Statement_of_Work.pdf

DEPARTMENT OF THE AIR FORCE

Ogden Air Logistics Center (OO-ALC) AFMC

Hill AFB, UT 84056-5609

Statement of Work (SOW)

PURCHASE REQUEST NO.

FD20202400599

FD20202400782

ESSENTIAL OVERHAUL/REMANUFACTURE FOR:

Dated: 02 June 2024

T-38 Gearbox

NSN: 1680-01-440-5106RP, PN: 14-51100-501/-503

SOW for the Essential Repair of T-38 Gearbox

1.0 Introduction

2.0 Definitions And Acronyms

3.0 Data

3.1 Commercial Asset Visibility Air Force (CAV AF) Asset Report

3.2 Contract Depot Maintenance (CDM) Production Report

3.3 Annual Government Property Physical Inventory Report

3.4 Teardown Deficiency Report

3.5 IUID Marking Plan

3.6 AFTO Form 95

3.7 Request for Deviation (RFD)

3.8 Remanufactured Data

3.9 Functional Test Data

3.10 Quality Deficiency Report

3.11 IPE report

3.12 Full Support Equipment Report

3.13 TDP

3.14 Contract Data Requirements List (CDRL)

4.0 Security

4.1 Per Export Control Limitations

5.0 Government Furnished Property (GFP)

5.1 Handling:

6.0 Supply Chain Requirements

7.0 Quality system requirements

7.1 Quality Deficiency Reports (QDRs):

7.2 PQDR Process:

8.0 Condemnation

8.1 Contractor’s Scrap Procedures:

8.2 Disposition of Scrap Items:

9.0 Handling

10.0 Teardown Deficiency Inspection

11.0 Test Equipment Standup

12.0 Initial Production Evaluation Requirements

13.0 General Remanufacture Requirements

13.1 Non-Destructive Inspection (NDI)

13.2 Mis-Identified Material

14.0 Specific Remanufacture Requirements

14.1 Notable Required Capabilities (but not limited to):

14.1.8 Notable High Expense Piece-Parts of the Accessory Drive Gearbox

14.2 Remanufacture/Overhaul:

14.3 Over and Above Work (O&A)

14.4 Beyond Economic Repair (BER):

14.5 Cannibalization:

14.6 Item Unique Identification (IUID) Marking:

14.7 Program Management Team (PMT):

14.8 Production Meeting:

14.9 Warranty:

15.0 Technical Publication Compliance

Appendix A

1.0 INTRODUCTION

1.1 This Statement of Work (SOW) establishes the minimum work requirements for essential overhaul/remanufacture of the T-38 Accessory Drive Gearbox (asset), to a serviceable “A” condition.

1.2 Remanufacture/overhaul consists of a complete tear-down, build-up, and testing IAW this SOW and the technical documents referenced in section 15.0. The overhaul processes used by the Contractor shall bring service life back to the remanufactured/overhauled asset. The assets shall be restored to like-new condition, but not necessarily cosmetically new. This effort is considered a Non-Mission Essential Supply, and the Contractor will not be required to provide these services during crisis.

2.0 DEFINITIONS AND ACRONYMS

ACRONYM OR

PHRASE

DEFINITION

ACO Administrative Contracting Officer – contracting officer who performs actions delegated by the PCO at the initiating activity

ADG Accessory Drive Gearbox ADR Accelerated Delivery Request – AFMC form 200, used to process accelerated delivery requirements to support high-priority backorders and MICAPS.

AF Air Force AFI Air Force Instruction AFMCI Air Force Material Command Instruction AFOSI Air Force Office of Special Investigation AFTO Air Force Technical Order – Authorized manual directing and providing instructions for performing work on Air Force Assets ASSEMBLY Two or more parts or subassemblies joined together to form a complete unit, structure, or other article.

AT Acceptance Test: The functional and operational tests performed on the end- item to ensure that all performance standards are satisfactorily met to restore the end-item to a serviceable condition.

BER Beyond Economical Repair - When the cost of repair exceeds 75% of the stock list price or the current replacement cost, whichever is greater.

BFWT Beyond Fair Wear and Tear BOM Bill of Materials CAC Common Access Card CAD Computer Aided Design CALIBRATION A comparison between two instruments, one of which is a standard of higher accuracy, to detect and correlate or adjust any variation in the accuracy of the instrument or equipment item being compared or tested.

CAV AF Commercial Asset Visibility Air Force. This is the asset production reporting system for Contractor repairs and GFM transactions.

CDRL Contract Data Requirements List CDM Contract Depot Maintenance CLIN Contract Line Item Number CMRS Contract Repair Management System CO Contracting Officer CONDEMN A normally repaired item which, due to the extent of required work process, has been deemed uneconomical to make serviceable.

COMPONENT A normally repaired item which, due to the extent of required work process, has been deemed uneconomical to make serviceable.

COR Contracting Officer Representative DCMA Defense Contract Management Agency

ACRONYM OR

PHRASE

DEFINITION

DD FORM 1348-1A Department of Defense (DoD) form required to be created and attached on all Government Property being shipped from the Contractor’s facility IAW DLM 4000.25-1 (ref most current amendment or replacement).

DFARS Defense Federal Acquisition Regulation Supplement DID Data Item Description DISASSEMBLE To remove the components that make up the end-item in accordance with disassembly instructions IAW Technical Data.

DoD Department of Defense DoDI Department of Defense Instruction ECA External Certificate Authority ECMRA Enterprise Contractor Manpower Reporting Application EDD Estimated Delivery Date EI Engineering Investigation EPA Environmental Protection Agency ES Equipment Specialist ESS Environmental Stress Screening ETIMS Enhanced Technical Information Management System FAR Federal Acquisition Regulation FLIS Federal Logistics Information System FOD Foreign Object Damage FY Fiscal Year GFP Government Furnished Property – Property in the possession of, or directly acquired by, the Government and subsequently furnished to the contractor for performance of a contract (see FAR part 45.101). For the purposes of this SOW, property includes materials, equipment, shipping containers, and carcasses provided to the contractor.

IAW In Accordance With IPE Initial Production Evaluation – An IPE is a planned Government review of early production items and processes to evaluate a Contractor’s ability to complete the work in accordance with the contract, applicable technical orders, and other guidance required by this SOW.

IUID Item Unique Identification – The program was an initiative incorporated by the Government to improve the tracking of assets during transit, operation, storage, and repair. This program was implemented to provide an easier means for the Contractor and DoD to track unique assets through electronically scanning the asset tag which identifies the item.

JCALS Joint Compute-Aided Acquisition and Logistics Support LMS Logistics Management Specialist MICAP Mission Incapable Awaiting Parts – The status of a weapon system, as determined by its ability to accomplish its assigned mission. MICAP situations are a grounded aircraft in need of an immediate serviceable asset or repair.

MILSTRAP Military Standard Transaction Reporting and Accountability Procedures MILSTRIP Military Standard Requisitioning and Issue Procedures NAC National Agency Check NDI Non-Destructive Inspection NFF No Fault Found NIIN The National Item Identification Number consists of a 2-digit National Codification

Bureau number designating the central cataloging office (whether North Atlantic Treaty Organization or other friendly country) that assigned the number and a 7-digit (xxx-xxxx) non-significant number.

NLT No Later Than

DEFINITION

NSN National Stock Number – The 13-digit stock number replacing the 11-digit Federal Stock Number. It consists of the 4-digit Federal Supply Classification code and the 9-digit National Item Identification Number. The National Item Identification Number consists of a 2-digit National Codification Bureau number designating the central cataloging office (whether North Atlantic Treaty Organization or other friendly country) that assigned the number and a 7-digit (xxx-xxxx) non-significant number. The number shall be arranged as follows: 9999-00-999-9999.

O&A Over and Above OEM Original manufacturer OO-ALC Ogden Air Logistics Complex OSHA Occupational Safety and Health Administration PCO Procuring Contracting Officer PM Program Manager – Government Individual responsible for the overall program or project.

PMO Program Management Office PMPS Parts, Material, and Process Selection PMR Program Management Review – Biannual review with contractor and government personnel to review contract status and to address all issues from both sides.

POC Point of Contact PQDR Product Quality Discrepancy Report – A tool to report or respond to deficiencies found with either repair or new manufacture of the end product.

PWS Performance Work Statement QA Quality Assurance QAR Quality Assurance Representative QASP Quality Assurance Surveillance Plan QDR Quality Deficiency Reporting RECOVERABLE An unserviceable item that can have maintenance performed to restore it to a serviceable condition.

REMANUFACTURE Major repair of an item, piece of equipment, or material which is degraded or inoperable (reference FAR 22.1003-6).

REPAIR The restoration of an item to a completely serviceable condition as prescribed by applicable technical data.

RFD Request for Deviation ROD Report of Discrepancy RTOK Retest Okay SDR Supply Discrepancy Report SERVICEABLE Capable of meeting the requirements and performing the function for which it was designed or modified and meets all test requirements established by this work specification and the Technical Data cited in the SOW

SP Supply Planner: The individual who develops and prepares the Contract Maintenance Purchase Request (PR) package during the duration of the contract.

SPI Special Packaging Instruction SRU Shop Replaceable Unit SOW Statement of Work TCTO Time Compliance Technical Order

TDP Technical Data Package

TECHNICAL DATA All government and contractor drawings, specifications, standards, Technical Orders (TOs), technical manuals, and all other technical publications necessary to restore an item to a serviceable condition.

TO Technical Order TODO Technical Order Distribution Offices UII Unique Item Identifier

DEFINITION

UNSERVICEABLE An item in a condition unfit for use but which can be restored to a serviceable condition after repair, rework, or repair. This condition includes items requiring calibration, test, modification, assembly, or the addition of components.

UPDATE To bring an end-item up to the latest acceptable Government approved configuration without changing its original form, fit or functional capability.

USAF United States Air Force USG United States Government WAWF Wide Area Work Flow - a paperless contracting DoD-wide application designed to eliminate paper from the receipts and acceptance process of the DoD contracting life cycle.

WCD Work Control Document – a procedural document used by facility personnel to perform activities such as maintenance, inspections, testing, or other work.

WR Work Request

3.0 DATA

Reporting and data requirements shall be provided in the Contract Data Requirements List (CDRL), DD Form 1423-1. The Contractor shall prepare and submit the following records, forms, or reports in support of this work effort.

3.1 Commercial Asset Visibility Air Force (CAV AF) Asset Report

Refer to the CAV AF Reporting Requirements Document for technical requirements/considerations, responsibilities, and reporting requirements of the CAV AF system. IAW CDRL A001.

The Contractor is required to report asset transactional data through electronic submission using the Government’s CAV AF system. The contractor is required to be able to perform all transactions in the Contractors User Guide, Version 9.0.4 or higher. The purpose of CAV AF is to maintain asset visibility and accountability throughout the remanufacture process, update asset condition and balance to Air Force Supply Systems, reports financial and inventory balances, and feed production and unit remanufacture costs to the maintenance and budgeting systems. Data entry into CAV AF generates the DD Form 1348- 1A which is mandatory for shipping and receiving transactions.

