Section_L_Atch_17-Airworthiness_Plan_for_APT_Program.pdf

Solicitation FA8617-17-R-6219 Section L – Attachment 17

Airworthiness Plan for the Advanced Pilot Training System (APT) i

Airworthiness Plan for the

Advanced Pilot Training Program

08 December 2016

Version 1.2

Prepared by:

Air Force Life Cycle Management Center

Training Aircraft Division

Advanced Pilot Training Branch

Wright-Patterson Air Force Base, Ohio 45433

DISTRIBUTION A: Approved for public release.

Solicitation FA8617-17-R-6219

Airworthiness Plan for the Advanced Pilot Training System (APT) ii

Table of Contents

1 PURPOSE

2 INTRODUCTION

2.1. Program Description

2.2. System Description

2.3. Advanced Pilot Training Acquisition Strategy

3 PROGRAM OFFICE AIRWORTHINESS SUPPORT

4 ADVANCED PILOT TRAINING PROGRAM AIRWORTHINESS OVERVIEW

4.1. Airworthiness Requirements

4.2. Aircraft Airworthiness Certification Schedule

4.3. Affected Sections of MIL-HDBK-516C

5 AIRWORTHINESS APPROACH FOR ALL PHASES OF ACQUISITION

5.1. Prior to Contract Award

5.2. Engineering and Manufacturing Development Phase

5.3. Production, Post-Milestone C

ANNEX 1 – REFERENCES

ANNEX 2 – ACRONYMS

ANNEX 3 – GLOSSARY

ANNEX 4 – AIRWORTHINESS PROJECT SMART TRACKER

Table of Figures Figure 2.3-1 – Advanced Pilot Training Program Schedule

Figure 3.0-1 – Advanced Pilot Training Program Airworthiness Responsibilities

Figure 3.0-2 – Airworthiness Process for Original Baseline and Modification

Figure 4.2-1 – Baseline Airworthiness Schedule

Figure 4.3-1 – MIL-HDBK-516C Sections Impacted by the Advanced Pilot Training Program .. 9

Figure 5.1-1 – Pre-Acquisition Airworthiness Tasks

Figure 5.2-1 – Engineering and Manufacturing Development-Phase Airworthiness Tasks

Figure 5.3-1 – Production-Phase Airworthiness Tasks

Solicitation FA8617-16-R-6219

Airworthiness Plan for the Advanced Pilot Training System (APT)

1 Purpose This is a plan for United States Air Force (USAF) Airworthiness Certification of the Advanced Pilot Training (APT) Aircraft. The plan complies with USAF policy and instruction for airworthiness; Air Force Policy Directive (AFPD) 62-6, Developmental Engineering; Air Force Instruction (AFI) 62-601, USAF Airworthiness; Airworthiness Bulletins (AWB); and implementation instructions published by the USAF Technical Airworthiness Authority (TAA) in AWB-002A, Airworthiness Planning. This document serves as a framework to guide implementation and execution of the certification program by the APT Program Office, prime contractor, and other stakeholders. It establishes the APT Program’s Airworthiness Certification Program with the USAF TAA. Other systems engineering processes supporting airworthiness are covered in the APT Program’s Systems Engineering Plan (SEP).

2 Introduction

2.1. Program Description

The APT Program is managed by the Air Force Life Cycle Management Center’s Mobility Directorate (AFLCMC/WL). The using command will be USAF’s Air Education and Training Command (AETC). The APT Program is an Acquisition Category-ID program. As a Major Defense Acquisition Program, it is currently on the Office of the Secretary of Defense’s Oversight List.

The APT Program plans to acquire and sustain an affordable, agile, and integrated APT System consisting of 350 aircraft, Ground Based Training System (GBTS) (46 Aircrew Training Devices and various other training devices), Maintenance Training Systems, support, infrastructure, and personnel.

The APT Program will replace the T-38C and its associated GBTS currently used in the USAF’s Specialized Undergraduate Pilot Training program, which provides advanced training for pilots in AETC’s fighter and bomber track as well as its Introduction to Fighter Fundamentals course.

The Advanced Pilot Training Family of Systems Analysis of Alternatives Update Final Report (Version 3.0), 21 Aug 2014, concluded that program requirements should be met with a viable alternative to the T-38C that will achieve an initial operational capability (IOC) on or about 2023. The USAF has subsequently changed the IOC date to 2024. The Analysis of Alternatives determined that the APT objective may be achieved by existing aircraft designs as well as those that are purpose-built. Requests for Information (RFI) and industry surveys have been conducted to identify candidate aircraft. Results include existing foreign aircraft that have been certified by their military airworthiness authorities as well as new purpose-built aircraft that will be designed/produced to meet APT Program requirements. No suitable commercial derivative aircraft have been identified from industry RFI responses.

Airworthiness Plan for the Advanced Pilot Training System (APT)

2.2. System Description

The advanced jet trainer platform will be a two-seat, highly maneuverable aircraft capable of performing aerobatic and combat-representative maneuvers consistent with the training profiles in planned APT Program syllabi. The APT Aircraft will bring new capabilities, including sustained-G maneuvers and a higher angle of attack. Together with updated avionics and an improved GBTS, the APT Program will provide training opportunities more closely aligned with today’s fourth and fifth-generation fighters. The aircraft will incorporate instrumentation and Communications, Navigation, and Surveillance/Air Traffic Management systems that allow operations in the National Airspace System as well as Military Operating Areas/Ranges. It will be capable of employment day or night in adverse weather.

