Statement Of Work - 70Z03823QB2000124.pdf

70Z03823QB2000124

REPAIR OF DYNAMIC COMPONENTS

STATEMENT OF WORK (SOW)

1.0 BACKGROUND

The United States Coast Guard (USCG) currently operates a fleet or approximately 98 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

This requirement is for the repair of the Dynamic Components used on the MH-65 aircraft. Work shall be performed using the Original Equipment Manufacturer (OEM) Component Maintenance

Manuals (CMM) and in accordance with this SOW. The OEM is Airbus Helicopter, France

[Commercial and Government Entity (CAGE) Code F0210].

Work shall be performed at the Contractor’s facility. The Contractor shall provide all necessary parts, materials, labor, tooling, test equipment and facilities to test, and repair the components listed in this contract.

3.0 APPLICABLE DOCUMENTS

3.1 Government Documents

• ACMS Significant Component History Record (SCHR)

• ACMS Configuration Report (CFG

• Maintenance Due List (MDL)

• MH-65 Variable Maintenance Listing and Interval Adjustments, DMPC D00VMX.0.

• Airworthiness Approval Tag, FAA Form 8130-3.

• European Unions Authorized Release Certificate of Airworthiness, EASA form 1.

• F-SUP-05-045 B, Repair Design Approval Sheet, RDAS.

• Unserviceable (repairable) Tag (Blue) – DD FORM 1577-2.

• Unserviceable (repairable) Tag (Green) – DD FORM 1577-2.

• Serviceable Tag-Material (Yellow) – DD Form 1574.

• Unserviceable (Condemned) Tag Material (Red) – DD Form 1577.

• Component Repair Record (CRR)

3.1.1 Corrosion Control

Corrosion removal and treatment of affected areas shall be accomplished in accordance with

(IAW) the OEM’s CMM’s.

3.1.2 Chemical Agents

Guidance for Selecting Chemical Agents and Processes for Depainting and General Cleaning of

Aircraft and Aviation Products shall be accomplished IAW the OEM’s CMM’s.

3.2 Industry Documents

Occupational Safety and Health Standards 1910.1025 (Lead), 1910.1026 (Hexavalent

Chromium) and 1910.1027 (Cadmium).

3.2.1 CMM

OEM CMM, and other applicable technical specifications for the components set forth in the

Schedule.

3.2.1.1 OEM Documents

Industry documents are not available from the USCG and shall be obtained from the OEM.

4.0 CONTRACTOR REQUIREMENTS

4.1 FAA Approved Repair Facility and OEM Approved

The Contractor shall be either a (1) FAA Approved Repair Facility or (2) equivalent European

Aviation Safety Agency (EASA) Approved Repair Facility in addition to being an OEM

Approved Repair Facility for the Dynamic Components listed in the Schedule of Services.

Contractor must provide:

• AIRBUS MRO (Maintenance Repair and Overhaul facility) Technical Assessment

Certificate

• Proof of Staff Qualification Certificates from mechanics, which are qualified by Airbus

Helicopter, via training.

• AIRBUS Training Report(s).

Components repaired and delivered to the Government shall be certified airworthy and ready for installation on a USCG aircraft. Contractor must provide proof of an established supply chain with the OEM for those parts required to be purchased through the OEM AND proof of enrollment in OEM technical publication subscription and compliance with tech publication audit requirements, if any, as set forth by the OEM with their proposal.

4.1.1 Certifications

Contractor shall provide copies of all certifications (e.g. FAA Repair Station Certificate, EASA

Part 145 certificate equivalent and Airbus Helicopter, France authorized repair station certification) with their proposal. The Contractor shall maintain the required certifications throughout the life of the resulting contract award. The Contractor shall notify the Contracting

Officer in writing, within five (5) working days following the receipt of component(s), when the

Contractor has a change in their certification status, and shall disclose all facts relevant to the change.