3.2 Contract Depot Maintenance (CDM) Production Report

The Contractor shall report monthly IAW CDRL A002 on all applicable categories, totals, and on-hand balances, providing all listed Data Item Description (DID) requirements for each remanufacture location, including Sub-Contractor facilities, if applicable, for the contract’s maintenance occurrence actions during the reporting period.

3.3 Annual Government Property Physical Inventory Report

The Contractor shall provide an Annual Government Property Physical Inventory Report IAW CDRL A003.

The Contractor shall conduct an annual 100% physical inventory over the course of a year’s time of each NIIN as not to impede maintenance operations. Upon completion of all NIIN’s 100% physical inventory, the Contractor shall provide the AF Government inventory listing of the result of all AF GFP in the Contractor’s possession. The report will be provided annually beginning one year after contract award.

3.4 Teardown Deficiency Report

The contractor shall generate a Teardown Deficiency Report that includes but is not limited to workmanship and non-conformance, material failure, packaging, handling, and shipping deficiencies. The report should further note the part number and identification of deficiencies found as well as the recommended corrective action, IAW CDRL A004.

3.5 IUID Marking Plan

The contractor shall provide an IUID marking plan (see section 14.6) IAW CDRL A005.

3.6 AFTO Form 95

The Contractor shall provide a completed AFTO Form 95, Significant Historical Data, with every asset remanufactured. The report shall be documented with any permanent history of significant maintenance actions during the remanufacture of the assets. The AFTO Form 95 will be included inside the box/crate with the remanufactured part prior to shipping IAW CDRL A006.

3.7 Request for Deviation (RFD)

The contractor shall submit requests for all deviations, waivers, and non-conformance for new and remanufactured parts. Requests will be submitted on an as needed basis IAW CDRL A007.

3.8 Remanufactured Data

The contractor shall collect data from each gearbox including a list of all replaced parts. This data shall be turned in as data sets IAW CDRL A008.

3.9 Functional Test Data

The contractor shall collect data from each gearbox of all functional test results. This data shall be turned in as data sets IAW CDRL A009.

3.10 Quality Deficiency Report

The contractor shall submit deficiencies in quality (see section 7.0) IAW CDRL A010.

3.11 Initial Testing Data

The contractor shall submit the required test data following the IPE inspection (see section 12.3) IAW

CDRL A011.

3.12 Full Support Equipment Report

The contractor shall submit a report demonstrating that the equipment meets or will meet requirements as described in section 11.2 IAW CDRL A012.

3.13 TDP

The contractor shall submit a TDP of the developed tooling, fixtures, etc. as described in sections 11.2 and

12.4 IAW CDRL A013.

3.14 Contract Data Requirements List (CDRL)

CDRL # Title Schedule SOW Ref.

A001 Commercial Asset Visibility Air Force

(CAV AF) Assets Report As required 3.1, 9.1

A002 Contract Depot Maintenance Production Report

Monthly 3.2

A003 Annual Government Property Inventory Report

Annually 3.3

A004 Teardown Finding Report As Required 3.4, 10.1.1, 10.1.4, 13.2, 14.2.4

A005 Item Unique Identification (IUID) Marking plan

Within 90 calendar days of award 3.5, 14.6.1

A006 AFTO 95 Every asset remanufactured 3.6

A007 Request for Deviation (RFD) As needed 3.7, 13.4

A008 Remanufacture Data Every 10 Assets* 3.8* A009 Functional Test Data Every 10 Assets* 3.9*,

14.2.7.4 A010 Quality Deficiency Report (QDR) As needed 3.10, 7.2.1

A011 Initial Testing Data Within 10 Business days after successful IPE

3.11, 11.3, 12.3, 12.3.3, 12.4

A012 Full Support Equipment Report Within 90 calendar days of award 3.12, 11.2

A013 Technical Data Package (TDP) Final submission within 45 days of IPE Approval

3.13, 11.2, 12.4, 14.1.7.2, 14.1.7.3

4.0 SECURITY

The Contractor shall ensure requirements for safeguarding of information and materials for protecting Government Property and data are fulfilled.

4.1 Per Export Control Limitations.

Foreign Disclosure Restrictions IAW AFMCI 21-113, 21- 149 and 23-102 do not apply.

5.0 GOVERNMENT FURNISHED PROPERTY (GFP)

GFP Accessory Drive Gearbox is property in the possession of, or directly acquired by, the Government and subsequently furnished to the Contractor for performance of a contract. The Contractor shall account for and track all GFP in their possession, and shall ensure GFP is protected from damage, weather, foreign matter, or pilferage when being handled or stored IAW DoD 5200.1-R. The GFP to be furnished to the Contractor is listed below.

Noun NSN Part Number Qty Purpose T-38 Gearbox 1680-01-440-5106 14-51100-501/-503 As per contract Remanufacture T-38 Gearbox 1680-01-440-5106 14-51100-501/-503 1 (A condition) IPE (loan lease) T-38 Gearbox 1680-01-440-5106 14-51100-501/-503 3 (F condition) IPE Oil Pump 4320-01-426-4367 3-51251-1 1 (A condition) IPE (loan lease)

5.1 Handling:

The Contractor shall exercise care to prevent any damages, pilferage, or loss of GFP while it is in the Contractor’s possession. The Contractor shall store all GFP in a secure area and provide protection against all adverse environment conditions. Reusable shipping containers, packaging, and crating material in which the GFP is received shall be handled with care.

