EN Industry Day Brief.pptx
PPTX presentation 703 KB Posted
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Defense Logistics Agency Aviation
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This is an Industry Day brief presentation outlining the Air Force's source qualification objectives and requirements for C-5M Super Galaxy structural honeycomb panel manufacturers. The 409th Supply Chain Management Squadron at Robins Air Force Base is seeking to expand its vendor base for over 500 National Stock Numbers covering honeycomb panels used throughout the aircraft's structure. The Government anticipates low-volume, high-value procurements with typical orders of 1-10 units, with initial tooling and set-up costs covered through a Material Related Set-up CLIN. The brief emphasizes that pre-qualified vendors will bypass First Article Testing, addressing historical 17% rejection rates and supply chain delays that have led to cannibalization and uneconomical repairs during Programmed Depot Maintenance operations.
Prospective vendors must submit a formal Source Qualification Request (SQR) in accordance with MIL-HDBK-831 or the Aviation Source Approval and Management Handbook, demonstrating aerospace manufacturing experience, past performance on commercial or military bonded honeycomb panel contracts from the past three years, AS9100 or equivalent quality management certification, and available experienced production and engineering staff. Required facility capabilities include autoclave, oven, and freezer equipment specifically for composite and metal bonding; ultrasonic and radiographic non-destructive testing capability; and single-location manufacturing for all surface preparation, bonding, and curing. The Government will complete submission reviews within 120 calendar days and may require on-site verification visits, process audits, and sample panel builds completed within 150 days, which will undergo destructive testing. Post-qualification, manufacturing processes cannot change without Contracting Officer approval, and qualification status is subject to revocation for Quality Deficiency Reports. Qualified vendors must maintain ISO 9002 or AS9100 certification, register in SAM and EJCP, and achieve Level II CMMC certification.
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Engineering Discussion Jonathan Harrison Electronics Engineer
AFLCMC/WLS
3 August 2026 C-5M Super Galaxy Division Unclassified
The Payload Airlifter — Greater Range, Greater Lift
Classification The classification of the brief is Unclassified
Government Intentions The Government’s plans and intentions are subject to change. Any formal request to provide information, collaboration or take any further action will be in writing to protect the interest of both the vendor and the Government.
Background C-5 honeycomb panels have a history of logistical challenges 1,000+ panels on the aircraft (over 40,000 sq ft) Some competitive, some restricted (source requires prior engineering approval) Complicated loft data can make manufacturing very difficult Traditional Production Lead Times (PLT) too long (some in excess of 1000 plus days) to support Programmed Depot Maintenance (PDM) flow Locally repaired in lieu of ordering new panels Repair costs ~2.5x value of new panels
Areas of Risk/Concern Loft data, drawings, specifications Material availability Qualification/Prequalification Process Quality Assurance/Quality Deficiency
Past Issues Missing loft data/supplemental drawings Incorrect data causes trim and fitment issues Contractors have different quality standards (does not conform to specifications, i.e. core cutting, rivet installation, finish application etc.)
Source Qualification Objective Pre-qualifying suppliers is critical to improving the C-5 Programed Depot Maintenance (PDM) schedule and overall aircraft availability.
| Current Challenge | Future State (Pre-Qualified Vendors) |
| Historical 17% First Article testing rejection rate. | Elimination of First Article Testing for qualified sources. |
| Delays in procurement lead to cannibalization or uneconomical repairs. | Robust procurement process ensuring on-time panel availability. |
| Supply shortages risk the time-sensitive, event-driven PDM schedule. | Improved supply posture and elimination of work stoppages during PDM. |
Submission Requirements Vendors must submit a formal Source Qualification Request (SQR) demonstrating comprehensive aerospace manufacturing experience and strict quality controls.
| Submission Category | Required Documentation |
| Qualification Format | SQR in accordance with MIL-HDBK-831 or the Aviation Source Approval and Management Handbook. |
| Past Performance | List of applicable commercial/military aerospace bonded honeycomb panel contracts from the past three years (must include Contract #, Value, Agency, Assets Shipped). |
| Quality Management | Detailed Company Quality Plan implementing AS9100 (or equivalent) and a Supplier/Subcontractor QA Plan. |
| Staffing & Expertise | Proof of availability for experienced production managers (scheduling/supply) and aerospace planning/engineering staff. |
Facility & Equipment Capabilities Manufacturing highly contoured bonded panels requires strict facility control and specialized equipment. All surface prep, bonding, and curing must occur in a single geographic location.
| Equipment / Area | Minimum Capability Requirements |
| Manufacturing Equipment | Autoclave, oven, and freezers specifically for composite/metal bond manufacturing and adhesive storage. |
| Inspection Equipment | Ability to operate or access ultrasonic and radiographic non-destructive testing (NDT) equipment. |
| General Construction | Detailed facility layout outlining, layup room, material storage/handling and bonding process flow throughout the facility. |
| Testing | Certification of test results (Tensile shear and drum peel) from 5 samples conducted by an independent testing facility. |
Source Evaluation & Site Visit Process The Government will review submissions within 120 calendar days and may mandate on-site verification.
| Evaluation Phase | Government Actions & Vendor Expectations |
| Site Visit | Verification of engineering capability to convert aircraft loft data to tooling data. Audits of process controls, autoclave logs, facilities and internal training/self-audit records. |
| Sample Panel Build | If documentation is insufficient, the vendor may be required to build a sample panel to blueprint within 150 days. |
| Destructive Testing | Any requested sample panel will be destructively tested by the Government and will not be returned. |
| Post-Qualification | Approved vendors bypass First Article Testing. Manufacturing processes cannot change without Contracting Officer approval. Qualification can be revoked for Quality Deficiency Reports. |
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