T53_APPENDIX_A_PWS_MAR2020.docx

T53 APPENDIX A - PWS

PERFORMANCE WORK STATEMENT (PWS)

For Inspection, Repair, and or Overhaul of the T53-L-703 Gas Turbine Engine Assembly

PREPARATION DATE: JANUARY 2020

PREPARING ORGANIZATION: AFLCMC/LPSC

TABLE OF CONTENTS

ATTACHMENTS (Separately attached documents to PWS):

A: CDRLS & DIDS SUMMARY

B: COMPREHENSIVE ENGINE MANAGEMENT SYSTEM (CEMS) ACCESS AND SECURITY CHECK PROCESS

1 DESCRIPTION OF SERVICES

1.1 Background

The United States Air Force (USAF) requires a T53-L-703 engine used in the TH-1H helicopter, to be disassembled, inspected, repaired and or overhauled, assembled and tested as required In Accordance With (IAW) Honeywell Original Equipment Manufacturer (OEM) commercial T53-L-703 manuals. The objective is to provide the USAF with serviceable T53-L-703 engines, in terms of reliability, quality, and affordability. A serviceable engine includes all accessories (such as but not limited to fuel control, accessory gearbox, production gearbox, over speed governor, life limited parts, etc.) to be considered a Ready for Issue (RFI) serviceable T53-L-703 engine. The USAF will not accept direct sale of engines or parts that have not been repaired / inspected / tested IAW Honeywell manuals. All repairs will be completed by a Honeywell authorized repair facility, that is also FAA or equivalent certified and ISO9001:2008 or higher version certified or AS9110 or higher version certified. The Contractor shall provide proof of Honeywell certification as an authorized engine / component repair facility for the T53- L-703 engine and its’ covered components for themselves or any subcontractor who is performing the maintenance actions as part of their proposal to be considered for evaluation of the T53-L-703 workload.

1.2 Scope

This PWS defines the requirements to return a T53-L-703 engine to serviceable condition. Some engines require scheduled inspections or life limited parts replacements. Other engines require repair due to failed performance on test cell or unscheduled engine removals (UERs), necessitating repair beyond the capabilities of the USAF Intermediate Level (I-Level) repair facility.

1.3 Mission Essential Services

There are no mission essential services for this PWS. If at any time, mission essential services should be designated, the Government Procuring Contracting Officer (PCO) will notify the Contractor and the Contractor shall provide a plan within ten (10) working days to the PCO for approval to meet the designated mission essential services as required / directed by the PCO.

1.4 General Requirements

1.4.1 Custody of Engines

The Contractor shall have a system of internal controls to manage (control, use, preserve, protect, repair and maintain) engines and associated subassemblies in its possession IAW Federal Acquisition Regulation (FAR) Part 145 or equivalent certifications.

1.4.2 Preservation

The Contractor shall follow the preservation/re-preservation requirements IAW technical order (T.O.) 2J-1-18. The Contractor shall inspect all engines and power sections received no later than the third (3rd) workday after receipt to determine the adequacy and proper documentation of preservation. End items with inadequate preservation shall be inducted or re- preserved IAW T.O. 2J-1-18 within ten (10) working days after inspection. For all other end items, the Contractor shall preserve items IAW applicable T.O.s.

1.4.3 The Contractor shall have capabilities and access to appropriate OEM commercial technical data, overhaul documents, and license agreements, required to accomplish the requirements in this PWS.

1.4.4 The Contractor shall provide and maintain the required support equipment per the T53 Commercial OEM manuals needed to accomplish all engine requirements of this PWS. No Government Furnished Equipment (GFE) exists nor will be furnished to support any requirements of this PWS.

1.4.5 Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as a Contractor and displaying distinguishing badges or other visible identification for meetings with Government personnel. In addition, Contractor personnel shall appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence.

1.4.6 Foreign Disclosure Restrictions do apply to this effort. There are no restrictions for workload performance to be done within the United States or at a Foreign location outside the United States. The Contractor shall maintain and adhere to all OEM technical data export control restrictions and also obtain any required customs / export shipping licenses should the Contractor intend to perform the workload outside of the United States.

1.4.7 The Contractor shall notify the Administrative Contracting Officer (ACO) or PCO electronically via email within one (1) workday from receipt of asset when an end item is received without a condition code tag, or when the condition code is inconsistent with the “Reason for Reparable Condition” or “Remarks” on the tag, or historical records. If end item is received with parts missing, contractor shall notify PCO once discrepancy is identified. The Contractor shall not proceed with work on the end item until instructions are provided by the ACO or PCO.

1.4.8 The Contractor shall prepare historical records of actions performed on each end item, on AFTO Form 95, which will be included with the engine, and shall provide a written and/or electronic copy to the AFLCMC/LPSEC Cognizant Engineering Authority (CEA) (via email) within two (2) working days of shipment. See para 1.12.5 for additional information.

1.4.9. The Contractor shall provide the standard commercial warranty as provided by the OEM for equipment installed in the engine. The standard engine warranty is one thousand (1000) Engine Flight Hours (EFH) or twenty-four (24) months for workmanship on the engine and all components. In addition, a two thousand (2000) EFH or forty-eight (48) months warranty is provided on all approved OEM parts installed. This warranty applies to non-OEM and OEM workmanship. Warranties listed above shall begin after Government acceptance of the serviceable T53-L-703 engine and its covered components. The Source of Repair (SOR) shall ensure the AF receives full warranty consideration and compensation. Warranty tracking and reporting shall be complied IAW Honeywell Commercial Technical Data. If future warranty work is required, the Contractor shall submit a written work scope for any item that was inducted as an Engineering Investigation (EI) or Teardown Report (TDR) IAW CDRL A006. The Contractor shall include in the written work scope the work required and all costs that would be incurred to bring the item back to serviceable condition to the Government PCO prior to performance of any required work. If the item is found to not be warranty related, and still requires repair/work efforts, contractor shall treat the action as an Over & Above (O&A) tasking worked under the Deficiency Reporting (DR) CLIN. Whether warranty work or other DR work, the Contractor shall provide the TDR reports IAW CDRL A006 and A010 and A011, Teardown Deficiency Report / Failure Analysis Report, to identify actions taken and root cause of failure.

1.4.10 Shipping and Transportation

The Contractor shall ensure all proper documentation is provided to DCMA for shipping and transporting serviceable assets against the transportation TAC code. Serviceable engines shall be shipped via air freight premium 1 shipping, but at a minimum must be shipped on air ride trailers.

1.5 Transition Phase-In

In order to access certain Government required systems to support the requirements for this PWS, the Contractor shall employ or have United States (U.S.) based U.S. National(s) capable of passing a favorable background check in order to gain CAC Card / Government Systems access. Due to the Government requirement to have digital fingerprints and background investigations / clearances in order to get a PKI / CAC Card to be able to access Government systems, and due to the length of time required to obtain the CAC Card, the Government will allow the Contractor a 45 day transition phase-in period after award to process steps required for access. The Contractor shall provide to the PCO a written email confirmation showing initiation of digital fingerprints sent to the FBI within ten (10) calendar days after contract award and will also provide a monthly status report IAW CDRL A001 showing progress / issues towards achieving issuance of CAC Cards and System Access Forms to perform Government system reporting as described in paragraphs 1.12 and 1.13. During the interim transition phase-in period, the Contractor shall still be responsible to provide the applicable maintenance data / system reporting actions to the Government via prescribed email procedures to the various Government System Offices of Responsibility for all items inducted into maintenance / repair until the Contractor has been able to obtain CAC Cards and system access to do the reporting requirements on their own as prescribed by this PWS. Government System contacts will be provided during the Post Award Conference after contract award.

Additionally, the Contractor shall provide a Transition Phase-In Plan with timeline and risks to address the following:

1.5.1 A facilities layout, workflow, location and methodology for where and how the workload will be performed at the beginning of contract period of performance.

1.5.2 Accomplishment of hiring/retraining skilled personnel.

1.5.3 A plan for equipment upkeep and maintenance, calibration to preclude any work stoppages that would effect on time delivery of engines.

1.5.4 A risk mitigation plan for possible work stoppages due to skilled personnel shortages or loss of facility usage due to emergencies / unforeseen events.

The Contractor shall report status of the transition phase-in IAW CDRL A001 as well as via scheduled telecoms with the PMO and PCO.

1.6 T53-L-703 Gas Turbine Engine Assembly Requirements

1.6.1 The Contractor shall perform all work IAW all pertinent Honeywell technical manuals, service bulletins, spare parts bulletins and temporary revisions. These may include, but are not limited to, Overhaul Repair Instructions (ORI) and/or Overhaul Modification Instructions (OMI) issued by OEM. These forms of instructions and publications will not be furnished by Air Force and can only be obtained directly through OEM. Contractor shall perform all work at the Contractor’s facility and /or at their OEM / Government CEA approved sub-vendor facilities.

1.6.2 Life Limited Parts

All 1250 and 2500 hour CLINs for hot section components and cold section components shall have a minimum of 1250 hours and a minimum of 2500 hours remaining respectively. In addition, all components shall have equivalent cycles remaining to achieve these hours. Cycle ratios shall be calculated in accordance with T.O. 2J-T53-4C, the Air Force supplement to the Honeywell maintenance manuals. CEMS records shall be reviewed for all cycle and hour limited components inducted for overhaul or repair and a determination shall be made for remaining hours and cycles. This build policy shall apply regardless of component source, whether new, cannibalized, or otherwise. Fuel Controls and Governors will have a minimum of 1250 hours of life remaining to meet the next 1250 interval.

1.6.3 All deviations from Honeywell technical maintenance manuals require approval from the Air Force CEA. The Contractor shall provide a deviation request in writing to the Government PCO and CEA via email describing the purpose for the deviation with all supporting details. The Contractor shall not proceed until guidance is provided by the PCO.

1.7 Repair and Inspection Requirements – Contractor shall perform work to include any material usage as applicable and within defined CLIN parameters as outlined in below paragraphs.

The Contractor shall comply with the designated turn around times established in below paragraphs to Section 1.7.