6.0 SUPPLY CHAIN REQUIREMENTS

6.1 Contracts must have their own supply chain established and maintained during the duration of the contract. The government will not provide parts for the remanufacture of the assets.

7.0 QUALITY SYSTEM REQUIREMENTS

7.1 Quality Deficiency Reports (QDRs):

Deficiency Reports consist of EIs and QDRs. The contractor shall investigate, take corrective action if necessary, and reply to user initiated QDRs forwarded to them by DCMA. This applies to all QDRs submitted against products remanufactured/overhauled by the contractor and/or their subcontractors or vendors. Sufficient priority shall be given to QDR investigations to allow timely corrective action and to meet timeline requirements of TO 00-35D-54.

7.2 PQDR Process:

If a GFP Accessory Drive Gearbox is received from the Contractor and at any time during the warranty period (see section 14.9.1) the asset becomes unserviceable the Government will initiate a PQDR and return the asset back to the Contractor. The Contractor shall bring the GFP Accessory Drive Gearbox to serviceable condition at no additional cost to the Government within 30 business days. In addition, if an asset is returned for rework as a result of a PQDR more than 1 time in any 12-month period then the Contractor shall conduct an EI at no additional cost to the Government before returning the GFP Accessory Drive Gearbox to serviceable condition. The Contractor shall coordinate actions with the PCO and LMS. Any tests that will be excluded as part of this effort will have prior written approval from the

LMS.

7.2.1 The contractor shall report findings in accordance with CDRL A010

7.2.2 In the event the final determination for the QDR returned unit is “No Fault Found (NFF)”, or any other category indicating that no deficiencies were found, the contractor may submit a proposal to the Government for the evaluation, test, and analysis costs. Such costs may be negotiated on an as needed basis. It is the intent of the Government to reasonably compensate the contractor for work required under the QDR Process when returned items meet the above described NFF condition.

8.0 CONDEMNATION

8.1 Contractor’s Scrap Procedures:

Disposition of condemned parts containing critical alloys and/or precious metals shall be IAW TO 00-25- 113 and FAR 45.6, titled "Reporting, Redistribution and Disposal of Contractor Inventory." The Government ES provides Disposition Instructions to the LMS with PCO included; this will be for items the contractor has deemed Beyond Economic Repair (BER) and has submitted a Request for Disposition to the LMS and PCO

8.2 Disposition of Scrap Items:

All condemned items shall be scrapped IAW the corresponding de-militarization (DEMIL) code assigned to that part number/NSN. Disposition shall be reported in CAV AF. DEMIL codes are found in Haystack Gold.

9.0 HANDLING

9.1 Record, Forms and Reports: The contractor shall make available to the appropriate PCO/Program office representative, IAW the DD 1423-1, the required information to enable them to review and/or verify monthly production status reports on assets and to enable them to complete their records or to complete such reports as may be required IAW CDRL A001.

10.0 TEARDOWN DEFICIENCY INSPECTION

10.1 An inspection shall be performed on the end-item upon its receipt at the contractor’s facility for the following:

10.1.1 Proper identity: NSN 1680-01-440-5106 Part Number 14-51100-501/-503, Accessory Drive Gearbox. Each item shall be inspected upon receipt to determine its condition and to ensure that its item identification corresponds to that shown on the contract schedule. Non-conforming assets shall be reported to the LMS IAW A004.

10.1.2 Physical damage.

10.1.3 Completeness as described in contractor Bill of Material (BOM).

10.1.4 Any deficiencies found shall be reported to the LMS IAW A004.

10.2 Consolidated Reparable Inventory (CRI): The contractor will act as the Consolidated Reparable Inventory (CRI) custodian to store reparable assets.

10.3 Inventory Records: The contractor shall keep detailed records of all AF assets in accordance with CAV

AF.

11.0 TEST EQUIPMENT STANDUP

11.1 The contractor shall develop test equipment capable of performing all test requirements as described in TO 16G1-102-3 and TO 7J4-2-34-3 and will provide test equipment documentation and repeatability testing results in accordance with the requirements outlined in 11.1-11.3.

11.2 Within 7 days of contract award the government will send one (1) F-condition gearbox to aid in test equipment development and early IPE preparation, this will also be used as one of the three IPE units described in Paragraph 12.0. The government will also initiate a loan lease for one (1) A-condition gearbox and one (1) A-condition oil pump within 100 calendar days of contract award for the contractor to perform validation/repeatability testing of testing equipment.

11.3 The contractor shall submit a full Support Equipment Report, within 90 calendar days of contract award, that details all the equipment specs, special tooling, fixtures, calibration requirements (see Appendix A), inspection equipment, etc. and that demonstrates the equipment meets or will meet requirements as described in TO 16G1-102-3 and TO 7J4-2-34-3 (CDRL A012). Included in this report shall also be an evaluation of the special tooling found in chapter 2 of each TO documenting the tools that can be procured and the tools that must be reverse engineered. An initial review showing progress of the TDP (CDRL A013) for any tooling, fixtures, etc. developed on this contract (see section 14.1.7) shall also be submitted with the Support Equipment Report (CDRL A012). TDP requirements do not apply to the oil pump, static, or dynamic test stands.

11.4 To show readiness for IPE inspection, the contractor shall provide a copy of as-built test stand performance characteristics and a copy of repeatability testing results IAW CDRL 011. Upon government receipt and approval of the data and test results, the two (2) remaining F-condition assets shall be shipped to the contractor in preparation for IPE inspection. This calibration data and repeatability test data shall be officially submitted IAW CDRL A011.

11.4.1 Repeatability data consists of running an A-condition asset multiple times on a test stand to show the stand’s repeatability. A successful run consists of installing an asset onto the test stand, the asset passing the test, and removing the asset from the test stand. Data is needed on each of the three different tests (oil pump tests, static tests, dynamic tests) showing 4 successful runs on each test.

11.4.2 In the event that the A-condition asset does not pass on the test stand, repeatability testing may be completed, but the discrepancy between a passing performance and a failing performance must be investigated and resolved before final acceptance of the test stand and successful completion of the IPE. Teardown of the A-condition asset as part of the investigation shall not be permitted unless directed by the PCO. Depending on the outcome of the investigation, repeatability testing may need to be redone.

12.0 INITIAL PRODUCTION EVALUATION REQUIREMENTS

12.1 IPE inspection shall be completed within sixty (60) calendar days of receipt of all IPE gearboxes. The IPE requirement will not be waived by the Government at the time of contract award.

12.2 The Contractor shall notify the LMS, with the PCO cc’d, of possible dates and the anticipated itinerary for the IPE inspection. The LMS shall notify the Contractor of the projected dates that the Government IPE Inspection Team will arrive at the Contractor’s facilities to conduct the IPE inspection. The Contractor shall permit entrance to the Evaluation Team into its facilities. This includes access to Contractor Wi-Fi, or other amenities as needed, for accomplishment of the IPE inspection.

12.3 The IPE inspection shall be conducted on three (3) Accessory Drive Gearbox assets of each line item delivered to the contractor in F condition. The contractor shall bring the condition of the three (3) F condition assets to 3 different states for IPE as follows: one (1) each asset out of the packaging and ready to be disassembled to follow the entire remanufacture procedure, one (1) each asset fully disassembled, cleaned, and ready for assembly and testing (including oil pump testing, governor leak testing, and clutch lock up testing mentioned in sections 14.1.1 through 14.1.4), and one (1) each asset assembled and ready for static and dynamic testing. Within 10 business days after IPE inspection, the contractor shall supply all testing data, including the 4 repeatability runs on the oil pump test, static test, and dynamic test, as well as all testing for each individual F-condition asset (CDRL A011).

12.3.1 Purpose of this is for the government to observe the process, procedure, and technicians to ensure disassembly, assembly, and testing are done IAW the TOs. The contractor shall provide a copy of all shop travelers/WCDs/documentation associated with repair and overhaul of each unit inspected.

12.3.2 Any action items from the IPE inspection shall be documented by the contractor and resolved before a final pass for the IPE can be given.

12.3.3 The government inspection team shall provide a pass/fail/redo report of the findings within ten

(10) business days of receipt of CDRL A011.

12.4 Final TDP submission (CDRL A013) shall be completed within 45 calendar days after submission of CDRL A011. See 14.1.7.2.

12.5 Before IPE inspection approval, the acquisition of materials or components for, or the remanufacture of the balance of the contract quantity, is at the sole risk of the Contractor. Before IPE inspection approval, the costs thereof shall not be allocable to this contract.

12.6 If the contractor passes IPE, remanufacture of the three (3) Accessory Drive Gearbox F condition assets used for IPE to serviceable condition will be completed under the IPE CLIN.

12.7 If the Contractor fails IPE, and depending on the results of the IPE, the Contractor may receive an additional attempt to redo part or all of the IPE at no cost to the government. The Contractor shall make any necessary changes or modifications and the additional attempt shall start no later than 45 calendar days after the previous IPE inspection.

12.8 Test Equipment and IPE Timetable

Item Timeline Ref

1. Full support equipment report, initial review of

TDP

Within 90 calendar days of award

11.2

2. Calibration data and test stand (as built) performance characteristics

Approx. 120 calendar days after award (or sooner if able)

11.3

3. Repeatability testing Within 45 days after calibration

11.3

4. IPE inspection Within 45 days after repeatability testing

12.3

TDP submission (if applicable) Within 45 calendar days after submission of CDRL A011

12.4

13.0 GENERAL REMANUFACTURE REQUIREMENTS

13.1 Non-Destructive Inspection (NDI)

The Contractor shall accomplish Non-Destructive Inspection (NDI) by disassembly to the extent necessary to assure a definite acceptance or rejection of the suspected item or area. NDI shall be performed IAW the

TO.

13.2 Mis-Identified Material

Upon receipt of misdirected or mis-identified material, contractor shall submit a Supply Discrepancy Report (SDR) in the WEBSDR system, https://home.daas.dla.mil/daashome/websdr.asp. In the event the contractor cannot access WEBSDR, then a Report of Discrepancy (ROD) shall be submitted to the government LMS for disposition IAW CDRL A004.

13.3 The contractor shall furnish all parts, plant facilities, labor, and equipment necessary to perform inspection, remanufacture/overhaul, and replacement of necessary components, functional/acceptance testing and calibration. Assets shall be restored to a serviceable condition that will enable them to perform their intended function. The contractor shall make no unauthorized modifications to any item.

13.4 Parts or material used shall be equal to or exceed the original requirements of technical data cited herein.

In the event deviation from the technical data is required, and the contractor desires the use of a substitute part, an approval request in letter form will be submitted through the LMS and PCO who will obtain the appropriate engineering approval. A copy of the request and any subsequent approvals shall be forwarded to DCMA QAR for informational purposes. Requests will be submitted on an as needed basis IAW CDRL A007.

14.0 SPECIFIC REMANUFACTURE REQUIREMENTS

14.1 Notable Required Capabilities (but not limited to):

The following capabilities, if not already acquired by the contractor, require test stands, training, additional fixtures, equipment, or special tooling to meet TO requirements. Reference TOs 16G1-102-3 and 7J4-2-34-3.

14.1.1 Oil pump flow testing (7J4-2-34-3, Section 7.1)

14.1.2 Governor leak rate and Governor/Input Shaft combo leak rate testing (16G1-102-3, Section

5.2.e)

14.1.3 Sprag clutch lock-up testing (16G1-102-3, Section 5.2.a)

14.1.4 Disk clutch lock-up testing (16G1-102-3, Section 5.2.a)

14.1.5 Gearbox static testing (16G1-102-3, Section 7.2.a)

14.1.5.1 Generator initial backlash

14.1.5.2 Input shaft backlash

14.1.6 Gearbox dynamic testing (16G1-102-3, Section 7.2.b)

14.1.6.1 Break-in runs

14.1.6.2 Performance runs

14.1.6.3 Vibration check

14.1.6.4 Leak check

14.1.7 Special tooling or fixtures, called out the in TO may not be procurable and require reverse engineering. If available, the Government may be able to share tooling drawings but there is no guarantee that the technical data is available.

14.1.7.1 Any reverse engineered tooling, fixtures, or equipment shall be approved prior to manufacture by the Government for authorization as a suitable equivalent for special tools called out in the TO.

14.1.7.2 All reverse engineered tooling, fixtures, or equipment, with the exception of test stands required for testing in sections 14.1.5 and 14.1.6, developed under this contract shall be delivered in a TDP IAW CDRL A013 and shall represent the approved, tested, and accepted configuration. TDP data includes, but is not limited to, CAD data, CAD models, model-based definition data sets, Gerber data (if applicable), master Bill of Materials and parts lists, schematics, wiring, diagrams, assembly drawings, functional block diagrams and flowcharts, and equipment layout (as applicable). The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement and manufacture of an interchangeable item that duplicates the physical and performance characteristics of the original product without additional design engineering effort or recourse to the original design activity. For any third-party items procured for this effort the contractor shall provide the OEM’s original nomenclature, key characteristics, and the data sheets as part of the TDP.

Vendor Item Control Drawings shall be used to specify the requirements for purchased items when such items have been approved for use in the design and are used without alteration, selection, or source qualification (testing of an item prior to procurement action to ensure that it satisfies the specified requirements).

14.1.7.3 All engineering product definition data created using Government funding because of this contract shall be considered a part of the TDP and shall be delivered to the Government with unlimited rights. The TDP shall be delivered in accordance with

CDRL A013.

14.1.8 Notable High Expense Piece-Parts of the Accessory Drive Gearbox

The following parts have been the top 5 most expensive parts to purchase and/or repair.

Replacement rates included (RR).

14.1.8.1 Input Shaft (PN 3-51232-501) RR 53%

14.1.8.2 Clutch Cylinder (PN 3-51131-1) RR 54%

14.1.8.3 Input Cap Assembly (14-51204-1) RR 70%

14.1.8.4 Cluster Gear for Disk Clutch (3-51145-1) RR 75%

14.1.8.5 Cluster Idler Gear (3-51147-1) RR 82%

14.2 Remanufacture/Overhaul:

Accomplishment of the specific work requirements will be IAW the TOs, test manuals, remanufacture manuals, and overhaul manuals. See section 15.0. If the contractor requests any deviations, they shall notify the LMS and PCO prior to work being started.

14.2.1 Disassembly: The contractor shall disassemble each asset to the extent necessary to accomplish inspection and determine reparability of the asset and component parts.

14.2.2 Cleaning, Corrosion Control, Treatment: The contractor shall clean the asset thoroughly prior to and after disassembly and maintain cleanliness during this remanufacture effort.

Accomplish corrosion control and treatment as required, using methods and materials IAW MIL-STD-1250, MIL-HDBK-454B, and MIL-HDBK-1568C.

14.2.3 Paint Removal: The paint shall be removed from each asset and component parts as necessary to complete the inspection process.

14.2.4 Inspection: An inspection for proper identity, completeness, and obvious damage shall be performed on each asset upon its receipt at the Contractor’s facility. Any deficiencies found as a result of the inspection shall be brought to the attention of the asset LMS IAW CDRL A004.

The contractor shall accomplish a thorough inspection of each asset to determine the reusability and reparability of the asset and component parts.

14.2.5 Overhaul: The asset shall be completely remanufactured/overhauled in accordance with TOs 16G1-102-3 and 7J4-2-34-3 and other government specifications and procedures as applicable to produce a serviceable asset.

14.2.6 Routine, Mission Impaired Capability Awaiting Parts (MICAP), Surge, and Essential DoD Contractor Services: The Contractor shall be responsible for returning serviceable assets in the time set forth in this contract.

14.2.7 Acceptance Testing: Completed assets shall meet the original product function specification for PN 14-51100-501/-503 per Technical Order 16G1-102-3. If USAF suspects any degradation in performance, the contractor may be required to verify performance through testing in accordance with the same specification.

The Contractor shall perform an acceptance test of each completed asset to assure serviceability prior to DCMA inspection. All tests/inspections shall be accomplished IAW the specifications found in Section 15.0.

14.2.7.1 Upon satisfactory completion of final acceptance test, the Contractor shall cover and seal all ports, vents, and electrical connections/plugs with suitable caps to prevent entry of foreign matter or damage during handling and shipment.

14.2.7.2 All completed work shall be subject to acceptance inspection by Defense Contract Management Agency (DCMA).

14.2.7.3 In the event of failure impacting delivery schedule, the contractor shall notify the appropriate DCMA liaison, PCO, and LMS of schedule changes within one (1) business day.

