line item number(s) will be reduced from the firm fixed repair price to the T&E/NFF/BER fee and disposition instructions will be provided by issuance of a order modification.

The Contractor shall prepare and include a failure data report with all returned components, indicating the USCG's reported failure and the fact that no fault was found or why the part was deemed BER. The USCG also reserves the right to request the component be returned as is when deemed BER.

8.0 OVER AND ABOVE SEPERATELY PRICED TASKS

Over and Above Separately Priced Items are tasks that are outside the repair scope of the OEM's CMM and are activated on a case-by-case basis via a modification to the applicable task order. If an over and above task(s) is required to complete repair work, the Contractor shall stop work on the applicable Main Rotor Blade and promptly notify the Contracting Officer in writing. The Contractor shall identify the applicable task order number, line item number and the required additional tasks that need to be performed and estimated completion time. The additional tasks shall be at the firm fixed prices established in the Schedule of Supplies/Services at the applicable. Over and above work shall be authorized and funded via issuance of a modification to the purchase order. The Contractor shall not perform any over and above tasks without having authorization to do so in the form of a modification to the contract.

8.1 Whirl Tower Testing. This test shall be performed on blades requiring dynamic balancing after repair and/or refinish when such actions require a weight shift that is greater than the maximum cell weight, or when the cells have insufficient weight to make the required shift, or if three (3) or more of the trim tab sections have been replaced during repair, or as required by the OEM CMM or as directed by the

Contracting Officer. The Master Blade for Whirl Tower Testing is located only in

France. The Contractor MUST have the capability to forward any Main Rotor Blades for this specific testing to France.

All blades requiring whirl tower testing shall be refinished prior to return to the

Government. When whirl tower testing is required, all changes and adjustments (i.e., tab and changes), shall be included in both the Failure Data and Component Repair

Record reports.

Main rotor blades which cannot be properly balanced after installation on USCG aircraft will be returned to the Contractor for repair. If no fault can be found after visual and technical inspections, the Contractor shall notify the Contracting Officer immediately for authorization for whirl tower testing. Upon agreement of the terms of the additional repair tasks, a Modification will be issued and shall be priced as specified under modification agreement. For those blades which faults can be found and were a part of the original repair, the necessary repair tasks shall be accomplished by the

Contractor at no additional cost to the USCG.

8.2 Metallic Tip Block Replacement, Root End Bushings Replacement and Bushing

Rebonding and Touch Up, Structural Skin Repair No Fault/Refinish With Whirltower and High Visibility Paint. These tasks shall be performed IAW the OEM's CMM

Maintenance Manual and cost will be agreed upon through modification to the associated Clin.

8.3 Main Rotor Blade Exchange. The Contractor shall be able to offer the USCG a Zero

Hour Factory new OEM issued Main Rotor Blade with a core exchange. Including installation of a new tip cap when a Main Rotor Blade cannot be balanced successfully.

Authorization and funding for a Main Rotor Blade Exchange will be with the issuance of a modification to the applicable line item.

Under the Main Rotor Blade Exchange program a new serial number is assigned. The

Contractor shall stencil on the bottom of the blade, in sequence below one another, the blade part number, serial number, tip weight and total weight to an accuracy of one gram, and tab settings 1 thru 4,. Stencil/Paint shall be IAW MIL-PRF-85285 Type

1 Class H Yellow FSC 13538.

The Contractor shall provide written notification to the Contracting Officer of the new serial number so that the applicable line item can be modified accordingly.

8.4 Blade Containers. Blade containers received in a damaged condition that require only minor repairs (parts and labor estimated to be less than $100.00) shall be repaired at Contractor's expense in a manner to prevent blade damage during shipment, handling and storage. If the Contractor determines that a replacement blade container is required, the Contractor shall promptly notify the Contracting

Officer in writing.

8.4.1 Contractor provided Blade Containers, part number: AT-SINGLE Blade, NSN

1615-01-HS2-9179. If a blade container cannot be provided by the Government as

Government Furnished Material (GFM) and the Government requests the Contractor replace the blade container, the Contractor shall be entitled to a agreed upon price adjustment. Contractor blade container replacement shall be authorized and funded via a modification to the purchase order. The contract shall not process with any blade container replacement without written authorization via a modification.

9.0 UNUSUAL DAMAGE

The USCG intends that all components specified in the schedule will be shipped for repair within the firm-fixed prices established in the resulting contract. Occasionally, components may be received in a condition outside the confines of the CMM. Those components may be determined Unusually Damaged. In order to be determined

Unusually Damaged, a component must be received for routine repair and upon evaluation any one of the following conditions are discovered:

Obvious misuse Cannibalization

Crash damage Acts of God

Because the MH-65 helicopter is used primarily around salt water at low altitude for search and rescue missions, corrosion is to be anticipated and is considered "normal" for the aircraft. Corrosion does not constitute unusual damage. Only components meeting one or more of the above criteria may be considered as Unusually Damaged.

All other components shall be repaired in accordance with the fixed repair prices established in the Schedule of Supplies/Services.

9.1 Unusual Damage Reporting Requirements. When a component is processed for

Unusual Damage Evaluation, the Contractor shall notify the Contracting Officer in writing within 15 calendar days of recent of order. The Government may request the

Contractor to submit an inspection condition report, pictures of the damage, and a repair quote listing all parts and labor needed to return the component to serviceable condition that meets CMM specifications.

The Contractor's delivery obligation shall stop from the date of notification that an item has been determined to be a candidate for "Unusual Damage Evaluation." The delivery obligation will be specified in the order modification and will apply only to those items specifically addressed by the modification. The Contractor is obligated to deliver all other components not individually addressed by the modification under the original delivery date specified on the order.

The Contracting Officer shall either initiate negotiations for a firm-fixed repair price with the Contractor or if repair is not desired provide dispositions instructions for the component. Authorization to proceed with repair work or disposition instructions if repair is not authorized shall be given via issuance of a order modification. If a component is returned to the USCG in a disassembled condition, the Contractor shall be entitled only to Test and Evaluation Fee established in the Schedule of

10.0 SERVICE BULLETINS

During the course of the Contract, a component may require the incorporation of a

Service Bulletin which is generated by the OEM. Either the Contractor or the USCG may receive notice of a Service Bulletin from the OEM. The Contractor shall promptly notify the Contracting Officer in writing when a Service Bulletin is received and advise if the Service Bulletin is mandatory or optional. Within 30 calendar days of receiving a

Service Bulletin the Contractor shall submit a quote detailing labor, materials and turn-around-time needed to incorporate the Service Bulletin into a component. Upon agreement of the price for incorporation of the service bulletin and providing funds are available, authorization to proceed with incorporation of the Service Bulletin will be provided by modification to the applicable line item(s). The Contractor shall not incorporate a Service Bulletin prior to receipt of a fully executed order modification.

The Contractor shall provide two (2) copies of all applicable service bulletins which are generated by the OEM. The Contracting Officer will notify the Contractor in writing when incorporation of mandatory or optional service bulletins is required.

11.0 PRODUCT/ENGINEERING CHANGES

The Contractor may develop designs and/or processes that will improve the reliability, maintainability, or operational performance of the components being repaired. (Any such changes would not be expected to affect overall aircraft performance or capability.) These may be provided to the Contracting Officer for consideration and approval. A quote shall also be provided that reflects the Contractor's costs and an incremental charge to be assessed each time the product change is incorporated into the component. The quote shall include a detailed breakdown of labor hours, material and other costs and turn-around time. Upon agreement of the price for incorporation of the change, the Contracting Officer will issue a modification to the applicable line items(s) to authorize and incorporate pricing for the change. The Contractor shall not incorporate proposed product or engineering changes prior to receipt of written authorization from the Contracting Officer.

12.0 CORROSION AND ENVIRONNŒNTAL REQUIREMENTS

12.1 Corrosion Environment. The USCG aircraft operate primarily around salt water, at low altitude, and are subject to corrosion. During inspection and functional test, the presence of corrosion shall constitute reason for a more thorough disassembly and inspection. Should corrosion be found, disassembly shall be made only to the extent necessary to remove corrosion or replace the part or parts affected. Corroded parts shall be replaced, except in those cases where removal of corrosion from a part will not impair efficiency or safe operation of the part. Corrosion removal and treatment of affected areas shall be accomplished in accordance with OEM work card procedures and technical instructions for the removal/treatment of corrosion and preservation of the rotor blade.