4.2 Subcontractor Qualifications

Subcontracting shall be limited to Contractors with FAA, or EASA repair certification, and approval as an authorized repair facility by the OEM. Documentation shall be provided to the

Government upon request to support the subcontractor’s qualifications/certifications and the contractor shall inform the Government of any subcontractors to be used. Contractors and sub-contractors shall have access to OEM authorized replacement parts.

5.0 REPAIR

5.1 General Repair

The Dynamic Components shall be repaired IAW the OEM’s most current CMM and shall also include repair and/or replacement of all related components. Components shall be repaired for the specific fault for which they were returned. A DD Form 1577-2/1577-3, Unserviceable

(Reparable) Tag-Material, or CG-1577-A (11-90), Unsatisfactory Report Tag, shall be attached to each non-Ready For Issue (RFI) item describing faults. The Contractor shall perform an inspection and correct deficiencies found. This shall include, but is not limited to, replacement of missing or broken parts and the removal of any foreign matter or corrosion.

If the repair of a component or component assembly exceeds the limit detailed in the CMM, but is acceptable or repairable by Airbus Helicopter Design Office (AHDO) approvals via Repair

Design Authorization Sheet (RDAS), the OEM or Contractor’s proposed detailed repair plan presented to AHDO and the approved RDAS from AHDO must be delivered to the USCG for historical archiving of the component or assembly. All approved repairs via AHDO by RDAS shall become the property of the USCG for future evaluations and like repair plan presentations to AHDO. Repeatable RDAS repairs shall be considered for revisions within OEM CMMs.

5.2 Corrosion

5.2.1 Corrosion Environment

USCG aircraft operate primarily around salt water, at low altitude, and are subject to corrosion.

During inspection and functional test, the presence of corrosion in a component shall constitute reason for a more thorough disassembly and inspection. Should corrosion be found, disassembly shall be made 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 shall not impair efficiency or safe operation of the part. Corrosion removal and treatment of affected areas shall be accomplished IAW the CMM.

In the case where specifications do not exist or are not clear, the Contractor shall provide written notification to the Contracting Officer. Disposition instructions shall be determined by the

USCG only and shall be provided via modification to the applicable Order.

5.3 Test and Evaluation/No Fault Found/Beyond Economical Repair (BER) Items

5.3.1 Test and Evaluation/No Fault Found

If, after visual and functional inspection, an item is found to meet manufacturer's minimum performance specifications as designated by the CMM and requires no parts or labor, the

Contractor shall be allowed the firm-fixed price in Contract Line Item Number (CLIN)s 0001 through 0019 and subsequent option period CLINs for each Test and Evaluation Inspection Fee.

The Contractor shall notify the Contracting Officer in writing of the applicable material condition and identify the applicable Order and CLINs. The order and applicable CLINs will be reduced from the firm fixed price to the Test and Evaluation Inspection Fee that will be provided by issuance of an Order modification.

5.3.2 BER Items

The Contractor may request an item to be determined BER if after initial inspection of the component the Contractor feels that the part requires significant repair outside of the scope of the normal repair procedures provided in the OEM’s CMM. The Contractor’s request shall be sent to the Contracting Officer for consideration. Only the USCG can determine a component BER.

The Contracting Officer will review the request and either accept or deny the BER determination. The notification shall list the Contract Number, CLIN, NSN, P/N and S/N with a brief description supporting the determination. If the KO denies the BER determination, the

Contractor shall repair the component back to RFI condition at the firm-fixed price rate agreed upon in the schedule. If the Contracting Officer determines an item to be BER, the Contracting

Officer shall make a unilateral decision as to component disposition. The Contractor shall return all BER items assembled to the Aviation Logistics Center. The Contractor shall not return any

BER item until they have been notified by a written modification to the applicable order. If the part is deemed BER, the Contractor shall be allowed the firm-fixed price in CLINs 0001 through

0019 and subsequent option period CLINs for each Test and Evaluation Inspection Fee. The

Contractor shall notify the Contracting Officer in writing of the applicable material condition and identify the applicable Order and CLINs. The Order and applicable CLINs will be reduced from the firm fixed price to the Test and Evaluation Inspection Fee that will be provided by issuance of an Order modification.