1.7.1 Teardown and Inspection (TD&I)

The Contractor shall provide all labor, material, and reports to the Government T53 Program Office to identify root cause analysis, primary failed item, failure mode, corrective actions required to restore serviceability of reparable engines, and recommendations to preclude recurrence IAW CDRL A006. The cycle time to complete a TD&I is dependent upon the level of teardown being accomplished as described in below sub CLINs. Teardown time shall begin after receipt of funded order and receipt of the repairable engine. This CLIN is further divided into three (3) sub-CLINs (LEVEL 1, LEVEL 2, and LEVEL 3) which will differentiate the amount of disassembly required to determine level of work required to return an engine to serviceable condition. Teardown reports are required whether the item is performed under warranty or just normal teardown assets. Sub CLINs are defined as follows:

0. 1250 Hour TD&I. The Contractor shall provide reports to the Government T53 Program Office to identify the work required to disassemble and inspect the engine to determine the work required to restore serviceability of reparable engines for 1250 Hour Repair Levels. TD&I turnaround time shall be no later than (NLT) ten (10) working days. An additional Air Force requirement that is not covered in the Honeywell manuals is to remove and fully inspect the 2nd Stage Power Turbine Nozzle per the Depot Manual WP 72-50-03 and Service Bulletin T53-L-703-130.

0.0.0.1 2500 Hour TD&I. The Contractor shall provide reports to the Government T53 Program Office to identify the work required to disassemble and inspect the engine to determine the work required to restore serviceability of reparable engines for 2500 Hour Repair Levels. TD&I turnaround time shall be NLT fifteen (15) working days. An additional Air Force requirement that is not covered in the Honeywell manuals is to remove and fully inspect the 2nd Stage Power Turbine Nozzle per the Depot Manual WP 72-50-03 and Service Bulletin T53-L-703-130.

0.0.0.2 5000 Hour TD&I. The Contractor shall provide reports to the Government T53 Program Office to identify the work required to disassemble and inspect the engine to determine the work required to restore serviceability of reparable engines for 5000 Hour Repair / Overhaul. TD&I turnaround time shall be NLT twenty (20) working days. An additional Air Force requirement that is not covered in the Honeywell manuals is to remove and fully inspect the 2nd Stage Power Turbine Nozzle per the Depot Manual WP 72-50-03 and Service Bulletin T53-L-703-130.

0.0.1 1250 Hour Inspection Work required for the 1250 hour inspection is defined by pertinent Honeywell technical maintenance manuals. In the case of these inspections contractor shall provide a teardown report IAW CDRL A006 to the government detailing the results of the inspection and perform / provide all labor work and material required to return the engine to serviceable condition. Contractor shall conduct Turbine Nozzle flow checks as a part of this effort. Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN. This CLIN is further divided into three (3) sub-CLINs (LEVEL 1, LEVEL 2, and LEVEL 3) which will differentiate the amount of work required to return an engine to serviceable condition is stated in the paragraphs below. The cycle time to complete any 1250 hour LEVEL 1-3 engine repair is thirty (30) working days after receipt of the bilaterally signed contracting document directing the repair. CLIN serviceability shall include any paint touch ups, all safety wires necessary for flight, torn clamp replacements, brackets and other external hardware, and any required corrosion treatments. Upon signed contracting document, the Contractor shall have no more than five (5) working days to induct the engine for repair action.

0.0.1.1 1250 Hour Inspection LEVEL 1 Repair 1250 Hour Inspection Level 1 area of repair scope defined as follows:

· No cracks or dust on forward side of Power Turbine Bearing Housing

· Gap between Rear Bearing Cover and Exhaust Diffuser is within limits

· No evidence of leaks from the Rear Second Power Turbine Housing Seal

· No Oil Leaks from the No. 2 Seals

· All wear on the Power Shaft splines is acceptable

· Combustion Liner and Housing, Exhaust Diffuser and Power Turbine Bearing Housing DO NOT need to be removed from Turbine Assembly for further inspection

· No Life Limited components require replacement

0.0.1.2 Hour Inspection LEVEL 2 Repair

1250 Hour Inspection Level 2 area of repair scope defined as follows:

· Gap between Rear Bearing Cover and Exhaust Diffuser exceeds limits requiring replacement of the Exhaust Diffuser or the Rear Bearing Cover

· Any additional disassembly is required to repair oil leaks

· Combustion Liner and Housing, Exhaust Diffuser or Power Turbine Bearing Housing need to be removed from Turbine Assembly for further inspection

· No more than three (3) life limited parts require replacement

0.0.1.3 1250 Hour Inspection LEVEL 3 Repair 1250 Hour Inspection Level 3 area of repair scope defined as follows:

· Additional disassembly is required for a more stringent inspection and/or repair of the Combustion Chamber or Second Power Turbine Rotor per applicable Technical Data

· Removal of the First Gas Producer Nozzle is required for addition inspection

· Four (4) or more life limited parts require replacement

1.7.3 2500 Hour Inspection Work required for the 2500 hour inspection is defined by pertinent Honeywell technical maintenance manuals. In the case of these inspections, Contractor shall provide a teardown report IAW CDRL A006 to the government detailing the results of the inspection and perform / provide all labor all work and material required to return the engine to serviceable condition. Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN. Contractor shall apply a single Item Unique Identification (IUID) label to the engine data plate IAW DODI 8320.04 and MIL-STD-130 and in conjunction with the Honeywell manual 2500 hour inspection. This CLIN will be further divided into three (3) sub-CLINs, LEVEL 1, LEVEL 2, and LEVEL 3, which will differentiate the amount of work required to return an engine to serviceable condition is stated in the paragraphs below. The cycle time to complete any 2500 hour Level 1-3 engine repair is fifty (50) working days after receipt of the bilaterally signed contracting document directing the repair action. CLIN serviceability shall include any paint touch ups, all safety wires necessary for flight, torn clamp replacements, brackets and other external hardware, and any required corrosion treatments. Upon signed contracting document, the Contractor shall have no more than five (5) working days to induct the engine for repair action.