12.2 Environmental requirements. All parts must be thoroughly cleaned IAW OEM’s applicable CMMs Guidance for Selecting Chemical Agents and Processes for Paint removal and General Cleaning of Aircraft and Aviation Products, to ensure they are as free as practicable of all hazardous dust to include hexavalent chromium, cadmium, lead, etc. prior to being returned to ALC. ALC may take random samples of parts to ensure they are free as practicable of all hazards. Information on these hazards can be found in Occupational Safety and Health Standards 1910.1025(lead), 1910.1026

(Hexavalent Chromium) and 1910.1027 (Cadmium).

13.0 CONTRACTOR VERIFICATION OF COMPONENTS

Upon receipt of components, the Contractor shall notify the Contracting Officer in writing and provide the following information: (l) date the component(s) received at the

Contractor's facility and, (2) confirmation of P/N's and S/N's on the equipment received and advise if any of this information does not exactly match the order. The Contractor shall NOT start work on equipment received that have P/N's or S/N's different than what is shown on the order unless a Modification has been issued correcting the discrepancy. The Government reserves the right to have "discrepant equipment" returned "as is". The Contractor's failure to confirm the equipment received may result in the Government's assumption that the components were received at the Contractor's facility within seven (7) calendar days of the date on the delivery order and the P/N and

S/N information on the equipment matches exactly the information on the order line item for the equipment.

14.0 PART NUMBER CHANGES

Certain repair tasks may necessitate the part number of the repaired main rotor blade to be changed according to the standards established in the OEM specifications and/or procedures. The Contractor shall notify the Contracting Officer in writing of the part number change. A line order modification will be issued authorizing the Contractor to change the blade part number on the blade. The Contractor shall report the change on the Failure Data Reports and ACMS Reports. NOTE: All repairs must be accomplished for the blade part number to change; otherwise the part number remains the same.

15.0 QUALITY ASSURANCE

15.1 Quality Control System. As a measure of quality the Contractor shall be either a

FAA Certified repair station or an EASA Approved Maintenance Organization for repair of the Main Rotor Blades. The Contractor shall have a Quality Control System in place that documents an Inspection Program and describes inspection procedures, quality assurance, inspections personnel and responsibilities, traceability of parts to the OEM and addresses work performed by any subcontractors. The Contractor shall maintain and use the Quality Control System for the life of the contract unless a change in procedures becomes necessary. The Contractor shall immediately notify the Contracting Officer when there is a change in quality control procedures including describing the change and any impact to contract performance.

The Contractor shall submit a copy of their Quality Assurance (QA) Manual with their quote and advise if the QA Manual has been reviewed and approved for use by the FAA for repair of Main Rotor Blades and Tip Caps. Records of conformance shall be maintained on file at the Contractor's facility and made available or provided for review by the Government upon request. The Government reserves the right to conduct a site visit of the Contractor's facility to verify the existence, adequacy and effectiveness of its quality assurance system as it pertains to USCG requirements.

15.2 Product Quality Deficiencies Report (PQDR). Repaired components found to have deficiencies will be returned to the Contractor for investigation under a no-cost warranty repair order. The order will include a copy of the QDR outlining the component deficiency. The Contractor shall report findings of the investigation to the Contracting

Officer within thirty (30) calendar days after receipt of the component. If agreed upon between parties that the component's deficiencies are not related to previous repairs completed by the Contractor, the Contractor's report of findings shall include a detailed quote that includes a complete breakdown of parts and labor necessary to return the component to serviceable condition. The Contracting Officer will either initiate negotiations for the work or accept the Contractor's quote and issue a modification to the purchase order line item authorizing and incorporating pricing for the repair work. The terms and conditions of the base contract including delivery obligations shall apply to all no-cost warranty repair order.