5.4 Service Bulletins

The Contractor shall notify the Contracting Officer in writing when incorporation of a service bulletin is required within thirty (30) calendar days following receipt of this service bulletin notification. The proposal shall contain a list of materials with associated prices, the number of labor hours required, turn-around-time needed to effect the Service Bulletin and any impact on the contract delivery schedule. The Labor Rate shall be at the Firm-Fixed Labor Rates under the contract period of performance for the component. The incremental charge agreed to for incorporation of a service bulletin shall apply only to those components into which the

Contractor incorporates a required service bulletin, not those into which the service bulletin has been previously incorporated. Upon agreement of the price for incorporation of the service bulletin, authority and price changes shall be incorporated into the contract via a contract modification. The Contractor shall not incorporate proposed service bulletins prior to receipt of written authorization from the Contracting Officer.

5.5 Product Improvements/Engineering Changes

The Contractor may develop designs and/or processes that shall 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 proposal shall also be provided that reflects an incremental charge to be assessed each time the Product Improvement

Package (PIP)/Engineering Change Proposal (ECP) is incorporated into the component. The proposal shall include a breakdown of labor hours, material, and other costs. Upon agreement of the price for incorporation of the change, authority and price changes shall be incorporated into the contract via a contract modification. The Contractor shall not incorporate proposed product improvements or engineering changes prior to receipt of written authorization from the

Contracting Officer. The Labor Rate shall be at the Firm-Fixed Labor Rates for each contract period of performance.

5.6 Pricing Exclusions – Unusual Damage

5.6.1 General

The USCG intends that all components specified in the schedule shall be shipped for repair within the firm-fixed prices established in the resulting contract. Those components may be determined unusually damaged. In order to be determined unusually damaged, a component shall be received for routine repair and upon evaluation any one of the following conditions are discovered:

• Obvious misuse

• Cannibalization

• Crash damage

• Acts of God

Only components meeting one or more of the above criteria may be considered as Unusually

Damaged. The conditions specified in this section, except Acts of God, apply to loss or damage occurring on locations other than those owned/ and/or controlled by the Contractor, or occurring while the assets are not under the Contractor’s position or custody.

5.6.2 Unusual Damage Evaluation

If a component is considered by the Contractor to be Unusually Damaged, the Contractor shall immediately notify the Contracting Officer in writing. The Contractor shall submit within fifteen

(15) calendar days after notification to the Contracting Officer a proposal to cover the cost of the repair. The Contractor shall submit an inspection condition report, pictures of the damage, and a repair proposal listing all parts and labor needed to return the component to satisfactory condition that meets OEM CMM specifications. The proposal shall include the Order Number, CLINs, NSN, P/N, and S/N of the component. The Contractor shall verify the cost of replacement parts with supporting invoices, catalogs, or other documentation acceptable to the

USCG and shall provide a teardown/evaluation report. 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 shall be specified in the Order modification and shall 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 proposal shall not include the work involved in the teardown and inspection, which shall have already occurred, as this is covered by the firm-fixed price specified under CLINs 0001/0019 and subsequent CLINs for each contract period of performance.

Within thirty (30) calendar days after receipt of the Contractor’s written proposal, the

Contracting Officer will make a written determination (subject to the Disputes clause) as to whether or not the component is determined to be Unusually Damaged. If the Contracting

Officer determines that an excluded item is BER, no Unusual Damage charges will apply. The

Contracting Officer will either initiate negotiations for a firm-fixed price with the Contractor or deny authorization for the repair based on information in the report and any other information which may be available. Upon mutual agreement as to price and delivery an Order modification will be issued authorizing the repair at the agreed upon terms. If repair is not desired, the

Contracting Officer will provide the Contractor with disposition instructions for the un-repaired item. In the event an item is returned to the USCG in a disassembled condition, the Contractor shall be entitled only to appropriate compensation at the Test and Evaluation Fee specified in the

Schedule of Services under CLINs 0001 through 0019 and subsequent option period CLINs under each contract period of performance.