The APT Aircraft will be capable of carrying external stowage, a non-jettisonable storage pod and/or a non-jettisonable weapon systems support pod, with structural and mechanical interfaces at the store location(s) in accordance with (IAW) Military Standards (MIL-STD)-8591, DoD Design Criteria: Airborne Stores, Suspension Equipment and Aircraft-Store Interface, and electrical interfaces IAW MIL-STD-1760, Department of Defense Interface Standard, Aircraft/Store Electrical Interconnection System. Capability for in-flight aerial refueling is an objective requirement; the threshold requirement is for the aircraft to be able to accommodate an in-flight refueling system in the future.

Some offerors’ proposed aircraft may include in-flight refueling capability. It is possible that some offerors will propose using aerial refueling during developmental test and evaluation (DT&E) to improve the efficiency of flight test operations even if not part of the production configuration. In that case, the capability would be removed from the test aircraft as part of an update to a production-representative configuration following DT&E.

2.3. Advanced Pilot Training Acquisition Strategy

The APT Program’s Acquisition Strategy calls for a single increment to full capability. Multiple potential offerors have been identified, and the Source Selection will be conducted as a best-value tradeoff evaluation. A single contract will cover the overall acquisition of both the aircraft and its GBTS from the Engineering and Manufacturing Development (EMD) Phase through full-rate production as well as initial sustainment support. Based on the employment of mature technology, the program will enter the acquisition cycle at Milestone (MS) B.

With respect to product support, the APT Program’s approach is designed to provide the Government with “freedom of choice” throughout the system’s life cycle, positioning it for organic sustainment to the maximum extent possible. Appropriate data and data rights will be pursued under competition during Source Selection.

The APT Program has also been designated as a pilot program for two key acquisition improvement initiatives: Own the Technical Baseline and Bending the Cost Curve. The

Airworthiness Plan for the Advanced Pilot Training System (APT)

Government will assume control of the APT Program’s functional baseline at System Requirements Review/System Functional Review (SRR/SFR), the allocated and initial product baselines at Critical Design Review (CDR) and the final product baseline at Physical Configuration Audit.

The acquisition schedule, showing key program milestones, is presented in Figure 2.3-1.

Figure 2.3-1 – Advanced Pilot Training Program Schedule

A flight demonstration will not be part of the source selection. Offerors, however, will be required to provide flight data as part of their proposal to demonstrate that the baseline aircraft they are proposing is capable of meeting selected APT Aircraft Key Performance Parameters and Key System Attributes. Offerors will collect this data under existing aircraft airworthiness certificates, e.g., Federal Aviation Administration or foreign military certifications. Government personnel will not fly on these aircraft as part of the source selection process.

Airworthiness Plan for the Advanced Pilot Training System (APT)

3 Program Office Airworthiness Support The APT Program airworthiness effort will be planned and executed by the APT Program Office. The program will adhere to USAF airworthiness policy and instructions, Airworthiness Bulletins, and delegations of technical authority from the TAA. The program’s Chief Engineer, Lead Systems Engineer, Airworthiness Engineer, and Subject Matter Experts (SME) will support the development, evaluation, and verification of all airworthiness products (see Figure 3.0-1).

Vacancies exist in Air Vehicle Subsystems, Electromagnetic Environmental Effects (E3), System Safety, and Stores Integration (electrical). These will be addressed by organic placement or with Government-contracted support personnel. The program office will obtain the support of the SEEK EAGLE Office for stores integration certification of the travel and weapons support pods;

the contractor will provide the technical support and artifacts necessary to obtain and maintain SEEK EAGLE stores certification.

Figure 3.0-1 – Advanced Pilot Training Program Airworthiness Responsibilities

Internal processes are in place to control the flow and quality of the engineering data and products produced to satisfy airworthiness requirements. A summary of airworthiness processes supporting the initial aircraft certification baseline and future modifications is presented in Figure 3.0-2 and is applicable throughout the life cycle of the weapon system. The contractor submits airworthiness products to the program office IAW contractual requirements. The APT Program Manager and Chief Engineer submit the certification bases (CB) and compliance reports to the TAA for approval. With contractor support, the program office prepares System Safety Risk Assessments (SSRA) for TAA-approved risks and obtains risk acceptance from the

Airworthiness Plan for the Advanced Pilot Training System (APT) appropriate authority. After risk acceptance, the TAA issues the flight authorization (MTC) or Military Flight Release (MFR)). The program office evaluates conformance of delivered aircraft to the MTC type design, and issues a Military Certificate of Airworthiness (MCA) for each aircraft that conforms.

The program monitors development of the design between Preliminary Design Review (PDR) and CDR and identifies required changes to the certification basis. Changes to the CB are resubmitted to the TAA for approval. If the baseline configuration is changed through an Engineering Change Proposal (ECP), the program office reviews airworthiness products prepared by the contractor, and consults with AFLCMC/WL’s Director of Engineering (DOE) on airworthiness impacts and reportability. The DOE may consult with the TAA for an official ruling on reportability. Reportable impacts are presented to the TAA for approval.

A Government-led airworthiness working group, comprised of Government and contractor airworthiness personnel, reviews certification status; identifies, tracks, and retires issues; and reviews airworthiness metrics. Consult the APT Program’s SEP for further details on engineering system requirements development, requirements management, change process, and technical reviews.

Figure 3.0-2 - Airworthiness Process for Original Baseline and Modification

Airworthiness Plan for the Advanced Pilot Training System (APT)

4 Advanced Pilot Training Program Airworthiness Overview

4.1. Airworthiness Requirements

There are two objectives of the APT airworthiness program. The first objective is to obtain a design-based Military Type Certificate (MTC) for operational APT Aircraft, which include production aircraft as well as production-representative aircraft, i.e., those that are updated from the EMD configuration. The second objective is to assure the continued airworthiness of APT Aircraft, ensuring operations and maintenance are IAW USAF airworthiness policy, procedures, and instructions.

The APT airworthiness CBs will be derived from Military Handbook (MIL-HDBK)-516C, Airworthiness Certification Criteria, with USAF-approved change notices incorporated. There will be two CBs for the APT Program, the APT CB to support issuance of an MTC, and the Experimental Flight Release Basis (EFRB) to support issuance of an MFR. Additional change notices to Military Handbook (MIL-HDBK) 516C, Airworthiness Certification Criteria, may be issued subsequent to contract award; the program office will determine whether to address MIL- HDBK-516C change notices released after contract award on a case-by-case basis.

Requirements changes could be addressed with an Engineering Change Proposal, as the magnitude of the change warrants.

The CBs will be formatted as Tailored Airworthiness Certification Criteria (TACC) spreadsheets IAW AWB-005, Tailored Airworthiness Certification Criteria /Modification Airworthiness Certification Criteria (TACC/MACC) Document Approval Process, The APT CB spreadsheet is hereinafter referred to as the TACC. The EFRB spreadsheet is simply called the EFRB. The TACC and EFRB formally document the APT airworthiness requirements and will cover the complete aircraft.

The program office will provide the USAF TAA-approved TACC with the APT Request for Proposal (RFP). This TACC assumes aerial refueling, an objective requirement, is not part of the APT type design; contractors will tailor the approved TACC after contract award. Resultant updates to the TACC will be resubmitted to the TAA for approval. If aerial refueling is offered, TACC tailoring will include aerial refueling criteria, standards, and methods of compliance from MIL-HDBK-516C, and the impacted tanker program offices will be contacted to complete airworthiness requirements for the tankers.

Compliance to CB criteria is reported in a compliance report (CR). There will be two CRs, one showing compliance to the TACC (the MTC CR) and one showing compliance to the EFRB (the MFR CR). The CRs will be formatted as TACC spreadsheets IAW AWB-005. Artifacts verifying satisfaction of MIL-HDBK-516C methods of compliance are integral to the CRs. Civil and foreign military airworthiness certificates will not be used to show compliance to the APT Program’s CBs. However, artifacts supporting these airworthiness certifications can be used to show compliance to the USAF CB if they are applicable to the APT design.

Airworthiness Plan for the Advanced Pilot Training System (APT)

Compliance artifacts will be made available by the contractor for review by the Government to support APT Program Office and TAA compliance findings. Artifacts will be in the English language and be the complete document (i.e., not excerpts, redactions, or a summary report of the original document). Compliance artifacts will include prime contractor, subcontractor, and vendor data as needed to support APT airworthiness requirements. After the program office has reviewed and assessed the CRs they will be submitted to the USAF TAA for approval.

Developmental test and evaluation flight testing is planned during EMD to support aircraft modifications and show compliance to the APT Program’s Aircraft System Specification and APT CB. The EFRB and the MFR CR will be submitted to the TAA IAW AWB-1009, Airworthiness Flight Authorizations – Military Type Certificate (MTC)/Military Flight Release (MFR), for approval of the MFR to support the flight test program. The program office will adhere to the TAA’s delegations of technical authorities when expanding flight test operations.

If the contractor plans to conduct flight operations prior to DT&E that directly support APT contract requirements or that are subject to the Ground Flight and Risk Clause, flight authorizations will comply with requirements in Department of Defense Directive (DoDD) 5030.61, Department of Defense Airworthiness Policy, AFPD 62-6, USAF Developmental Engineering, USAF Airworthiness, and AFI 62-601, USAF Airworthiness, AFMC Supplement 1.

USAF flight certification requirements for operation of contractor production-representative aircraft after contract award and before the start of DT&E will be evaluated by the Government based on USAF guidance and policy and aircraft airworthiness certification(s) that are current at that time. Information on USAF airworthiness requirements for contractor-owned and contractor-operated aircraft can be found in AWB-1012, USAF Airworthiness (AW) Requirements for Contractor-Owned and Contractor-Operated (COCO) Aircraft.

Configuration of EMD aircraft may differ from the MTC type design. If that is the case, the contractor will be required to update and conform EMD aircraft to the latest, production-representative configuration prior to the start of Initial Operational Test and Evaluation (IOT&E). The flight test MFR will be maintained to support operation of EMD aircraft until they are conformed to the production configuration.

The MTC CR is intended to demonstrate compliance of the operational aircraft design to the APT CB. The MTC CR will be submitted to the TAA IAW AWB-1009 for approval of the MTC to support operational test and mission operations. Issuance of the MTC is planned prior to IOT&E, which is scheduled to start approximately nine months after submission of the MTC CR. If the MTC has not been issued within that time, IOT&E will be conducted under an MFR.

The contractor will be required to document conformance of both production aircraft and production-representative aircraft to the type design. If updated aircraft do not conform, an MFR or a separate MTC will be sought for the post-update configuration. The program office will verify individual aircraft conformity to the MTC type design and its condition for safe operation and will issue an MCA for each operational aircraft.

Airworthiness Plan for the Advanced Pilot Training System (APT)

The program office will maintain configuration status accounting of delivered aircraft.

Configuration changes will be controlled through a configuration control board (CCB) and airworthiness determinations made and documented IAW AWB-007, Determining Reportability of Modifications.

4.2. Aircraft Airworthiness Certification Schedule

The APT Program’s airworthiness tasks and milestones leading to the MTC are shown in Figure 4.2-1 related to constraining APT Program events. The figure does not reflect timing of contractor deliveries, described in the Statement of Work (SOW), that support these events.

Detailed actions to accomplish these tasks and milestones are described in Section 5 of this document. The schedule for TAA review and approval of airworthiness products is detailed in the TAA’s Airworthiness Project Smart Tracker, shown in Annex 4. If the program schedule changes, the program office will update the tracker and resubmit it to the TAA for approval.

Figure 4.2-1 - Airworthiness Schedule

4.3. Affected Sections of MIL-HDBK-516C

The scope of the APT Program’s CB is indicated by the applicable (check marked) sections of MIL-HDBK-516C shown in Figure 4.3-1. The table gives support for TACC development and the need for specific engineering disciplines. It provides a brief description of the significant design/mission requirement(s) impacting the applicable MIL-HDBK-516C section(s).

Secticted by the APT Program

Airworthiness Plan for the Advanced Pilot Training System (APT)

Applicable MIL-HDBK-516C Sections Description/Remarks of Impact to

MIL-HDBK-516C Criteria

4 – Systems Engineering

4.1 Design criteria

4.2 Tools and databases

4.3 Materials selection

4.4 Manufacturing and quality

4.5 Op. & maint. manuals/tech orders

4.6 Configuration management

Incorporate change notice (CN) 516CN-1, Section 4.4.6, “Control of Safety-related Articles.”

5 – Structures

5.1 Loads

5.2 Structural dynamics

5.3 Strength

5.4 Damage tolerance and durability

(fatigue)

5.5 Mass properties

5.6 Flight release

Airframe structure may vary from traditional aluminum to composite materials.

Incorporate change notice 516CN-2, Sections 5.7.1 through 5.7.5, “Service Life Limit.”

Standards will be chosen for “trainer” aircraft. Incorporate change notice 516CN-3, Section 5.1.8, “Analysis and Testing of Realistic Ground Loading Conditions.”

6 – Flight Technology

6.1 Flying qualities

6.2 Vehicle control functions

6.3 Aerodynamics and

performance

Flight controls of candidate aircraft vary from traditional hydro-mechanical to quad-redundant fly-by-wire with stability augmentation.

7 – Propulsion

7.1 Propulsion risk management

7.2 Gas turbine engine applications

7.3 Alternate propulsion systems

Candidate aircraft include one or two engine configurations.

Engines may not be currently certified to the range of angle of attack, sideslip, G-force, & temperature day necessary to meet APT requirements. Other potential differences may be in customer bleed flow levels required to achieve cockpit air temperature requirements.

Sub-elements also need to be considered, for example, horsepower extraction, engine mount loads, and increased bleed flow impacts to max bleed temperature, which may consequently exceed the Environmental Control System T3 limit.

APT Aircraft will be turbofan or turbojet powered.

Airworthiness Plan for the Advanced Pilot Training System (APT)

Applicable MIL-HDBK-516C Sections Description/Remarks of Impact to

MIL-HDBK-516C Criteria

8 – Air Vehicle Subsystems

8.1 Hydraulic/pneumatic systems

8.2 Environmental control system

8.3 Fuel system

8.4 Fire and hazard protection

8.5 Landing gear and deceleration

systems

8.6 Auxiliary/emergency power

system(s)

8.7 Aerial refueling

8.8 Mechanisms

8.9 External cargo hook systems

(rotary wing)

8.10 External rescue hoist

(rotary wing)

8.11 Fast rope insertion/extraction

Systems (rotary wing)

There are no austere runway operations.

An aircraft arresting system will not be utilized.

Aircraft configuration may have in-flight refueling capability.

Section 8.9 through 8.11: Criteria not applicable for fixed wing aircraft.

9 – Crew Systems

9.1 Escape and egress system

9.2 Crew stations, control stations & a/c

interiors

9.3 Air system lighting

9.4 Human performance

9.5 Life support systems

9.6 Transparency integration

9.7 Crash survivability

9.8 Lavatories, galleys, and areas

not continuously occupied

Incorporate change notice 516CN-5, Section 9.1.1, “Escape System Safety Compatibility.” Crew stations compatible with Anthropometric Cases 1-7.

APT Aircraft will not have subject areas.

10 – Diagnostic Systems

10.1 Failure modes

10.2 Operation

11 – Avionics

11.1 Avionics architecture

11.2 Avionics subsystems

11.3 Air vehicle avionics

Airworthiness Plan for the Advanced Pilot Training System (APT)

Applicable MIL-HDBK-516C Sections Description/Remarks of Impact to

MIL-HDBK-516C Criteria

12 – Electrical Systems

12.1 Electric power generation sys

12.2 Electrical wiring/power distribution

13 – EMI/EMC

13.1 Component/subsystem E3 qual

13.2 System-level E3 qual

14 – System Safety

14.1 System safety program

14.2 Safety design requirements

14.3 Software safety program

15 – Computer Resources

15.1 System processing architecture

15.2 Design & functional integration of

SPA elements

15.3 Processing hardware/electronics

15.4 Software development processes

15.5 Software architecture & design

15.6 Software qual and installation

16 – Maintenance

16.1 Maintenance manuals/checklists

16.2 Inspection requirements

APT Program will use standard USAF Technical Order manuals.

17 – Armament and Stores Integration

17.1 Gun/rocket integration and

interface

17.2 Stores integration

17.3 Laser integration

17.4 Safety interlocks

No weapons carriage.

Requirement for external carriage of a non-jettisonable travel pod and/or weapons systems support pod.

18 – Passenger Safety

18.1 Survivability of passengers

18.2 Fire resistance

18.3 Physiology requirements of

occupants

APT Aircraft will not carry passengers.

Airworthiness Plan for the Advanced Pilot Training System (APT)

Applicable MIL-HDBK-516C Sections Description/Remarks of Impact to

MIL-HDBK-516C Criteria

19 – Materials

19.1 Properties and processes

19.2 Corrosion

19.3 Non-destructive inspection

19.4 Wear and erosion

This section is applicable for Navy and Marine Corps aircraft only. It is not required for Air Force or Army aircraft.

20 – Air Transport, Airdrop, Mission / Test, Equipment and Cargo / Payload Safety

20.1 Air transportability and airdrop

20.2 Mission/test equipment operations

and installation

APT Aircraft will not have transport or airdrop capability.

