ATCH_5_PreQual.pdf

SOURCE PRE-QUALIFICATION REQUIREMENTS

(Public Law 98-525, 10 United States Code Section 2319)

AMSC C: This part requires engineering source approval by the control activity to maintain the quality of the part. An alternative source must qualify according to the design control activity’s procedures as approved by the cognizant government engineering activity, AFLCMC/WIUED.

SECTION A: ITEM IDENTIFICATION

The items listed below can be Overhauled and Repaired by separate or the same contractor:

Stock Number (NSN) Part Number Nomenclature Tech Order 1615-01-061-6615 212-040-001-111 Transmission Assy USAF TO 3R7-2-6-3

SECTION B: JUSTIFICATION FOR ESTABLISHING A QUALIFICATION REQUIREMENT

Transmission Assembly (P/N: 212-040-001-111) drives the main rotor mast through a series of gears and has accessory drives for the hydraulic pumps, rotor brake disc, tachometer-generator, and tail rotor drive shaft. The transmission is located forward of the engines and is coupled to the engines by a main drive shaft coming from the combining gearbox. A chip detector system is installed in the transmission.

It illuminates a light on the chip detector caution panel if metallic particles contact it. Transmission lubrication is accomplished by a self-contained pressurized oil system, with a submerged oil pump in the sump located in the bottom of the transmission. An oil cooler system is incorporated in the transmission oil system. The transmission oil cooler is installed aft of the engine combining gearbox above the engine oil cooler and receives cooling air from the blowers mounted on the combining gearbox.

Sources must have quality procedures and processes to ensure that the work being performed complies with the respective drawing and Technical Order. Outstanding quality and thoroughness of the overhaul and repair is required. Records shall be maintained for all work performed, including the results of all required inspections. Maintenance records shall be provided to the Government upon request. All disassembly actions, component inspections, time change of components as required, assembly actions, and functional checks shall be performed in accordance with the applicable USAF TOs. After final assembly, all testing required in the TO shall be performed including a 2.8 hour run-in test on a certified test stand. Run-in on aircraft is not acceptable. This component is a Critical Safety Item, and the failure of which will result in an unacceptable chance of loss of aircraft and aircrew. Therefore, repair and overhaul sources must qualify in accordance with the appropriate Government engineering activity, AFLCMC/WIUED Engineering office, Robins AFB, GA. Additionally, the qualification procedures must be approved by AFLCMC/WIUED Engineering office. USAF TO 3R7-2-6-3 provides essential information to accomplish repair and maintenance functions on the noted items.

SECTION C: QUALIFICATION REQUIREMENTS

This section contains the minimum requirements necessary to become a qualified bidder on the equipment listed in Section A. The repair and overhaul of this component will return unserviceable component to serviceable condition per the USAF TO listed in Section A. The extent of internal parts replacement required shall be determined by the inspections and the disassembly/assembly required to restore this item to serviceable condition. Some parts are life limited and will require replacement according to the accumulated flight hours and individual part retirement requirement.

a. Potential bidders shall provide a summary of the company’s capabilities. This shall include a list of similar components currently overhauled, a detailed factory layout, a list of the machinery, fixtures, tooling and test and inspection equipment. Certifications for inspection (NDI) operators and equipment shall be provided. At a minimum, vendors will be required to have the special tooling and the special test equipment called out in T.O.s listed below:

Technical Order Noun Special Tools and Test Equipment

USAF TO 3R7-2-6-3 Transmission Assy Listed in USAF TO 3R7-2-6-3

Alternatives to the special tooling and/or test equipment may be used, provided the potential bidder can demonstrate that they have an equivalent piece of equipment that can accomplish the same task successfully in accordance with the applicable technical data. Each individual similar piece of equipment will require Government evaluation and approval. Alternate tools/equipment must be identified by part number and potential bidders must specify by part number which piece of equipment the alternate is replacing. Alternate tools/equipment must receive approval from the applicable government engineering activity, AFLCMC/WIUED (Huey Helicopter Engineering Section) before such tools/equipment are used to overhaul/repair any flight safety critical components. The transmission assembly is a flight safety critical component.

b. Potential bidders shall demonstrate the ability and have experience in repair and overhaul of similar critical safety components, which are currently in use on commercial or military helicopters.

Potential bidders shall provide the following information for similar items:

1. Contract Number

2. Procuring Agency

3. Contract Value

4. Number of Assets Shipped

5. Percentage of On-Time vs. Late Deliveries

c. Potential bidders shall provide a detailed quality plan implementing AS9100 or ISO 9001 (or equivalent). Provide certification for the quality plan that is in use.

d. Potential bidders shall provide a detailed repair and a detailed overhaul plan describing repair, overhaul and inspection procedures and shall provide for:

1. Traceability of batch/lot for repaired / overhauled material.

2. Identification of material sources. Sources for raw materials must be documented for each type of material. No material waivers will be granted.

3. Identification of sources for process not done in house shall be documented.

e. Potential bidders shall perform a minimum of 75% of the repair and overhaul workload in-house.