5.7 Replacement Parts

5.7.1 Systematically Replaced Parts

The firm fixed repair prices established in the contract shall include all parts that are systematically replaced during repair as required by the CMM.

5.7.2 Serviceable Parts

Parts of a component found to be in a serviceable condition as a result of inspection and functional testing may be reused. Missing parts or parts found to be defective shall be replaced with new parts that meet or exceed CMM specifications and drawings, except as noted in the

SOW.

5.7.3 Environmental Requirements

All parts shall be thoroughly cleaned IAW applicable CMMs to ensure they are as free as practicable of all hazardous dust to include hexavalent chromium, cadmium, lead, etc., prior to being returned to Aviation Logistics Center (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 (OSHA) 1910.1025 (lead), 1910.1026 (Hexavalent

Chromium) and 1910.1027 (Cadmium).

6.0 QUALITY ASSURANCE PROVISIONS

6.1 Responsibility for Inspections and Tests

The Contractor shall operate with an established inspection system IAW FAA procedures for all components. Records of conformance shall be made available or provided for review by the

Government upon request. The Government reserves the right to conduct sight visits at

Contractor’s facility to verify the existence, adequacy and effectiveness of the quality system.

Upon request of the Government, the Contractor(s) shall forward a copy of their current certification and Quality Assurance Manual for review.

6.2 Traceability of Parts

Replacement parts used during repair shall be in new condition. All replacement part(s) used in the repair shall be: (1) approved by the OEM, Airbus Helicopter, France, or (2) approved by a FAA certified source of supply for the specific part. Only parts that have traceability to the manufacturer of those specific part(s) or alternate part(s) shall be used. Alternate parts shall satisfy all form, fit, and function requirements of the original parts and conform to the approved configuration of the assembly.

Installation of new surplus, including military new surplus, and overhauled replacement parts is not permitted. Parts replaced during repair shall be disposed of as scrap, which means to render those items unusable for their intended purpose.

6.3 Product Quality Deficiencies Report (PQDR)

Repaired components found to have deficiencies shall be returned to the Contractor for investigation under a no-cost Warranty Repair Order. The order will include a copy of the PQDR outlining the component deficiency. The Contractor shall report findings of the investigation 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 proposal that includes a complete breakdown of parts and labor necessary to return the component to serviceable condition. The

KO will either initiate negotiations for the work or accept the Contractor’s proposal and issue a modification to the order 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 orders.

6.4 Requirements for Supplier Changes

The Contractor shall, immediately upon discovery, notify and disclose conditions to the

Contracting Officer of any event, supply change, material change, supply malfunction, counterfeit/suspect parts or material defect or non-airworthy condition of components used in the repair are found to potentially cause non-conformity to the original specifications of this contract. The Government reserves the right to inspect any non-conforming product or component. Therefore, the Contractor shall obtain approval from the Contracting Officer prior to the disposition of any non-conforming product or component.

The contractor’s quality control manual shall address in detail the contractor’s risk management, test, inspection, non-conforming product and counterfeit/suspect parts processes.

The Contractor shall immediately notify the Contracting Officer of any changes that potentially have an impact on the product. Changes may include but are not limited to products, processes, material, supplier sources, manufacturing facility location and personnel qualifications.

Upon notification of the change, the USCG will approve or deny the change. Facility location changes may require the Government to perform a facility inspection. The contractor shall allow the Government access to all applicable areas of the contractor’s facilities to ensure compliance with contractual requirements.

The contractor shall retain all records IAW with FAR

4.7 Contractor Records Retention. The contractor shall be required to permit Government access to applicable records retained at any level of the supply chain.

Unless otherwise specified, the Contractor shall flow down all requirements in this contract to their supply chain, to include all subcontractors and suppliers.

6.5 Inspection and Acceptance

Final inspection and acceptance of material under this contract shall be performed at destination by local receiving personnel and shall consist of count, condition and verification that all required documentation has been provided. ALC considers components RFI upon acceptance.

7.0 USCG ASSET COMPUTERIZED MAINTENANCE SYSTEM (ACMS)

REQUIREMENTS

7.1 ACMS Documentation

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 found in Section 7.2 and Section 7.3 below. This tracking provides historical records of reasons for removals/repairs, flight times, cycles, item location, status, and an effective method of configuration control.

7.2 Significant Component History Report (SCHR) Records

The SCHR records the maintenance history of the serial number tracked components and current

SCHR shall be attached to the component. It remains with its corresponding part until reinstalled on an aircraft or is annotated “BER” scrapped and returned to the address specified in section

10.4, unless otherwise instructed by the USCG. The SCHR for scrapped components shall be returned with the component.

7.3 Configuration Report

The configuration report identifies all the components in an assembly that the USCG follows in operation. This may be above the requirements of the OEM Airworthy Limitations Section

(ALS). It will remain with the corresponding assembly and be returned with the assembly. If the OEM provides a Log Card to capture the components followed in operation, it must mirror the component list of the configuration report.

7.4 Component Repair Record (CRR)

The CRR record allows documentation of maintenance performed on serial number tracked components by the Contractor and enrolls or removes components from ACMS when those components are scrapped, added to, or removed from the USCG parts inventory. The original

CRR, which includes pre-printed identification for each part, shall be supplied with the part and shall be returned with the part. The Contractor shall ensure the original CRR is fully completed and returned with the component. The following areas of the CRR shall be completed by the

Contractor: TSN, TSO, Manufacturer, Date of Manufacture, Narrative Summary, Repair Facility, Work Order Number, Date Work Completed, Item Beyond Economical Repair, Maintenance

Actions complied with during the course of the Repair, Authorized Signature or Quality

Assurance Stamp. The “Narrative Summary” section shall include all work performed, any

RDAS performed (cannot include references to an offside database). CRR listed “Maintenance

Actions complied with during the course of this Repair” must be properly recorded by checking the appropriate listed “maintenance action.” If unsure about which “Maintenance Actions were complied with during the course of the Repair” contact your government representative for clarification. Any original CRR returned incomplete or not properly completed, shall not be accepted by the government. Until a properly competed CRR is received by the USCG, the

Contractor shall not invoice for the component. The Contractor shall retain a copy of the CRR for 90 calendar days. The information provided in the CRR shall be used by the USCG to update the component SCHRs.

7.5 Reporting Discrepancies

The Contractor shall verify the data included in the SCHR and CRR attached to the component 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.

8.0 DOCUMENTATION REQUIREMENTS

8.1 Contractor Verification of Receipt of Components

(a) Within five (5) working days following the receipt of component(s), the Contractor shall provide written notification of the following to the Administrative Contract Specialist.

1) Date of receipt of component(s).

2) Confirmation of S/N(s) received, as applicable.

3) Applicable Order and CLINs

Notification via email is preferred.

8.2 Monthly Reports

The Contractor shall submit a Monthly Report (to the person designated at contract award) that includes equipment received for repair for the current month, equipment received for repair during previous months and is still in process and equipment shipped/delivered during the report period. The Monthly Report shall be submitted within ten (10) calendar days of the end of each month and shall include the Contract Number, Order Number(s), CLINs, Item Name, P/N, NSN, S/N, date equipment was received at the Contractor’s facility, and estimated delivery date and/or updated status. A sample monthly report can be found in Appendix B. Electronic submissions compatible with Microsoft Office is acceptable.