16.0 AVIATION COMPUTERIZED MAINTENANCE SYSTEM (ACMS)

REQUIREMENTS

16.1 The ACMS used by the USCG is designed to capture, store, and report asset maintenance information. The Contractor shall comply with all USCG ACMS documentation requirements.

Components are serial tracked under USCG ACMS. The Component Repair Record

(CRR) records the maintenance performed by the Contractor on a SIN tracked component. This tracking provides historical records of repairs, flight times, cycles, item location, status, and an effective method of configuration control. Components that are SIN tracked under USCG ACMS should, at the time of receipt, have a blank CRR and a current SCHR attached to the component. The Contractor shall complete the CRR to ensure the maintenance performed on a component is documented.

The Contractor shall verify the data included in the CRR and SCHR that is attached to the component correspond with the NSN, P/N, and S/N of the component received.

The Contractor shall promptly report discrepancies to the USCG Contracting Officer prior to performing any work.

The original CRR, which includes pre-printed identification for each part, will be supplied with the part and must be returned with the part. The following areas of the CRR must be correctly documented: Narrative summary of work performed (cannot include references to an offsite database), facility performing work, facility work order number, date work performed. Mark "appropriate maintenance procedures" completed during rework/overhaul and authorizing signature. If unsure about which "appropriate maintenance procedures" were completed contact the Contracting Officer for clarification.

The information provided in the CRR will be used by the USCG to update the component

SCHR. Any original CRR returned not properly completed will not be accepted by the

Government.

16.2 The Contractor shall provide two (2) copies of the completed CRR as follows:

l) One copy of the CRR shall remain with the material and is to be returned with the component upon completion of the repair.

2) A second copy of the CRR shall be mailed to:

COMMANDNG OFFICER

ATTN: ACMS

USCG AVIATION LOGISTIC CENTER

1664 WEEKSVILLE ROAD BLDG 63

ELIZABETH CITY, NC 27909-5001

17.0 SPECIAL INSTRUCTIONS

17.1 Accelerated Turn-Around-Time and Delivery. Only the Contracting Officer may request and authorize an accelerated turn-around-time and delivery if needed by the

Government for delivery to the USCG, ALC Receiving Department, Weeksville Rd., Elizabeth City, NC 27909. In the event an accelerated turn-around-time and delivery is needed, which the Contractor can meet, the Contractor shall be entitled to compensation for additional labor hours and expedited freight costs necessary to complete performance earlier than the turnaround-time and delivery schedule established in the

Contract. After receiving a written request from the Contracting Officer for an accelerated turn-around-time and delivery, the Contractor shall provide a written response within two (2) business days advising if an accelerated turn-around-time and delivery can be accomplished and include any additional costs necessary for the accelerated performance. Accelerated performance will be authorized in writing via a Order Modification. If the Contractor accelerates turn-around-time and delivery on its own initiative in order to meet the delivery schedule established in the contract Order, the additional costs are not recoverable from the Government.

17.2 Aircraft on Ground (AOG) Situations. An Aircraft on Ground (AOG) situation necessitates a special schedule and requires accelerated repair completion and expedited delivery to the applicable USCG Air Station. In the event an AOG status occurs as a result of a lack of any of the components specified in the schedule, the Contractor will be notified by the Government in writing of the AOG situation and the applicable USCG

Air Station and will be requested to provide a written response within twenty-four (24) hours of the request. The Contractor's response shall provide l) status of the component(s) needed to satisfy the AOG condition that includes what USCG items in-house for repair are closest to completion under normal working conditions and 2) an estimate of the labor hours needed to accelerate repair completion. The accelerated repair work will be authorized via a purchase order modification in conjunction with mutually agreed upon prices, delivery, and shipping costs reimbursement for next day delivery to the applicable USCG Air Station.

In the event of an AOG situation, the Order and applicable Line Item Number will be modified to reflect the USCG Air Station's delivery address and the applicable USCG

Requisition Number. The Contractor shall be required to ensure the Requisition Number is included on shipping/delivery tickets so that the Material Receipt can be processed by the applicable USCG Air Station receiving personnel.