1.7.1.1 2500 Hour Inspection LEVEL 1 Repair 2500 Hour Inspection Level 1 area of repair scope defined as follows:

No reported Compressor Surge (stall)

· No reported Overspeeds

· No reported Over torque conditions

· No cracks or dust on forward side of Power Turbine Bearing Housing

· Gap between Rear Bearing Cover and Exhaust Diffuser is within limits

· All wear on the Power Shaft splines is acceptable

· Combustion Liner and Housing, Exhaust Diffuser and Power Turbine Bearing Housing do NOT need to be removed from Turbine Assembly for further inspection

· Centrifugal Compressor Impeller is not damaged beyond limits

· No mutilated Diffuser Vanes

· No Life Limited components require replacement

1.7.3.2 2500 Hour Inspection LEVEL 2 Repair 2500 Hour Inspection Level 2 area of repair scope defined as follows:

· Gap between Rear Bearing Cover and Exhaust Diffuser exceeds limits

· requiring replacement of the Exhaust Diffuser or the Rear Bearing Cover

· Any additional disassembly is required to repair oil leaks

· Combustion Liner and Housing, Exhaust Diffuser or Power Turbine Bearing Housing need to be removed from Turbine Assembly for further inspection

· No more than five (5) life limited parts require replacement

1.7.3.3 2500 Hour Inspection LEVEL 3 Repair 2500 Hour Inspection Level 3 area of repair scope defined as follows:

· Additional disassembly is required for a more stringent inspection and/or repair of the Combustion Chamber or Second Power Turbine Rotor per applicable Technical Data

· Removal of the First Gas Producer Nozzle is required for addition inspection

· Any cause to disassemble the Reduction Gearbox

· Any cause to disassemble the Accessory Gearbox

· Six (6) or more life limited parts require replacement

1.7.3.4 5000 Hour Inspection Overhaul / Repair This CLIN covers all overhaul / repair actions to complete a 5000 Hour Inspection of the T53 engine and return to serviceability. 5000 Hour Inspections are a complete overhaul. Work required for the 5000 hour inspection is defined by pertinent Honeywell technical maintenance manuals. In the case of these inspections, Contractor shall provide a teardown report IAW CDRL A006 to the government detailing the results of the inspection and perform / provide all labor work and material required to return the engine to serviceable condition. The Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN. The cycle time to complete a 5000 hour engine repair is seventy (70) working days after receipt of the bilaterally signed contracting document directing the repair action. CLIN serviceability shall include any paint touch ups, all safety wires necessary for flight, torn clamp replacements, brackets and other external hardware, and any required corrosion treatments. Upon signed contracting document, the Contractor shall have no more than five (5) working days to induct the engine for repair action.

1.7.2 Over and Above (O&A) – Unscheduled Engine Removals (UERs) This CLIN includes necessary repair efforts for unscheduled and unpredictable engine events that require repair / overhaul to restore the engine and /or its’ embedded components to serviceability. These are UER events that generate for repair for reasons other than those noted in repair efforts above and for those O&A efforts within the general scope of the contract, not covered by the line item(s) for the basic work under the contract, and necessary in order to satisfactorily complete the contract requirements. Contractor shall include all test cell runs and associated fuel costs necessary to perform this inspection as a part of this CLIN. All engines identified as Foreign Object Damage (FOD) and all engines that yield findings of FOD during Teardown, will have a nondestructive evaluation completed using “Failure Analysis Service Technology” (FAST) 2208 Melville Rd, Hanger E Prescott, AZ 86301 (800) 657-5664. O&A efforts shall be covered by an O&A CLIN IAW DFARS 252.217-7028. Unknown repairs or other supporting actions for production may be added to the contract under the O&A CLIN. These actions will be requested by the ACO/PCO and must be incorporated via task order. It is the Government’s intent to have a Firm-Fixed-Price (FFP) Labor Wrap Rate set for the O&A CLIN up front for proposal price evaluation that may be applied to negotiated labor hours for each specific task as required along with added material costs per event. This rate shall include all contractor assumed risks for repair and other supporting functions required. Estimated hours of total O&A UER actions is estimated at eighty (80) hours on average per UER event. For fixed hourly rate items, the price negotiated by the ACO shall be based on “hands-on” labor hours multiplied by the contract fixed hourly labor wrap rate. The number of “hands-on” labor hours required shall be negotiated by the Contractor and the ACO. The fixed hourly labor wrap rate includes charges for “hands-on” labor, any labor cost, which is not considered “hands-on” for which the Contractor accounts as direct labor, burdens, general and administrative expenses, and other allowable costs and profit. At any time during the contract performance, when sufficient data becomes available on a repetitive task being performed in the fixed hourly rate category, either the Contractor or the PCO may request a negotiation to establish a FFP for that item for the remaining life of the contract. The ACO shall advise the PCO of all such agreements in order that changes can be incorporated in periodic contract modifications.

1.7.3 Over and Above (O&A) – Other Actions

This CLIN includes engines that generate for repair for reasons other than those noted in repair efforts above and for those O&A efforts within the general scope of the contract not covered by the line item(s) for the basic work under the contract, and necessary in order to satisfactorily complete the contract requirements. O&A efforts shall be covered by an O&A CLIN IAW DFARS 252.217-7028. Unknown repairs or other supporting actions for production may be added to the contract under the O&A CLIN. These actions will be requested by the ACO / PCO and must be incorporated via task order. It is the Government’s intent to have a FFP Labor Wrap Rate set for the O&A CLIN up front for proposal price evaluation that may be applied to negotiated labor hours for each specific task as required along with added material costs per event. This rate shall include all contractor assumed risks for repair and other supporting functions required. Estimated hours of total O&A actions for this contract shall not exceed 5000 hours. For fixed hourly rate items, the price negotiated by the Administrative Contracting Officer (ACO) shall be based on “hands-on” labor hours multiplied by the contract fixed hourly labor wrap rate. The number of “hands-on” labor hours required shall be negotiated by the Contractor and the ACO. The fixed hourly labor wrap rate includes charges for “hands-on” labor, any labor cost, which is not considered “hands-on” for which the Contractor accounts as direct labor, burdens, general and administrative expenses, and other allowable costs and profit. At any time during the contract performance, when sufficient data becomes available on a repetitive task being performed in the fixed hourly rate category, either the Contractor or the PCO may request a negotiation to establish a FFP for that item for the remaining life of the contract. The ACO shall advise the PCO of all such agreements in order that changes can be incorporated in periodic contract modifications. Items to be classified as O&A may include the following but are not limited to:

1.7.3.1 Technical Assistance and Engineering Analysis

The Contractor shall provide technical assistance/engineering production analysis and support services as directed by the ACO/PCO. Services may include, but are not limited to, support of and facility access for Government CEA or an agent on their behalf, in regards to technical assistance for modifications and upgrades to components or engines, to correct deficiencies, performance improvement, technical analysis to determine and accomplish necessary rework, replacement, or modification, and engineering assistance for workarounds and other production related activities.

1.7.3.2 Item Unique Identification (IUID)

IUID part-marking compliance is a Department of Defense (DoD) mandate for items contained within Government inventory systems and as identified by DoD criterion requirements. IUID requirements beyond the 2500 hour inspection for the T53 engine have not been identified at this time. When directed by the PCO, the Contractor shall follow the latest DoD instructions to install IUID compliant marks.

1.7.3.3 Safety Investigation Board (SIB)

The Contractor shall support SIB or Single Investigating Officer (SIO) mishap investigations in coordination with the CEA. Contractor tasks shall include reprioritizing engine induction schedules, impounding hardware (to include quarantine of whole engine and its parts or quarantine of parts of engine as directed by SIO or CEA), coordinating work flow (disassembly, inspections, test, subcontracted O&A analyses, etc.), photographic support, damage assessment and cost determination.

1.7.3.4 Teardown Reporting

The Contractor shall provide reports to the Government T53 Program Office to identify root cause analysis, primary failed item, failure mode, corrective action, and a recommendation to preclude recurrence IAW CDRL A006. The Government will request these reports on a case by case basis through the PCO or ACO office as required for events not covered in repair efforts above.

1.7.3.5 PACER / Analytical Condition Inspection (ACI)

The Contractor shall perform ACIs as follows:

I. General:

a. Contractor shall ensure that all ACI assets are processed expeditiously. This includes priority processing of the disassembly, cleaning, inspection, machining, specialized repair, assembly and testing if required.

b. ACIs must be performed in a secured and dedicated work area that has controlled access. ACI hardware must be segregated and identified separately from production assets. ACI workload will take priority over all production workloads. The maintenance facility will assign a monitor(s) who will be responsible for expediting the ACI workload through to completion. Monitor(s) must have authority over all aspects of the ACI.

c. ACI results shall be documented in a report. Report is due one-hundred twenty (120) working days after completion of the clean layout inspection.

d. Perform ACI as follows:

i. Provide AFLCMC/LPSE CEA Pacer/ACI point of contact three (3) weeks advance notice of date scheduled for the dirty layout inspection via email.

ii. AFLCMC/LPSE CEA ACI point of contact will provide notification of dirty layout inspection attendees within seven (7) working days.

iii. Dirty layout inspection consists of visual examination of the as is removed parts to identify any anomalies. This will include externals, accessories, as well as module parts. Record any anomalies.

iv. After completion of the dirty layout inspection, all parts will be cleaned per applicable technical order and collected for the clean layout inspection.

v. Provide AFLCMC/LPSE Pacer/ACI point of contact three (3) weeks advance notice of date scheduled for the clean layout inspection via email.

vi. AFLCMC/LPSE Pacer/ACI point of contact will provide notification of clean layout inspection attendees within seven (7) working days.

vii. Detailed clean layout inspection requirements will be provided via a Statement of Work (SOW) with attached parts listings at time of O&A generated ACI event tasking. Additionally, SOW will also provide the part features that require Fluorescent Penetrant Inspection and Eddy Current Inspection.

e. After completion of ACI, overhaul/repair modules per applicable technical orders.

f. Overhaul/repair externals and accessories per applicable technical orders. Externals and accessories must have 1000 hours minimum for reinstallation.

g. Rebuild engine per applicable technical orders.

h. Perform engine acceptance testing

i. Engine shipping address will be provided by AFLCMC/LPSE Pacer/ACI point of contact after engine acceptance test is successfully completed.

1.7.4 Over and Above (O&A) – Deficiency Report Investigations This CLIN includes engines that generate for repair for reasons other than those noted in repair efforts above and for those O&A efforts within the general scope of the contract not covered by the line item(s) for the basic work under the contract, and necessary in order to satisfactorily complete the contract requirements. O&A efforts shall be covered by an O&A CLIN IAW DFARS 252.217-7028. Unknown repairs or other supporting actions for production may be added to the contract under the O&A CLIN. These actions will be requested by the ACO / PCO and must be incorporated via task order. It is the Government’s intent to have a FFP Labor Wrap Rate set for the O&A CLIN up front for proposal price evaluation that may be applied to negotiated labor hours for each specific task as required along with added material costs per event. This rate shall include all contractor assumed risks for repair and other supporting functions required. Estimated hours of total O&A actions for this contract shall not exceed 5000 hours. For fixed hourly rate items, the price negotiated by the Administrative Contracting Officer (ACO) shall be based on “hands-on” labor hours multiplied by the contract fixed hourly labor wrap rate. The number of “hands-on” labor hours required shall be negotiated by the Contractor and the ACO. The fixed hourly labor wrap rate includes charges for “hands-on” labor, any labor cost, which is not considered “hands-on” for which the Contractor accounts as direct labor, burdens, general and administrative expenses, and other allowable costs and profit. At any time during the contract performance, when sufficient data becomes available on a repetitive task being performed in the fixed hourly rate category, either the Contractor or the PCO may request a negotiation to establish a FFP for that item for the remaining life of the contract. The ACO shall advise the PCO of all such agreements in order that changes can be incorporated in periodic contract modifications.

· Deficiency Report Investigation. The Contractor shall perform investigations of deficiency report items as directed by the Government (See para 1.11.3 and 1.11.4 and IAW CDRLs A010 and A011).

· Deficiency Report Repair. The Contractor shall repair deficiency report items as directed by the Government IAW T.O. 00-35D-54. The Contractor shall provide deficiency report to the Government within ninety (90) calendar days of DR disposition.

1.7.5 Test Cell Run Support

The Contractor shall conduct Test Cell Runs IAW with the Honeywell Overhaul Manuals to provide contingency test cell facility / capability for T53 engines not repaired under the outline CLINs to this contract, if requested by the ACO / PCO. The test cell FFP effort shall include all fuel and materials to perform a serviceable test cell run.

1.7.6 CDRLs / Data

This CLIN covers the requirements to provide data in support of specified CDRLs to this PWS. This CLIN will not be separately priced and costs for data should be included as part of the end-item costs for engine, repairs, and testing CLINs. The Contractor shall prepare accurate data deliverables and submit in a timely manner IAW with each CDRL’s delivery need date.

1.7.7 Travel

Travel will be FFP IAW Joint Travel Regulations (JTR). The Contractor shall travel to support Government meetings at the request of the Government PCO.

1.8 Testing and Government Acceptance

1.81. The Contractor shall test engines in the operational configuration, and attach a copy of the final run sheet to the engine AFTO Form 95. Any work necessary to correct a failed engine test cell run shall be the Contractor’s responsibility and will not be charged to the Air Force.

1.8.2. The Contractor shall maintain test acceptance run sheets with the record of maintenance actions accomplished. After completion of engine repair or inspection, contractor shall transfer test data/engine records package to AFLCMC/LPSC Engineering within five (5) working days. Each package will include the test cell run data IAW CDRL A014.

1.8.1 The Contractor shall ensure the engine is given a complete final inspection, IAW applicable Honeywell manuals, documented with date, inspector’s name, and phone number.

1.9 Management and Logistics Requirements

1.9.1 The Contractor shall have and maintain a program management structure to accomplish administrative planning, coordination of program requirements, and to optimize workflow by organizing, directing, and controlling production and supply actions.

1.9.2 The Contractor shall deliver all correspondence and documents required by this PWS, including forms, Contract Data Requirements Listings (CDRLs), and required notifications in electronic format via e-mail, unless otherwise authorized by the PCO.

1.9.3 The Contractor shall notify the PCO and Government Program Manager (PM) via email within two (2) working days in the event a part or technical problem is anticipated to cause a work stoppage or production delay. Notification will include a get-well plan to mitigate work stoppage.

1.9.4 The Contractor shall deliver engines for CLIN / Sub CLINS above as specified per CLIN / Sub CLIN estimated flow days, unless directed / negotiated by PCO / ACO to submit items sooner. For test cell contingency support, the contractor shall test and return engines within seven (7) working days from receipt of asset, unless directed / negotiated by PCO / ACO to submit items sooner. For O&A CLINS, the contractor shall deliver task orders as negotiated by the ACO for each O&A event. The Contractor shall deliver all CDRLs IAW specified CDRL delivery dates.

1.9.5 The Contractor shall provide notice to the PCO if an engine exceeds the allowed delivery schedules specified. The notice shall include the reason for delinquency, corrective action(s) taken, and status of any parts on order to restore production schedule.

1.9.6 The Contractor shall obtain, maintain and use accounts necessary to access programs, databases and websites to perform deficiency reporting and engine management. Accounts may include, but are not limited to, Joint Deficiency Reporting System (JDRS) and CEMS. Some databases, such as CEMS, will require a Public Key Infrastructure (PKI) certificate. CEMS database access requires a National Agency Check with Inquiries (NACI) and Credit Check for a security investigation via a completed AF IMT 2583 form with fingerprints provided. CEMS reporting by contractor will also require an established Department of Defense Activity Address Coded (DODAAC) / Stock Record Account Number (SRAN). See 1.12 Reporting Requirements for additional information and Attachment B to this PWS – CEMs Access and Security Check Process. Until CEMS access is obtained, CEMS reporting shall be performed CEMS required spreadsheet reporting information for all CEMs transactions and transmitted via email no later than two (2) working days after completed maintenance action to the CEMS Program Office Help Desk “cems.pmo.helpdesk@us.af.mil” for official input into CEMS system. After CEMS access is obtained, the Contractor will report CEMS transactions as required per CEMS CDRLs.

1.9.7 The Contractor shall participate in teleconferences, meetings, and other program reviews per Table 1.9.7.1 or as requested and upon notification from the PCO. Travel will be directed by the PCO and paid IAW FAR Part 31 and the JTR under the Travel CLIN (see paragraph 1.7.9). Conference Agendas and Minutes: The Contractor shall provide agendas and minutes for PMRs IAW CDRLs A008 and A009.

Table 1.9.7.1

1.9.7 The Contractor shall complete all required data fields on the Contractor Manpower Reporting Application (CMRA) found at http://www.ecmra.mil. Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, contractor shall report all data no later than 31 October of each calendar year. Contractor may direct questions to the CMRA help desk, or consult user’s manuals for government and contractor personnel at the website above.

1.9.7.1 Uses and Safeguarding of Information

Information from the secure website is considered proprietary in nature when the contract number and Contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the Contractor name and contract number associated with the data.

1.10 Material Management

1.10.1 The Contractor shall review all incoming shipping documents to ensure shipments and documents are accurate. The Contractor shall submit proper documentation (see Reporting Requirements 1.12.1) upon discovery of discrepancies for items of supply received for overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damage or improperly packaged shipment, etc.

1.10.2 The Contractor shall perform a visual inspection upon receipt of the engine assembly for any shipping container damage using appropriate OEM technical data. The Contractor shall report to the PCO if the assembly is misidentified, misdirected, or incomplete (missing parts); the Contractor shall obtain disposition instructions from the PCO. The Contractor shall initiate a Supply Discrepancy Report (SDR), SF 364, for any assets received in other than the contracted packaging.

1.10.3 The Contractor shall ensure USAF engines with their embedded components are not comingled with other non-USAF components being overhauled at the Contractor’s or sub-vendor facilities. Contractor shall ensure disassembled, usable parts are not commingled with contractor existing inventory.

1.10.4 The Contractor shall provide all consumable materials used for repair / overhaul. The Contractor shall dispose of consumables IAW local, state and federal regulations. The Contractor shall procure all parts required to complete the USAF requirements.

1.10.5 The Contractor shall ensure all replacement parts used for repair are procured from the OEM or OEM approved sources. All Contractor Furnished Material (CFM) parts shall be new or overhauled condition with traceability of origin and from approved OEM sources. The Contractor shall forecast and maintain ample inventory to promote minimal production disruption to meet the USAF required/requested delivery schedules. Contractor may procure CFM from the Defense Logistics Agency (DLA).

1.10.6 Prior to serviceable shipment, the Contractor shall contact Defense Contract Management Agency (DCMA) by email to schedule inspection and acceptance. If DCMA does not reply within three (3) working days of the request, the Contractor shall notify the PCO via email for further direction. Upon shipment of the asset(s), the Contractor shall provide tracking number information to the PCO and PM for each shipment. DCMA shall inspect and accept items IAW DCMA policies and procedures.

1.10.6.1 The following Department of Defense Activity Address Code (DODAAC) will be used when shipping engine assembly and components: Ft Rucker FB3034.