Test aircraft will have test instrumentation installed.

Figure 4.3-1 - MIL-HDBK-516C Sections Impacted by the Advanced Pilot Training Program

5 Airworthiness Approach for All Phases of Acquisition This section details program office and TAA activities leading to award of the MTC and delivery and support of fielded aircraft. It is organized by acquisition phase.

5.1. Prior to Contract Award

This phase comprises the release of Special Notices to Industry, a draft RFP, the final RFP, and source selection activities leading to contract award. Draft airworthiness inputs to the RFP (Aircraft System Specification, SOW, Sections L and M, Contract Data Requirements Lists, draft CB (TACC), and this Airworthiness Plan) will be shared with potential contractors through Special Notices released through Federal Business Opportunities at www.fbo.gov (FedBizOpps).

These draft airworthiness inputs will clearly identify the requirements for USAF airworthiness certification, Government access to compliance data, and the contractor’s responsibility in this process. Contractor responses to the drafts will be used to finalize RFP airworthiness documents. Airworthiness language in the RFP will be coordinated with the TAA and updated prior to final RFP release. The airworthiness CB will be submitted to the TAA for approval before final RFP release. The TAA-approved CB will be included in the RFP. The TAA-approved CB will go on contract at award (post source selection). Offerors will provide a tailored CB as part of their proposal, and the program office will assess the risk of offeror changes to USAF certification; however, the risk assessment will be for evaluation purposes only. Figure 5.1-1 summarizes airworthiness actions and products during this acquisition phase.

Airworthiness Plan for the Advanced Pilot Training System (APT)

AW

Product

Delivered to TAA

Task/Action Who? Applicable Guidance, References, and Remarks

Special Notices To Industry

Prepare draft AW Plan, draft CB, & draft AW contract language.

Program Office

(PO)

AWB-004A, Development of an Airworthiness Certification Basis (paragraph 6c, attachment 2).

AWB-005, TACC / Modification Airworthiness Certification Criteria (MACC) Document Construction and Format.

Single/multi-document developed/assembled by program office; includes briefing.

Release draft AW Plan to industry.

PO

Release draft SOW to industry. PO Release draft CB to industry. PO

Update draft AW Plan based on industry inputs.

AW Plan Approval

X Submit draft AW Plan to TAA for Technical Director (TD) Kick-Off Meeting.

PO

Provide draft contract language and CB as backup information.

Conduct TAA TD Kick-Off Meeting.

TAA

Update AW Plan.

Developed/assembled by program office.

Program office evaluates before TAA assessment.

X Submit updated AW Plan to TAA. PO TAA approval of AW Plan. TAA

DRAFT RFP

Update draft CB and AW contract language based on industry inputs.

PO

AWB-004A (instructions, paragraph 9, attachment 2 or paragraph 7, certification based on prior use of Military-Specification/Standard).

AWB-005 (paragraph 6, attachment 2 is template).

AWB-003A, TACC/MACC Document Approval Process.

Updated/assembled by program office.

Coordination of RFP language with TAA.

AW Plan, draft CB, AW contract language incorporated into draft

RFP.

Airworthiness Plan for the Advanced Pilot Training System (APT)

AW

Product

Delivered to TAA

Task/Action Who? Applicable Guidance, References, and

CB Approval

Informally coordinate the CB document with AFLCMC’s Engineering Directorate airworthiness SMEs.

PO

AWB-003A (paragraph 4a).

X Submit CB to TAA. PO

Prepare documentation for TD Forum.

PO

AWB-003A.

Developed/assembled by program office.

X Submit TD package.

Request TD Forum.

Conduct TD Forum. TAA Program office presents.

Conduct CB evaluation. TAA AWB-003A (paragraph 5a6, attachment 2, attachment 4).

Program office interaction/comment resolution during TAA evaluation.

PO

AWB-003A (paragraph 5a5).

TAA approval of CB. TAA

CB, AW Plan contract language incorporated into RFP.

RFP RELEASE & SOURCE SELECTION

Evaluate risk of offerors’ AW Plans and CB mark-ups during source selection.

Indicates a program office airworthiness product (page/document/paper).

Figure 5.1-1 - Pre-Acquisition Airworthiness Tasks

5.2. Engineering and Manufacturing Development Phase

This section describes airworthiness activities initiated during EMD and comprises execution of the contract from contract award through delivery of the EMD aircraft and DT&E up until

IOT&E.

Following contract award, the TAA-approved CB will be tailored by the Contractor. The CB updates will be reviewed and approved by the program office prior to submission to the TAA for USAF approval. The CB will be updated again after the CDR and submitted to the TAA for approval after program office processing.

The contractor will use the approved APT Program CB after contract award as a starting point to prepare the EFRB for the DT&E flight test program. This plan assumes the draft EFRB will be

Airworthiness Plan for the Advanced Pilot Training System (APT) submitted to the TAA for approval after PDR; if the contractor plans to conduct flight tests that directly support APT contract requirements or that are subject to the Ground Flight and Risk Clause prior to DT&E, as shown in Figure 2.3-1, then an EFRB will be required earlier.

If aerial refueling is part of the EMD program, certification requirements will be captured in the EFRB. The program office will work with the appropriate tanker organization(s) to initiate an assessment of the airworthiness impact of an APT Receiver Aircraft on the tanker. The APT Program’s design and performance information needed for this assessment will be provided to the KC-46 and Legacy Tanker Program Offices by the contractor through the APT Program Office. The tanker organization will document the aerial refueling assessment through the Airworthiness Determination Process IAW AWB-007. If it is determined the APT Receiver has an airworthiness impact on a tanker, a Modification Airworthiness Certification Criteria (MACC) basis will be prepared for the tanker(s). If the impact is reportable, the MACC will be submitted for approval to the TAA by the tanker organization concurrent with submission of the APT EFRB by the APT Program. The USAF will subsequently process the necessary APT Aerial Refueling Clearance to Test Letter to support DT&E.

The contractor will prepare the EFRB Compliance Report and provide compliance artifacts for review (electronic access). The program office will review and approve the EFRB Compliance Report, verifying non-compliances and resultant risks and hazards. The program office will subsequently submit the EFRB Compliance Report to the TAA for USAF approval. Artifact data use will be IAW the glossary definition.

The program office, with contractor support, will prepare SSRAs for approved hazards as directed by the USAF TAA. After risk acceptance, the program office will request that the TAA issue the DT&E MFR and request test build-up approval be delegated to AFLCMC/WL’s DOE.

Release of the MFR is planned to support the Aircraft Test Readiness Review; however, an MFR must be in place prior to the first scheduled flight test.

Figure 5.2-1 summarizes airworthiness actions and products during this acquisition phase.

Airworthiness Plan for the Advanced Pilot Training System (APT)

AW

Product

Delivered to TAA

Task/Action Who? Applicable Guidance, References, and Remarks

CONTRACT AWARD

SRR/SFR

CB Update Approval

Update CB-Rev 1.

Program Office

Single/multi-document updated/assembled by contractor.

Contractor submits, and program office approves before TAA assessment.

Forum

Program Office

Developed for AW briefing to TDs.

Submit with CB-Rev 1.

X Submit CB-Rev 1 to TAA.

Request TD Forum.

Office

Conduct CB-Rev1 evaluation. TAA

Interaction with TAA during CB- Rev 1 evaluation.

Program Office

CB-Rev 1 updated with agreed-to changes.

TAA approval of CB-Rev 1. TAA AWB-003A (paragraph 3A).

Flight Test EFRB approval

Prepare Draft EFRB. Program

AWB-005 (paragraph 4).

Contractor prepares.

X Submit Draft EFRB to TAA. Program

Interaction with TAA during EFRB evaluation.

Program Office

Draft EFRB updated with agreed-to changes.

TAA approval of EFRB. TAA

CDR

CB Update Approval

Update CB-Rev 1 for CDR final configuration; generate CB-Rev 2.

Program Office

CB-Rev 1 updated/assembled by Contractor.

Program office evaluates before TAA assessment.

Forum.

Program Office

Developed for AW briefing to TDs.

Submitted with CB-Rev 2.

X Submit CB-Rev 2 to TAA.

Request TD Forum.

Conduct CB-Rev 2 evaluation. TAA Program office interacts with TAA as necessary.

TAA approval of CB-Rev 2. TAA AWB-003A (paragraph 3A).

Airworthiness Plan for the Advanced Pilot Training System (APT)

AW

Product

Delivered to TAA

Task/Action Who? Applicable Guidance, References, and

DT&E EFRB CR approval

Prepare EFRB CR.

Office

AWB-013A, Risk Identification and Acceptance for Airworthiness Determinations (attachment 2 for content).

Contractor prepares & submits to Program Office.

Program office evaluates before TAA assessment.

X Submit EFRB CR and SSRAs to

TAA.

Program Office

Contractor submits, and program office approves.

Conduct EFRB evaluation. TAA Program office interacts with TAA as necessary.

Identify hazards/risks & secure risk acceptance.

Program Office

Contractor prepares & submits to program office for evaluation before TAA assessment.

TAA approval of EFRB CR. TAA

Issue MFR for DT&E.

TAA AWB-1009 (paragraph 3c1, paragraph 5, paragraph 6, paragraph 7).

Indicates a program office airworthiness product (page/document/paper).

Figure 5.2-1 – Engineering and Manufacturing Development-Phase Airworthiness Tasks

5.3. Production, Post-Milestone C

The contractor will prepare the MTC Compliance Report and provide access to artifacts demonstrating compliance to the approved CB following DT&E. The program office will review and approve the CR for accuracy and adequacy and submit it to the TAA. The TAA will approve and issue the MTC, to include aerial refueling if required, after risk acceptance for identified hazards. Artifact data use will be IAW the glossary definition.

Aircraft used for DT&E will be updated to the latest, production-representative design configuration for AETC familiarization and IOT&E. Following confirmation that these EMD aircraft conform to MTC type design and issuance of MCAs by the program office, the aircraft will be delivered to AETC, the using command. EMD aircraft not delivered to AETC (e.g., test article) will be managed by the Air Force Materiel Command either at an Air Force Test Center facility or a contractor facility to be determined at a later date. The flight test MFR will be maintained to support operation of aircraft in the EMD configuration until they are conformed to the production configuration. Until conformance occurs, the program office will update the MFR as the aircraft configuration and operations change.

Airworthiness Plan for the Advanced Pilot Training System (APT)

A program office objective is to achieve MTC approval by the Operational Test Readiness Review (OTRR) so that the type certificate will be in place for AETC familiarization and IOT&E. OTRR is scheduled approximately nine months after DT&E test report delivery.

IOT&E is planned to start approximately three months after the OTRR. AETC familiarization will coincide with OTRR. If the MTC has not been awarded by OTRR, then familiarization and IOT&E will be conducted under an MFR until the MTC has been approved and MCAs can be issued.

If aerial refueling is part of the production aircraft capabilities, the USAF TAA will certify the technical capability and safety of the APT design and tanker/receiver pair compatibility as part of the MTC assessment. In addition, the USAF will prepare and submit the Technical Compatibility Assessment to the United States Transportation Command to support Operational Clearance for aerial refueling operations.

Following the MS C decision, Low Rate Initial Production lots will be produced to the approved MTC type design. The program office will issue MCAs after verifying conformity and acceptance of individual aircraft. Changes to the approved configuration will be controlled by Government-chaired configuration control and airworthiness boards (AB). Proposed changes that affect airworthiness will be evaluated through the Airworthiness Determination Process IAW AWB-007. Contractor-initiated Engineering Change Proposals will be accompanied by Airworthiness Determination Forms when submitted to the Government. Changes will be assessed by the program office’s AB prior to CCB processing. Records of non-reportable determinations will be maintained by the program office, and reportable modifications will be approved by the TAA IAW AWB-003A. The program office will submit an annual summary of reportability determinations to AFLCMC/WL’s DOE who will, in turn, submit an integrated AFLCMC/WL summary to the TAA.

Aircraft will be maintained and operated IAW approved Technical Orders and continued airworthiness requirements. Aircraft undergoing repairs will follow AFPD 62-6 and AFI 62-601 to assure continued MCA validity. Maintenance policy and procedures are prescribed by AFI 21-101.

Figure 5.3-1 summarizes airworthiness actions and products during this acquisition phase.

Airworthiness Plan for the Advanced Pilot Training System (APT)

AW

Product

Delivered to TAA

Task/Action Who?

Applicable Guidance, References, and

Remarks

OTRR

MTC CR Approval

Prepare CB CR.

Office

AWB-013A (attachment 2 for content).

Contractor prepares & submits to Program Office.

Program office evaluates before TAA assessment.

X Submit CB CR and SSRAs to

TAA.

Program Office

AWB-013A (attachment 2 for content).

Contractor submits, and program office approves.

Conduct CB CR evaluation. TAA Program Office interacts with TAA during finding of compliance.

TAA approval of MTC for Mission Design Series (MDS).

TAA AWB-1009 (paragraph 4, attachment 2).

Evaluate aircraft build & operational condition for safe flight.

X Issue MCA. Program

Placed on aircraft meeting USAF AW requirements.

IOT&E

Indicates a program office airworthiness product (page/document/paper).

Figure 5.3-1 - Production-Phase Airworthiness Tasks

Airworthiness Plan for the Advanced Pilot Training System (APT)

AIRWORTHINESS PLAN ANNEXES

The following annexes are included:

Annex 1 References

Annex 2 Acronyms

Annex 3 Glossary

Annex 4 Airworthiness Project Smart Tracker

Airworthiness Plan for the Advanced Pilot Training System (APT)

Annex 1 – References

Advanced Pilot Training Family of Systems Analysis of Alternatives Update Final Report (Version 3.0), 21 August 2014.

AFGM 2014-01, Air Force Guidance Memorandum to AFI 21-101, 22 April 2014.

AFI 21-101, Aircraft Equipment and Maintenance, 19 May 2015.

AFI 21-101_AFGM 2014-01, Air Force Guidance Memorandum to AFI 21-101, 22 April 2014.

AFI 62-601, USAF Airworthiness, 12 May 2011.

AFPD 62-6, USAF Developmental Engineering, USAF Airworthiness, 11 June 2010.

DoDD 5030.61, Department of Defense Airworthiness Policy, 25 June2015 MIL-HDBK 516C, Airworthiness Certification Criteria, 12 December 2014.

Military Standards (MIL-STD)-8591, Department of Defense Design Criteria: Standard Airborne Stores, Suspension Equipment and Aircraft-Store Interface (Carriage Phase), December 12, 2005.

USAF AWB‒013A, Risk Identification and Acceptance for Airworthiness Determinations, 29 June 2011.

USAF AWB‒002A, Airworthiness Planning, 17 May 2011.

USAF AWB‒003A, Tailored Airworthiness Certification Criteria /Modification Airworthiness Certification Criteria (TACC/MACC) Document Approval Process, 17 June 2001.

USAF AWB‒004A, Development of an Airworthiness Certification Basis, 17 June 2011.

USAF AWB‒005, Tailored Airworthiness Certification Criteria/Modification Airworthiness Certification Criteria (TACC/MACC) Document Construction and Format, 27 September 2010.

USAF AWB‒007, Determining Reportability of Modifications, 5 May 2011.

USAF AWB–1009, Airworthiness Flight Authorizations – Miltary Type Certificate (MTC)/Military Flight Release (MFF), 25 March 2016.

USAF AWB-1012, USAF Airworthiness (AW) Requirements for Contractor-Owned and Contractor-Operated (COCO) Aircraft, 19 August 2015.

Airworthiness Plan for the Advanced Pilot Training System (APT)

Annex 2 – Acronyms

AB Airworthiness Board AETC Air Education and Training Command AFGM Air Force Guidance Memorandum AFI Air Force Instruction AFLCMC Air Force Life Cycle Management Center AFLCMC/WL Air Force Life Cycle Management Center/Mobility Directorate AFPD Air Force Policy Directive APT Advanced Pilot Training AW Airworthiness AWB Airworthiness Bulletin CB Certification Basis (plural: Certification Bases) CCB Configuration Control Board CDR Critical Design Review CN Change Notice CR Compliance Report DOE Director of Engineering DT&E Developmental Test and Evaluation E3 Electromagnetic Environmental Effects EFRB Experimental Flight Release Basis EMD Engineering and Manufacturing Development GBTS Ground Based Training System IAW In Accordance With IOC Initial Operational Capability IOT&E Initial Operational Test & Evaluation MACC Modification Airworthiness Certification Criteria MCA Military Certificate of Airworthiness MDS Mission Design Series MFR Military Flight Release MIL-HDBK Military Handbook MIL-STD Military Standards MS Milestone MTC Military Type Certificate OTRR Operational Test Readiness Review PDR Preliminary Design Review RFI Request For Information RFP Request for Proposal

Airworthiness Plan for the Advanced Pilot Training System (APT)

SEP Systems Engineering Plan SFR System Functional Review SME Subject Matter Expert SOW Statement of Work SPA System Processing Architecture SRR System Requirements Review SSRA System Safety Risk Assessment TAA Technical Airworthiness Authority TACC Tailored Airworthiness Certification Criteria TD Technical Director USAF United States Air Force

Airworthiness Plan for the Advanced Pilot Training System (APT)

Annex 3 – Glossary

Access (Data). Secure, single-point interface, to a contractor data repository or repositories that enables and allows unimpaired and unrestricted viewing, information sharing, and creation of derivative works through the copying of excerpts into briefing charts and reports. To be accessible, data must be formatted so that it can be opened using contract-prescribed application software. For access, data items must be complete documents, not excerpts, redactions, or summaries. Access extends from a single user, to multiple, simultaneous users; must be enabled 24 hours a day every day of the year with the exception of service disruptions or maintenance outages; and extends from the date and time a data item is first made electronically available through contract termination.

Access does not include storage or archiving within data systems other than the contractor’s, printing, photocopying, manipulation, alteration, or transfer of possession.

Users of accessed data must respect all contractual and legal requirements for data rights, security, licenses, copyrights, and other distribution restrictions that apply to the data. Items in the database should be marked with the applicable use (e.g., Use (Airworthiness), Use (Test)) as well as the data rights associated with the data item (e.g., Unlimited Rights, Government Purpose Rights, Limited Rights, Restricted Rights, Negotiated License Rights, SBIR Data Rights, Commercial Technical Director License rights).

Accuracy. A technical document/artifact is accurate if it is free of errors (correct method, procedural steps, in the correct order, parts data that match parts used, etc.).

Adequacy. A technical document/artifact is adequate if it permits the intended users to perform tasks IAW the approved USAF airworthiness certification methods and procedures. Specifically, it must enable the user to read and understand all materials to a level that results in successful airworthiness task performance.

Airworthiness. The property of an air vehicle / aircraft system configuration to safely attain, sustain, and terminate flight IAW the approved usage limits.

Available. Suitable and ready for use when and where required for Government review.

Certification (Airworthiness). Airworthiness certification is a repeatable process implemented to verify that a specific air vehicle / aircraft system can be, or has been, safely maintained and operated within its described flight envelope.

Certification Basis (CB). The set of approved airworthiness certification criteria, standards, methods of compliance, and exemptions that apply to a specific air system. The certification criteria, in turn, are typically derived from MIL-HDBK 516C, Airworthiness Certification Criteria.

Compliance Data. Documentation of activities that provide technical substantiation of compliance with MIL-HDBK-516C criteria and standards, also called Methods of Compliance

Airworthiness Plan for the Advanced Pilot Training System (APT)

(includes, for example, documentation analyses, inspections, drawings, modeling, simulations, test plans and test results, and any other relevant technical data that verifies compliance).

Compliance Report. This document defines the approved CB with references to substantiating data that show compliance with the CB and lists risk levels and acceptance for non-compliant criteria. This document is used for final approval of an MTC or MFR.

Conformity. Process of assuring that the aircraft configuration matches that of the type design.

Data. Recorded information regardless of the form or method of recording.

Data Use (Airworthiness). Data accessed will be limited to use by USAF personnel and their authorized designees only for the purposes of determining compliance with APT airworthiness CB and issuance of an MTC and MFRs, establishing conformity of delivered APT Aircraft to the MTC type design, assessing airworthiness impacts of configuration changes to APT Aircraft, maintaining continued airworthiness of the APT fleet; and securing USAF TAA for the APT Program approvals as needed.

Database. A collection of related data stored in one or more computerized files in a manner that can be accessed by users or computer programs via a database management system.

Delivery (Data). Government acquired data in the physical possession of the Government. The data must be formatted IAW accepted data standards and have the appropriate Government rights to ensure usability by the Government.

Developmental Test and Evaluation (DT&E). Any testing used to assist in the development and maturation of products, product elements, or manufacturing or support processes. Also, any engineering-type test used to verify status of technical progress, verify that design risks are minimized, substantiate achievement of contract technical performance, and certify readiness for initial operational testing. Developmental tests generally require instrumentation and measurements and are accomplished by engineers, technicians, or operator-maintainer test personnel in a controlled environment to facilitate failure analysis.

Experimental Flight Release Basis (EFRB). The limited set of approved airworthiness certification criteria, standards, and methods of compliance tailored to reflect the exact configuration and capabilities of the flight test or developmental aircraft. It is derived from the approved airworthiness CB documented in the TACC/MACC document and serves as a checklist against which readiness to initiate flight test may be assessed.

Mission Design Series (MDS): A three-part designation that identifies the unique configuration of an aircraft. The MDS includes the type of aircraft, the model number, and a variant or block identifier.

Modification. A configuration change to hardware or software.

Airworthiness Plan for the Advanced Pilot Training System (APT)

Modification Airworthiness Certification Criteria (MACC): The airworthiness CB that documents the applicable criteria, standards, methods of compliance, and other pertinent system information for modifications that impact airworthiness.

Program Office. The organization that directs the development, production, and deployment of new defense systems. The program office is staffed by the program manager to achieve the cost, schedule, and performance parameters specified in the Milestone Decision Authority-approved Acquisition Program Baseline. It is the single point of contact with industry, Government agencies, and other participating entities.

Single Point Interface. A web-based data interface that provides a single point of access to all technical data, no matter where stored, required for APT Program purposes as stated in defined data use.

Technical Airworthiness Authority (TAA). The TAA is the USAF official authorized to define airworthiness standards, approve the CB, issue findings of compliance, and issue MTCs and other flight releases.

Tailored Airworthiness Certification Criteria (TACC). The TACC is comprised of a description of the aircraft system as well as airworthiness certification criteria, standards, and methods of compliance. Criteria may be designated as non-applicable; the reasoning supporting this designation is included in the TACC. Standards and methods of compliance may be tailored.