8.3 Airworthiness Certification for Repaired Equipment

Dynamic Components repaired by the MRO facility shall be certified airworthy and suitable for installation on USCG aircraft. Each repaired component shall be tagged with a DD Form 1574, Serviceable Condition Code Tag, and include an FAA Form 8130–3, Airworthiness Approval

Tag, or equivalent EASA Form 1. All forms not attached shall be packaged with each component. In case of loss of records, all FAA Form 8130-3’s, and EASA Form 1’s, shall be available for review upon request. All repairs performed shall be properly documented in the remarks section on FAA From 8130-3.

8.4 Periodic Inventory Reporting

The USCG ALC conducts regular checks of its inventory accuracy. Inventory count checks are on a quarterly basis via random sampling. Therefore, the USCG may periodically request, in writing, that the Contractor account for USCG assets at their facility. In the event that assets on this contract are chosen in the quarterly random sample, the Contractor shall physically verify the P/N and S/N of the particular assets in their possession. The USCG will provide a standard inventory form for the Contractor to fill out and sign. Response to these requests shall be done in one (1) business day by the Contractor, at no additional cost to the government.

9.0 SPECIAL INSTRUCTIONS

9.1 Aircraft on Ground (AOG) Situations

Upon notification from the USCG that an AOG situation exists, the Contractor shall make every effort to expedite the repair and initiate shipment with seven (7) calendar days or less. Material shall be shipped by the fastest traceable means, e.g. air freight “next day delivery”. The shipping container shall be marked on the outside in highly visible lettering “A.O.G”.

In the event an AOG status occurs as a result of a lack of any of the components specified in the schedule, the Contractor may be notified by the Government in writing of the AOG situation and applicable USCG Air Station and shall be requested to provide a written response within twenty-four (24) hours with the following information: 1) 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 shall be authorized via an Order Modification in conjunction with mutually agreed upon prices, delivery, and shipping cost reimbursement for next day delivery to the applicable USCG Air Station.

In the event of an AOG situation, the Order and applicable Order CLINs shall be modified to reflect the USCG Air Stations delivery address and the applicable USCG Requisition Number.

The Contractor shall be required to ensure the Requisition Number is included on shipping documents/delivery tickets so that the Material Receipt can be processed by the applicable

USCG Air Station receiving personnel.

10.0 WARRANTY

The Government may accept the Contractor’s standard commercial warranty for major repairs.

All assets returned under warranty shall be tested IAW Section 5.0. The warranty shall begin from the date the component is installed on the aircraft and extend for twelve (12) months after installation, unless corrosion or damage is found on the outside of the component.

11.0 TASK REQUIREMENTS

11.1 Delivery Schedule

Actual delivery lead times will be determined at contract award. Orders issued under the contract will specify actual delivery dates based on contract lead times. The desired delivery schedule for the

Dynamic Components is 120 calendar days After Receipt of Material (ARM) and all required documentation at Contractor’s facility.

Earlier delivery is desired if there are no extra costs to the Government.

12.0 APPENDICES

Appendix A – Definitions

Appendix B – Sample Monthly Report

Appendix A – Definitions

Aircraft on the Ground (AOG) -- Condition indicating that an otherwise operational aircraft is temporarily grounded awaiting repair and return of the part or component. This condition requires that the component be handled as a high priority and that the return be expedited.

Asset Computerize Maintenance System (ACMS) -- U.S. Coast Guard owned component tracking program.

Beyond Economic Repair (BER) -- Condition of a part deeming replacement with a new part more cost effective than repair. Final determination of a BER condition shall be at the discretion of the Contracting Officer.

No Fault Found (NFF) -- Found to meet manufacturer’s minimum performance specification and requires no parts or labor.

Scrap -- To render an item unusable for its intended purpose. This applies to items that have been determined by the Government to be BER.

Unusual Damage -- Items which have been severely damaged due to mishandling or crash damage or in which repairable assemblies have been removed or swapped out. Components that are missing consumable items are not considered to be unusually damaged.