The Contractor shall package items according to Special Packaging Instructions (SPIs) by obtaining access to the SPIRES website and IAW T.O. 00-85-20. The Contractor shall obtain a DD Form 2875 access and PKI CAC card access to SPIRES system to ensure that they are using the latest SPI references. SPI website link is found at https://spires.wpafb.af.mil/. The Contractor shall place a serviceable tag, DD Form 1574, inside the package along with the assembly as well as outside the package. The Contractor is responsible for remanufacturing/returning damage engine shipping trailers to serviceable condition in accordance with TM 1-8145-695-24&P (applies to both T53 and T55 shipping and storage containers). This effort shall be priced as part of each CLIN FFP. The Contractor shall use the Government Transportation Accounting Code identified in the contract for transportation costs. Serviceable engine shipments shall have all required and appropriate shipping documents specifying air freight shipment (or air ride trailers at a minimum).

1.11 Quality Requirements

1.11.1 The Contractor shall deliver all engines in a fully tested, serviceable and Ready for Installation (RFI) condition. The Contractor shall have in place and maintain a quality management system in compliance with ISO 9001:2008 or higher versions or AS9110. Contractor shall make available for review upon request by the Government the quality system procedures, planning, and other documentation and data that comprise the quality system. The Government will, at their discretion, perform any inspections, verifications, and evaluations to ascertain conformance to the ISO 9001:2008/or higher versions or AS9110 requirements and the adequacy of implementing procedures. The Government reserves the right to issue corrective actions against the Contractor’s quality system because of audits or inspections. The Contractor shall implement appropriate corrective actions to bring the quality system into compliance.

1.11.2 The Contractor shall have in place and maintain procedures to maintain measuring and test equipment IAW ISO 10021:2003, ANSI/NCSL Z504.3-2006, or equivalent.

1.11.3 The Contractor shall support product audits, at the determination of the Government on overhauled engines and components. The Government may select at random such quantities of end items as may be necessary to determine quality of workmanship and materials.

1.11.4 The Contractor shall investigate all Deficiency Reports submitted by the USAF against reportedly defective items overhauled by this contract IAW Technical Order (T.O.) 00-35D-54 and prepare a report of findings (see Reporting Requirements 1.12.3).

1.12 Reporting Requirements

The Contractor shall submit on time, correct and complete reports IAW prescribed Contract Data Requirements Lists (CDRLS) and as directed by language to this PWS. The Contractor shall refer to the applicable CDRL for timeframe and report requirements as well as the Data Item Descriptions for report formatting. See Attachment A for a listing of all CDRLS & DIDs. The Contractor shall not report more than one (1) document late per quarter and no document shall be received later than five (5) working days. The Contractor shall not submit reports that require more than two (2) corrections per report per quarter. The Contractor shall also accomplish reporting on Small Business IAW CDRL A013 and via the ESRS Small Business Database reporting procedures. It is important to note that the SB CDRL A013 reporting and the ESRS database reporting are different.

1.12.1 Report of Shipping (Item) and Packing Discrepancy

The Contractor shall submit a Standard Form (SF)-364 IAW Technical Order (T.O.) 00-35D-54 upon discovery of discrepancies for items of supply received for overage, wrong item, duplication of shipment, misdirected shipment, non-receipt, damage or improperly packaged shipment. The Contractor shall enter all discrepancies into the web-based system, Web Supply Discrepancy Report (SDR). Upon receipt of USAF disposition, the Contractor shall complete the directed action and close the supply discrepancy. In those situations where the SDR initiator is unable to gain access to the AF WebSDR, continued use of manual forms is permitted. A copy of the form will be forwarded through the ACO and Quality Assurance (QA) activity for corrective action.

1.12.2 Teardown Report

The Contractor shall provide AFLCMC/LPSC Engineering a teardown report documenting extent of engine damage and deficiencies. Report may be written in Contractor format IAW CDRL A006. Reports are required for all items (warranty and non-warranty repairs).

1.12.3 Material Deficiency Report

The Contractor shall submit a report whenever a material or a quality deficiency, as defined by TO 00-35D-54, occurs. This includes CAT I and II Engineering Investigation Material Deficiency Reports (MDR). The Contractor shall provide a Statement of Work (SOW) for pricing request. Contractor shall deliver a formal report of findings to the Government after receipt and analysis of the deficient material exhibit for all Mishap Investigations and CAT I & CAT II deficiency reports. If failed components require additional lab analysis, the Contractor may use independent agencies for analytical evaluation. The Contractor may request support from Government CEA for additional guidance and disposition via PCO. DR will be input to the Joint Deficiency Reporting System (JDRS). Reports shall be submitted IAW CDRL A010.

1.12.4 Product Quality Deficiency Report (PQDR)

The Contractor shall investigate and document PQDR findings, using JDRS, on all design and quality control (material) deficiencies found IAW the procedures of T.O. 00- 35D-54. The Contractor shall review the reported discrepancy from the field and schedule PQDR exhibit for investigation. The Contractor shall investigate returned PQDR following exhibit receipt. Contractor shall provide substantiation of root cause of failure against reported field failure in closeout report. After completion of the PQDR investigation, the Contractor shall request disposition of exhibit through the PCO to PM for material induction into current delivery order or next delivery order submission. Contractor shall submit reports IAW CDRL A010.

1.12.5 Significant Historical Data

The Contractor shall retain all pre-existing Significant Historical Data on the AFTO Form 95 or transcribe/copy pre- existing data from other forms or records onto an AFTO Form 95.