14.2.7.4 The acceptance test report for each completed asset shall be delivered to the government IAW CDRL A009.

14.2.8 Marking, Packaging, Shipping:

The marking and packaging shall be in accordance with the Special Packaging Instructions (SPI), TO 00-85B-3 How to package AF spares.

Reusable shipping containers, packaging, and crating material in which the asset is received shall be handled with care. Reusable containers shall be stored for reuse, and configuration of the containers shall not be altered. All assets will always be returned or shipped utilizing form DD 1348-1A unless otherwise directed by the Government. Contractor is required to comply with all CAV AF requirements identified in the CDRLs and attachments to the contract.

Additionally, upon completion of the remanufacture, the contractor is required to print the DD1348-1A (in triplicate) from CAV AF. Place one copy on the outside of the shipment container, one copy inside the shipment container, and retain the third copy for the contractor's records.

If at any time the reusable shipping container arrives at the contractor facility damaged beyond repair, the contractor will accomplish associated remanufacture of such packaging, or provide new packaging. The contractor shall be responsible for ensuring that containers are IAW the

Special Packaging Instructions (SPI). Costs associated with such remanufacture shall be negotiated through the PCO and included in the O&A line item via modification to the contract.

14.2.8.1 Delivery Schedule: The delivery of serviceable asset, PN: 14-51100-501/-503, shall be IAW the contractually agreed delivery schedule.

14.2.8.2 Government Acceptance Inspection: All work will be subject to government acceptance inspection and shall conform to this work specification, the technical orders and other applicable directives as listed in Section 15.0.

14.3 Over and Above Work (O&A)

14.3.1 For assets determined by the contractor to require O&A work, the contractor shall forward detailed remanufacture actions necessary to return the asset to serviceable condition, delineating required actions, parts (noun, NSN, part number), and costs, through the LMS with PCO included for determination. Information gathered during initial inspection should be documented. The contractor shall retain any evidence of possible O&A issues to show BFWT or catastrophic failure. Units received with missing parts or units with an unusual premature failure, damaged from improper packaging, being dropped prior to packaging, fire, accident, submersion, misapplication of power, inept attempts at maintenance, mis-configured, FOD, excessive corrosion due to lack of proper preservation, lack of lubrication or other unusual damage may also be considered O&A and not conditions included in the fixed overhaul pricing.

14.3.2 If BFWT or catastrophic failure is suspected, as a minimum, photos of the damaged equipment shall be taken and a narrative of the findings shall be sent to the LMS with PCO included. Then, it will be priced, negotiated, and approved by the PCO through a contract modification, prior to the work being initiated. O&A remanufacture must be remanufactured and returned within a negotiated time and documented on the contract modification.

14.3.3 The individual assets that require O&A remanufacture will be listed under the O&A CLIN and will include the necessary asset identifying information, including the part number, serial number, dollar amount that exceeds the standard unit price to remanufacture the asset, inspection and acceptance information, and specified delivery schedule.

14.4 Beyond Economic Repair (BER):

14.4.1 For assets determined by the contractor to be BER, the contractor shall forward detailed repair actions necessary to return asset to serviceable condition delineating required actions, parts (noun, NSN, part number), and costs, through the LMS with PCO included. The PCO will provide the final determination/disposition details.

14.4.1.1 BER is usually defined where the total cost of the repair of any end item received exceeds 75% of the Stock Listed price.

14.4.2 Costs shall be only for those components and sub-components that are over and above the remanufacture actions already included in the remanufacture CLIN of those assets and which are not included in the Bill of Materials (BOM) replacement percentages supporting those CLIN costs.

14.4.3 If asset is deemed BER by the contractor, the government will verify claims of BER based on documentation and pictures provided by the contractor through the LMS with PCO included. If the government concurs and the assets includes salvageable Air Force managed component parts, disposition instruction will be provided for those parts. The PCO will provide the final contractual disposition instructions.

14.4.4 BER CLIN is meant to reimburse screening efforts when assets are identified to not be feasibly remanufactured before work takes place. BER CLIN is not meant to compensate all troubleshooting efforts on an item after the work is done. The individual asset that is deemed BER will be listed under the appropriate CLIN by the PCO.

14.4.5 The contractor shall follow disposition instructions provided by the PCO.

14.5 Cannibalization:

Cannibalization of piece part/sub-components from unserviceable assets and creating a situation where assets are BER shall not be allowed. The contractor is allowed to borrow components from assets waiting remanufacture to maintain workflow and meet schedules, but such actions must be documented and available for review upon request by the Government. Components must be replaced at no additional cost to the Government. The contractor will be allowed to retain condemned units for cannibalization of spare parts upon review from the LMS with PCO included. Upon completion of the contract, the contractor shall dispose of parts retained for cannibalization.

14.6 Item Unique Identification (IUID) Marking:

IAW AFMCI 20-105 Para 3.12

14.6.1 The contactor shall provide and conform to an IUID marking plan. A copy of the Contractor’s IUID marking plan will be provided to DCMA and the LMS within 90 calendar days of contract award. IAW CDRL A005.

14.6.2 The Contractor shall replace damaged or missing markings, identification, and decals. IUID markings are required for all assets and subcomponents to the assets IAW the Technical Data listed in Section 15.0.

14.6.3 Each completed end-item will be permanently and legibly marked with the Contractor’s facility identification. This identification will display the name of the Contractor facility, date of maintenance and contract number. This identification can be by decalcomania, rubber stamp, or stencil. When using rubber stamp or stencil, use permanent, waterproof ink or paint of contrasting color; also, end-item identification plates shall reflect the latest configuration/update, i.e., National Stock Number (NSN), Part Number as applicable.

14.6.4 For items that do not have an IUID marking specifications the Contractor shall develop the marking specifications in accordance with the latest version of MIL-STD-130N.

14.6.5 IUID markings currently in place on items undergoing remanufacture shall be protected from damage or removal during remanufacture. Ensure 2-D matrix IUID markings are readable per T.O. 00-25-260. Should IUID marking be rendered unreadable during remanufacture, the Contractor shall notify the PCO for determination.

14.6.6 IUID markings which may be potentially destroyed during remanufacture due to technical direction (i.e. paint removal, sand blasting, etc.) shall be recorded prior to maintenance action and replaced with the same Unique Item Identifier (UII) as part of the remanufacture action.

14.6.7 The Contractor shall submit the required and applicable data for legacy items to the DoD IUID Registry per the data submission procedures at http://www.acq.osd.mil/dpap/pdi/uid/data_submission_information.html.

14.7 Program Management Team (PMT):

The contractor shall designate a Program Management Team. This team will be responsible for all aspects of this contract to ensure contractor performance. There shall be designated POCs for Contractor and Government interface and problem resolution.

14.8 Production Meeting:

Production meetings may be requested and held via teleconference as needed.

14.9 Warranty:

14.9.1 Warranty of Work: The Contractor shall warranty their work IAW industry standards. The Contractor shall provide the terms of their warranty in their bid or proposal prior to contract award. Any rework that is done under warranty shall be at no additional cost to the Government.

15.0 TECHNICAL PUBLICATION COMPLIANCE

15.1 Compliance with all TOs, TCTOs, Directives, Government Specifications, Drawings, and other Technical Publications listed in this section shall be mandatory when:

They have not been previously accomplished.

It is pertinent to the assets or installed equipment.

It prescribes Air Force Policies, use of materials and procedures for overhaul.

15.2 The contractor shall coordinate all Part Number changes/requests with Government Engineering/Equipment Specialist and provide new/changed Part Number information to the Government Equipment Specialist prior to implementation.

15.3 TO Updates: The contractor shall comply with the latest dated TOs and other directives during the period of performance. In the event of a TO change during the period of performance, the contractor shall evaluate the impact of the change on costs, schedules, and any other pertinent factors. The contractor shall provide a written evaluation, along with specific justification/applicable data documenting the impact on the contractor’s performance to the LMS with PCO included within ten (10) business days after receipt of the change. The contractor shall not incorporate these TO changes until approved by the PCO.

15.3.1 Enhanced Technical Information Management System (ETIMS)

If the contractor needs a method to access the latest TO updates, the contractor may contact the LMS with PCO included for assistance.

15.4 No technical related issue in this document shall be construed as taking precedence over TOs and/or manufacturer drawings, and their accompanying documents and specifications for these assets.

15.5 The contractor shall comply with urgent action, immediate action, and safety TCTO’s within the allotted time frame.

15.6 Applicable Documents and Technical Orders

ASME Y14.38M Abbreviations and Acronyms Revision and Redesignation of ASME Y1.1

CAV AF Manual Commercial Asset Visibility Air Force (Version 8 or higher)

MIL-HDBK-1568

Materials and Processes for Corrosion Prevention and Control in Aerospace Systems

MIL-STD-130L Identification Marking of U.S. Military Property

TO 00-85B-3 How to package AF spares

TO 00-20-1

Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures (1 JUN 2018)

TO 00-20-2 Maintenance Data Documentation (15 MAR 2016)

TO 00-20-5 Aerospace Vehicle/Equipment Inspection and Documentation

TO 00-25-195

Source Maintenance, and Recoverability Coding of Air Force3 Weapons System

TO 00-25-234

General Shop Practice Requirements for the Remanufacture Maintenance, and Test of Electrical Equipment (Change 7, 25 MAR 2018)

TO 00-25-260 Unique identification Asset Marking and Tracking (15 OCT 2013)

TO 00-35D-54 USAF Deficiency Reporting, Investigation, and Resolution

TO 00-5-1 AF Technical Order System (16 JUL 2018)

TO 00-5-2 AF Technical Order Distribution System

TO 00-5-3 AF Technical Order Life Cycle Management

TO 1-1-1 Operation Instructions, Cleaning of Aerospace Equipment

TO 1-1-2 Corrosion Control and Treatment for Aircraft and Missiles

TO 1-1-4 Air Force Standard Exterior Finishes

TO 1-1-8

Application and Removal of Organic Coatings Aerospace and Non- Aerospace Equipment

TO 1-1A-8 Structural Hardware

TO 1-1-691 Aircraft Weapon System Cleaning and Corrosion Control

TO 32B14-3-1-101 Torque Indicating Devices

TO 33B-1-1 Non-Destructive Inspection Methods, Basic Theory (15 OCT 2018)

TO 33B-1-2

Nondestructive Inspection Methods, General Procedures and Process Controls

TO 16G2-7-2-3 Technical Manual Drive Assembly (PTO shaft and input/output couplings)

TO 16G1-102-2 Technical Manual Intermediate Maintenance

TO 16G1-102-3 Technical Manual Overhaul

TO 16G1-102-4 Technical Manual, Illustrated Parts Breakdown

TO 7J4-2-34-3

Technical Manual Overhaul Instructions for Gearbox Internal Oil Pump Assembly and/or supporting technical data and drawing.

APPENDIX A

Calibration accuracy tables shall be provided to interested parties by the PCO.