Testing shall not be sub-contracted to a third-party facility. Final 2.8 hour transmission run-in test after overhaul shall be accomplished on a certified test stand. The 2.8 hour run-in test may be accomplished outside the overhaul contractor’s facility. Test reports shall be provided following the run-in test. Test parameters and pass/fail criteria are listed in USAF TO in Section A.

f. After qualification the repair and overhaul plan processes, vendor sources, quality procedures etc.

shall not be changed without the approval of AFLCMC/WIUED, obtained through the contracting officer.

g. Conditional approval may be granted based upon submittal of a Source Approval Request providing the documentation requested herein. Full Pre-Qualification Status shall not be granted until bidders pass a one-time First Article Test after approval of a First Article Test Plan. Once vendors have had the Source Approval Request approved and passed First Article Testing, Pre-Qualification status will be granted.

h. The Source Pre-Award Qualification Requirements detailed in this document shall be waived for companies who have already passed qualification or pre/post-award qualification for items listed in Section A. Additionally, companies who currently possess official certification as a Bell authorized service center for Component Repair & Overhaul for Bell 205, 212, or UH-1 model helicopters and have performed a Transmission Assembly Repair and Overhaul in the last 3 years are currently qualified to repair, overhaul and test the items listed in Section A.

i. This qualification process shall be waived for companies who have already passed pre-qualification:

Bell Helicopter Textron (CAGE 97499), and Arista (CAGE 6SR03) are currently qualified to repair, overhaul, and test the subject items. These vendors are Air Force approved and are waived from the requirement to complete a First Article Inspection. Any other OEM Bell certified vendors that bid and are awarded this contract will also be waived. OEM certification claims must be verified prior to approval.

j. The Air Force may not qualify potential bidders who have had quality problems when delivering similar or identical items to the government. Potential bidders who have produced similar items for the commercial market shall also be considered for qualification and shall provide commercial brochures and at least five (5) references with phone numbers. Potential Bidders shall be ISO 9001:2015 certified.

k. The United States Government reserves the right to witness all post-award qualification testing.

The contractor shall provide test time and location to Rotary Wing SPO Engineering no later than 60 days prior to the start of post-award qualification testing.

l. Potential bidders will have to obtain access to the USAF Technical Order system- the Enhanced Technical Information Management System (ETIMs). This system is the source for the most up to date USAF TOs.

m. The Government will perform an initial review of all information/material submitted for source qualification consideration. Within 45 working days a response will be provided to the submitter of either acceptance of all required materials/information for source qualification consideration or rejection of the submittal with identification of missing material/information required for successful resubmittal. Once the Government has provided a formal response that all required materials and information have been received that are required for source qualification a final response to potential bidder source qualification will be provided within 180 days. If clarification of information is required during the review process by the Government then the 180 day review process will be extended by the amount of time required for the potential bidder to provide the additional information.

SECTION D: ESTIMATE OF THE TEST AND EVALUATION COSTS

This cost estimate is required per FAR 9.2029(a)(1)(ii) and 10 U.S.C. 2319(b)(3). It is intended to identify the costs for test and evaluation which will likely be incurred by the potential offeror to become qualified to repair and/or overhaul each part associated with the requirements being sought via the above PR. The below total pertains to only a single part; therefore, this should be multiplied by the number of items a company seeks to qualify.

Section Description Est. Cost

A Shipping N/A B Dimensional/Electronic Verification

a. Chemical N/A

b. Metallurgical N/A

(1) Destructive N/A

(2) Non-Destructive N/A

c. Dimensional N/A

d. Electronic N/A

e. Mechanical N/A

f. Non-Destructive Inspection N/A

C Nuclear Harness N/A D Form, Fit, Function, and Interface N/A E OEM Qualification Testing

a. Laboratory Costs N/A

b. Flight/Data Reduction & Analysis Costs N/A

F Travel to Contractor or Test Site N/A G SAR Package Development/Evaluation $ 6,000.00

TOTAL = $ 6,000.00

Comments & Methodology: The above sections are listed in AFMCI 23-113 (Pg 22-23). The Integrated Product Team (to include Engineering) met to evaluate each category and determined that most of these T&E tasks will not be required by AFLCMC/WIUED in order to become considered for qualification. The vast majority of expenses that will be incurred by the Contractor will likely be associated with administrative labor performed to (1) substantiate their Company's technical capabilities and (2) vet that information internally for finalization of their SAR package for submittal to the Government. This is an estimated level of effort for EACH part. The basis of estimate for Section D consists of an approximated 80 man-hours at a rate of $75/hr.

SECTION E: GOVERNMENT CONTACT

The Government Point of Contact for the technical requirements specified for qualification is:

Coby Giddens Rotary Wing Systems and Integrity Engineer - AFLCMC/WIUED AFLCMC/WIUED, 370 Richard Ray Blvd. Bldg. 300., Robins AFB, GA 31098-1670.

478-926-7255 coby.giddens.1@us.af.mil

SECTION F: SIGNATURE BLOCK

AFLCMC/WIUED Engineer:

AFLCMC/WIUED Branch Chief: