Repair_Qualification_Requirements_for_Critical_Safety_Items.pdf

12 July 2018 RQR-PSD-1 Revision 2

REPAIR QUALIFICATION REQUIREMENTS (RQR) FOR

PROPULSION CRITICAL SAFETY ITEMS (CSI) & CRITICAL

APPLICATION ITEMS (CAI)

WARNING: This Qualification Requirement (QR) does not apply to any items with a Repair Method Suffix Code (RMSC) of G, A, B, H, L, U or Y. AFLCMC/LPS Engineering Support Activity (ESA) must obtain a waiver for these items, except for G coded items, from the appropriate authorization office, AFLCMC/LPS or AFSC/PK, depending upon the item criticality.

1. APPLICATION. This QR applies to CSI and CAI with an ERRC code of C, P, S, T or U and a RMSC code of C, D, K, M, N, P, Q, R, S, V and Z. This QR does not apply to items with an RMSC of G, A, B, H, L, U and Y.

1.1. The intent of this QR is to meet the Operational Safety, Suitability and Effectiveness (OSS&E) requirement, while maximizing competition and complying with AFMCI 23-113, Pre-Award Qualification of New or Additional Parts Sources and the Use of the Source Approval Request (SAR) and the Joint Aeronautical Commander’s Group Aviation Sources Approval and Management (SAM) Handbook.

1.2. This QR sets Qualification Waiver, SAR and Source Resubstantiation Request (SRR) requirements.

2. SCOPE.

2.1. This QR establishes the minimum technical requirements, which Potential Sources (PS) must satisfy in order to obtain ESA approval to repair propulsion items for the specific applications. This RQR may have two phases, depending on ESA determination. The first phase is Waiver or SAR submittal and evaluation; the second phase is the Source Demonstration (SD) and evaluation.

2.2. The PS may qualify for a number of waivers. The waiver conditions are defined in section

7. PS should submit a waiver request when one of the waiver conditions applies.

2.3. If the PS does not qualify for any of the waivers, then the PS must submit a SAR package.

The SAR requirements are defined in section 8.

2.4. Approved sources shall submit SRR packages prior to expiration of the current approval period or when any significant changes to ownership, address, process sequence, process parameters, technical data, Sub-Tier Supplier (STS) and/or significant quality deficiencies occur. The re-substantiation requirements are defined in section 9.

2.4.1. Significant changes, as defined in FAR 9.207, or unresolved quality deficiencies may result in additional testing, or revocation of source approval status, depending on the nature and extent of the changes and/or quality deficiencies.

2.4.2. If an SRR is not submitted prior to the expiration date or after significant changes have occurred, the associated CAGE shall be removed from the approved sources listing.

2.5. ESA source approval expiration is defined in section 12.

2.6. Once the Waiver or SAR phase is complete, the ESA will notify the PS if they need to complete the SD. The SD requirements are defined in section 15.

3. CONTRACTOR RESPONSIBILITY STANDARDS (FAR 9.104).

3.1. PS must submit a complete waiver request or SAR data package as defined per the category selected.

3.2. General standards as specified in FAR 9.104-1 apply.

3.3. Special standards as specified in FAR 9.104-2 apply.

3.4. Certification Regarding Responsibility Matters as specified in FAR 9.105-1 apply.

3.5. Qualifications Requirements as specified in FAR 9.2 apply.

3.6. Higher-Level Contract Quality Requirement as specified in FAR 52.246-11 apply.

4. POTENTIAL SOURCE SUBMITTAL DETERMINATION.

4.1. The forecasts contained on the Requirement Projections on the Web (RPOW) through the Strategic Alternate Sourcing Program Office (SASPO) website may or may not generate due to variability in customer demands and priorities. The forecast data is for planning purposes only and does not constitute an invitation for bid or request for proposal and is not a commitment by the government to purchase the described items.

4.2. The PS should consider submitting a SAR package for evaluation after considering the following:

4.2.1. Has the United States Air Force (USAF) listed a requirement in the Federal Business Opportunities (FEDBIZOPPs) at www.fbo.gov or the RPOW through SASPO’s website (http://www.tinker.af.mil/Home/429SMCSSASPO)?

4.2.2. Has the procurement history for the item been researched and determined to be active?

4.2.3. Has the PS established that they can conduct business with the Government?

4.3. Technical Data Request.

4.3.1. Requests Related to Procurement Announcements. Request should be submitted to the announcing Contracting Officer and specify the solicitation, specific drawing(s) and specification(s) for verification and authorization of requested data on company letter head.

The PS must provide an approved DD Form 2345.

4.3.2. Requests Related to SAR Package Approval –The PS must provide a justification letter identifying specific drawing(s) and specification(s) on company letter head to the Tinker Engineering Drawing Public Sales. The PS must provide an approved DD Form 2345.

4.3.2.1. SAR Data Request can be submitted via Mail to:

AFLCMC/LZPTP

Technical Orders Sales

7851 Arnold Ave. Bldg. 3, Rm. 205 Tinker AFB, OK 73145

4.3.2.2. SAR Data Requests can be submitted via Email to:

AFLCMC.EZGTP.PUBSALE@us.af.mil

4.4. Small Business office (SBO) contact information can be found at www.tinker.af.mil/sbo.asp and the SASPO contact information can be found at www.tinker.af.mil/429scms.saspo, along with other helpful tips.

5. SAR, WAIVER, OR RE-SUBSTANTIATION FORMAT. All financial data must be redacted from all documents submitted.

5.1. SAR(s), WAIVER(s), OR RE-SUBSTANTIATION(s) packages can be submitted in one of three ways:

5.1.1. The packages can be submitted in a 3 ring binder. The three-ring binder or a similar product will contain a table of contents and 21 A-U element tabs. This will significantly reduce the turn-around time for engineering evaluation as well as reduce the likelihood of oversight or loss of valuable data that could have a significant bearing on the outcome of the evaluation.

5.1.2. The package can be submitted on a Compact Disc (CD) in a .pdf file format. The package can be a single .pdf file with index to each element or a series of folders for each element.

5.1.3. The package can be a combination of the physical paper and CD with .pdf files.

5.2. The documentation should follow the RQR call out order. Quality Manual and supporting documentation can be submitted on a CD in .pdf file format. All CDs should be scanned for viruses prior to submitting the documentation.

5.3. A table of contents is required for both physical paper and electronic submittal.

5.4. Each package will have the required tabs. If an element is not required by the category selected, it must be labeled and the PS must state that the element does not apply.

6. USE OF PROPRIETARY DATA IN SOURCE APPROVAL REQUESTS. PSs are not to utilize intellectual property (IP) of any third parties without appropriate authorization of the IP owner. The PSs are cautioned that no part of the government QR is intended to endorse or encourage the improper use of IP developed by the Original Equipment Manufacturer (OEM) or any other third party.

7. QUALIFICATION WAIVER REQUIREMENTS. All required waiver elements are listed in Table 1 and defined in section 8.

7.1. QUALIFICATION WAIVER REQUEST DETERMINATION. The PS may apply for a waiver for part of the qualification requirements, if any of the following Source Qualification Waiver Criteria (QWC) apply.

7.1.1. QWC1: The PS submits written certification that the articles have been supplied within three (3) years for CSI or within seven (7) years for CAI to the DOD or OEM (e.g., DD Form 250, Material Inspection and Receiving Report, Purchase Order, invoice, e.g.).

This waiver condition will be used to meet the AFI 20-106 waiver conditions.

7.1.2. QWC2: The PS is qualified on the right-hand article and requests to be qualified on the left-hand article. If the right-hand and left-hand articles are mirror images of each other, then approval can generally be given.

7.1.3. QWC3: A source qualified to provide an assembly is usually qualified to provide subassemblies, major components and items of that assembly. Applies only if all the manufacturing or repair for subcomponents is conducted in-house and elements G, H, K L and M were provided during the qualification of the assembly.

7.1.4. QWC4: A source qualified to provide earlier dash numbers of a basic P/N may be qualified to provide other dash numbers of that same basic P/N, provided there is no increase in complexity, criticality or other relevant requirements.

7.1.5. QWC5: Does not Apply, PS must submit SAR CAT II.

7.1.6. QWC6: A previously qualified source, which has been purchased, sold, merged, absorbed, reformed, split, etc., may qualify, if it can be established that the qualification is currently with the PS and that the PS has the same or equivalent facilities, tooling, equipment, personnel and utilizes the original forging, castings, etc., in the repair process.

7.1.7. QWC7: Other.

7.1.7.1. The PS will provide a cover letter detailing the specifics of how the waiver category applies.

7.1.7.2. SBO will forward the request to the ESA, who will determine if the QWC7 applies. If it is determined that the QCW7 applies, the ESA will specify the elements required for the waiver and the submitter will provide the required data.

7.1.8. QWC8: Manufacturer. A source qualified to manufacture an item, may qualify to repair the item, if it can be established that PS has the same or equivalent facilities, tooling, equipment, data and personnel and utilizes them for the repair of the item.

7.1.9. If the waiver is granted and the offeror is awarded a contract, the offeror may be required to undergo Source Demonstration (SD) or In-Process Evaluation (IPE) to verify production capability.

7.2. QUALIFICATION WAIVER REQUEST (QWR) REQUIREMENTS. QWC elements are listed in Table 1 and defined in section 8. The CSI production documentation will be frozen, after the ESA has granted approval or after the SD or IPE is completed, if required. Filled in block designates a mandatory requirement.

QWC

ELEMENT REQUIRED ELEMENTS 1 2 3 4 6 7 8

A COVER LETTER

B TECHNICAL DATA RIGHTS CERTIFICATION STATEMENT (CRITICAL)

C BROCHURE & CORRESPONDENCE

D QUALITY ASSURANCE DOCUMENTATION

E SUBJECT ITEM TECHNICAL DATA

G SUB-TIER SUPPLIER LIST (FROZEN FOR CSI)

H QUALITY HISTORY

J SIMILARITIES/DIFFERENCES OF SUBJECT/SIMILAR ITEMS

K PURCHASE ORDERS &SHIPPING DOCUMENTS

L TRAVELERS & PROCESS/OPERATIONS SHEETS (POS) (FROZEN FOR CSI)

M MANUFACTURE PROCESS SHEETS AND/OR INSPECTION METHOD

SHEETS (IMS) (FROZEN FOR CSI)

N PRIME CONTRACTOR’S QUALITY RATING SYSTEM REPORT

O LICENSEE AGREEMENT (IF APPLICABLE)

Q VALUE ADDED (BY PRIME OR OEM)

T GOVERNMENT/PRIME CONTRACTOR SURVEYS

U MASTER TOOLING CERTIFICATIONS

AA ESA/OEM APPROVAL LETTER

AB NOVATION LETTER

The ESA will specify the elements required for QWC7, see Section 7.1.7.

Table 1. Qualification Waiver Request Requirements

8. SOURCE APPROVAL REQUEST REQUIREMENTS. SAR elements are listed in Table 2 and defined below.

8.1. SAR Categories Determination. There are five (5) SAR categories and three (3) formats:

8.1.1. ACTUAL ITEM (Category I). This category covers PSs who repair the exact (Subject) item, using OEM technical data, for the prime contractor, OEM, another service, civil agencies, foreign governments or for the civil sector under Federal Aviation Administration (FAA). Category applies to CSI and CAI. The item will be repaired and evaluated against the ESA approved technical data.

8.1.2. SIMILAR ITEM (Category II). This category covers the PSs who have not previously repaired the subject item, but have repaired other items similar in complexity, design, criticality, industrial processes, materials and application for the prime contractor, OEM, another service, civil agencies, foreign governments or for the civil sector under FAA. Category applies to CSI and CAI. The item will be repaired and evaluated against the ESA approved technical data.

8.1.3. NEW REPAIRER OF ITEM (Category III). This category covers the PSs, who do not meet Category I or II criteria, but have the legal access to the OEM’s technical data and intends to repair to the ESA approved technical data with the same part number.

Category applies to CAI only, and cannot be used for CSI. The item will be repaired and evaluated against the ESA approved technical data.

8.1.4. PRE-DEVELOPED REPAIR (Category IV). This category covers unsolicited SAR submittals by PSs who have a previously developed repair that has: been fully validated and verified, successfully performed on regular production parts, and those parts that have undergone the repair have had sufficient operational experience, including either AMT (Accelerated Mission Testing) or field operational use. This category will require all elements of a SAR Package and any additional information as determined by the ESA.

8.1.5. DEVELOPING REPAIR (Category V). This category covers the PSs who have a repair, or could develop a repair, that will satisfy the need of the USAF in accordance with an advertised requirement. PS approval of a Category V SAR may still require repair verification, validation, and testing prior to complete approval of PS as an approved source.

This category will require all elements of a SAR Package and any additional information as determined by the ESA.

8.2. SAR Format Determination.

8.2.1. If multiple SAR packages are to be submitted within a three month period, then the PS can submit one Master SAR (MSAR) package and a series of SAR lite packages for each additional output NSN that is submitted.

8.2.2. MSAR Package is the same as individual SAR packages.

8.2.2.1. The MSAR must be constructed in a manner that allows for the reduction of data in SAR lites by including all part numbers or providing an enterprise point of view.

8.2.2.2. The MSAR should be the most complex of parts within the set of parts that will be submitted.

8.2.3. SAR lite packages. The SAR lite packages must be submitted within three months of the MSAR submittal.

8.2.3.1. The SAR lite package will only contain the unique part data for each additional

NSN

8.2.3.2. Each SAR lite package cover letter will reference the MSAR.

8.2.4. ASSEMBLY SAR PACKAGE REQUIREMENTS. The PS may submit a SAR package for an assembly that is separable into multiple procurable items, such as a whole engine or an engine module, using the following format. Required assembly elements are defined in Table 2.

8.2.4.1. HIGHEST LEVEL ASSEMBLY (HLA). The assembly SAR package must contain a Master SAR for the highest level assembly.

8.2.4.1.1 The HLA Master SAR must contain a matrix of all embedded parts with assigned significant Industrial processes (Appendix B) along with certifications used throughout the assembly. Methods of certification include, but are not limited to, NADCAP, OEM, DOD (Air Force, DCMA, Navy, or Army certification and/or audit), or other external audit and/or certification, will be reviewed by the ESA for process control and acceptability.

8.2.4.1.2 The HLA Master SAR must contain a matrix of all embedded parts with assigned sub-tier supplier list for all embedded parts within the HLA.

8.2.4.1.3 The HLA Master SAR must contain a matrix of all embedded parts with assigned tooling list for all embedded parts within the HLA.

8.2.4.2. ASSEMBLY SAR LITE PACKAGES. A SAR lite package must be turned in for each critical safety item (CSI) embedded within the assembly. A SAR lite package must also be turned in for any embedded part that the PS desires to become an approved source. Filled in block designates a mandatory requirement.

CAT I CAT II CAT III Remarks

CRITICALITY APPLICABILITY CI CI

CAI

ONLY

CI – Critical Safety & Application Items

ELEMENT REQUIRED ELEMENTS M S M S M S M (MASTER) S (SARLITE)

A COVER LETTER

B

TECHNICAL DATA RIGHTS

CERTIFICATION STATEMENT

Include all NSN and PN

C BROCHURE & CORRESPONDENCE Submit the complete tool list.

D

QUALITY ASSURANCE

DOCUMENTATION

Only submit once for all the SARs *Site Survey meets requirement

E SUBJECT ITEM TECHNICAL DATA For all NSN and PN.

F SUBJECT ITEM SPECIFICATIONS For all NSN and PN.

G

SUB-TIER SUPPLIER LIST (FROZEN FOR

CSI)

H QUALITY HISTORY Include all NSN and PN.

I SIMILAR ITEM TECHNICAL DATA

J

SIMILARITIES/DIFFERENCES OF

SUBJECT/SIMILAR ITEMS

K

PURCHASE ORDERS &SHIPPING

DOCUMENTS

L

TRAVELERS & PROCESS/OPERATIONS

SHEETS (POS) (FROZEN FOR CSI)

M

MANUFACTURE PROCESS SHEETS

AND/OR INSPECTION METHOD SHEETS

(IMS) (FROZEN FOR CSI)

N

PRIME CONTRACTOR’S QUALITY

RATING SYSTEM REPORT

Only submit once for all the SARs.

O LICENSEE AGREEMENT (IF APPLICABLE) Include all NSN and PN.

P VALUE ADDED (BY PRIME OR OEM)

For all NSN and PN. Only submit once for all the SARs.

Q

GOVERNMENT/PRIME CONTRACTOR

SURVEYS

Submit once per CAGE.

T MASTER TOOLING CERTIFICATIONS

U

GOVERNMENT QUALITY ASSURANCE

COMPLIANCE

Include all NSN and PN.

Table 2. Source Approval Request Requirements

8.3 Element A, Cover Letter. Provide a cover letter that includes the following information:

Solicitation Number (if applicable):

Contracting Officer POC (if applicable):

Engine Type:

Company Name:

Company CAGE:

Company Address:

Company Point of Contact: (Name, phone, fax and email):

Company Size: (Large or Small), Qualification Requirement Designation and Revision: (i.e. RQR-PSD-1, Rev 2) Qualification Waiver Criteria: (if Applicable) SAR: (SAR, Master SAR or SARlite (Master SAR Date: ______________)) Technical Data Proprietary: No, Yes or Partial (Select One) NSN(s):

Part Number(s):

Nomenclature:

Type: (New or Distributor (New)) Submittal Category: (Cat I (Subject), Cat II (Similar) or (Cat III (New Repairer)) ERRC Code (if known):

SAR Package Inventory: (Paper/Binder, CDs, Electronic or sample parts).

Disposition: (Return to Vendor or Destroy)

8.3.1. For proprietary technical data, the PS must provide a statement that proprietary data or processes will be used and submit an ownership statement or a Licensing Agreement that conveys the rights to specifically use the data or process in element O.

8.3.2. PS must provide a statement that the contractor is willing to provide a technical briefing on the SAR package submittal to the procuring activity or ESA, if required.

8.3.3. PS must provide a disposal statement that directs the destruction/shredding of the submitted material or the return of the submitted material at their expense after the evaluation is complete.

8.3.3.1. If no disposal statement is provided, the SAR will be shredded, after the evaluation is complete.

8.3.3.2. If the SAR is to be returned, SBO will contact the cover letter POC to obtain the authorization shipping code or label to return the submitted material.

8.4 Element B, TECHNICAL DATA RIGHTS CERTIFICATION STATEMENT. The PS must provide a certification of rights to use technical data in the format provided in Appendix A, signed on company letterhead by an authorized binding company official, President, Owner or Facility General Manager. This certificate states the data was obtained by legal means and the company has the rights to use the data supplied in the SAR for repair purposes.

8.5. Element C, BROCHURE AND CORRESPONDENCE.

8.5.1. Provide a company brochure and website if available.

8.5.2. Provide a synopsis outlining the applicant firm's capabilities, experience, facilities including location, number of buildings and square footage.

8.6. Element D, QUALITY ASSURANCE DOCUMENTATION. Provide a synopsis of the proposed PS's Quality Assurance System (QAS) capabilities, reporting system and its certifications.

8.6.1. Quality Assurance System (QAS)

8.6.1.1. Provide a statement that the DOD site survey approval letter with a current expiration date has been attached in Tab Q or

8.6.1.2. Provide a copy of the PS's QAS manual and all supporting/referenced documentation. A copy of the documentation may be kept by the ESA.

8.6.2. The PS’s QAS must comply with the requirements as described in this document and meet one of the following, AS9100, ISO 9001:2008, NATO AQAP-2070 or equivalent.

Provide a copy of the QAS certificate with a valid expiration date.

8.6.3. Significant Industrial Process must be certified per 8.2.4.1.1. Provide a copy of Significant Industrial Process approvals, certifications, and relevant documentation for those that require certification as denoted in Appendix B.

8.7. Element E, SUBJECT ITEM TECHNICAL DATA. The subject item technical data may include references to materials, mandatory inspections, inspection intervals, processes and specifications.

Note: Before proprietary data is submitted, the PS should determine if the data is available (see section 4.3). If so, it should be submitted in place of the proprietary marked data, else a license agreement or ownership statement will be required in Element L.

8.7.1. For Government Technical Data.

8.7.1.1. If located within the United States or Canada, provide the PS’s DD form 2345 with a valid expiration date, Repair Data List (RDL) and the latest legible revision of all technical data required to disassemble, clean, inspect, repair, assemble and test the subject item or a copy of the sales receipt detailing the data purchased.

8.7.1.2. If not located within the United States or Canada, provide a copy of the export control license, RDL, and the latest legible revision of all technical data required to disassemble, clean, inspect, repair, assemble and test the subject item or a copy of the sales receipt detailing the data purchased.

8.7.2. For Proprietary Technical Data.

8.7.2.1. If proprietary data can be submitted, provide RDL and the latest legible revision of all technical data required to disassemble, clean, inspect, repair, assemble and test for the subject item.

8.7.2.2. If proprietary data cannot be provided, submit a statement declaring that the data cannot be submitted and the licensing agreement or ownership statement that ensures the most current data will be used to perform the required work, RDL and a copy of the title page. The images may be redacted to only reveal the technical data number, title, revision and proprietary statement.

8.7.3. Provide a special tool statement detailing the tooling or tooling drawings availability, ownership, usage rights and state if the special tools will be leased, purchased or manufactured.

8.8. Element F, SUBJECT ITEM SPECIFICATIONS.

8.8.1. For Government available Subject specifications, provide:

8.8.1.1. For CAT I and III, Subject Item, provide a complete list of the applicable specifications identified on the subject item technical data and a copy of the title page of the latest revision of each specification.

8.8.1.2. For CAT II, Similar Item, provide a complete list of the applicable specifications identified on the subject and similar item(s) technical data and a copy of the title page of the latest revision of each specification.

8.8.2. For Proprietary, OEM or Prime Subject Specifications, provide:

8.8.2.1. For CAT I and III, Subject Item, provide a complete list of the applicable specifications identified on the subject item technical data and a copy of the title page of the latest revision of each specification. The images may be redacted to reveal the Specification Number, Title, Revision and proprietary statement.

8.8.2.2. For CAT II, Similar Item, provide a complete list of the applicable specifications identified on the subject and similar item(s) technical data and a copy of the title page of the latest revision of each specification. The images may be redacted to reveal the Specification Number, Title, Revision and proprietary statement.

8.8.3. For PS or Internal specifications, identify the commercial or government equivalent specification (if known/available) and provide a copy of the latest revision of each specification.

8.9. Element G, SUB-TIER SUPPLIER (STS) INFORMATION. Significant Industrial Processes approval/certification is required for those processes denoted in Appendix B.

AS9100, ISO 9001:2008, NATO AQAP-2070 or equivalent is required for all STS used to perform work on CSIs and CAIs. Provide a matrix, figure 1, with the CAGE, STS Name, Specification/Process, certification/approval date, ISO 9001:2008, and AS 9100 or equivalent for all STSs. Please select all that apply.

G. SUB-TIER SUPPLIER (STS) ( SUB-VENDOR) INFORMATION: Yes No N/A

1. Are STS used for manufacture or repair?

2. If STS are used for manufacture or repair, enter data below (all that apply): Certifications or Approval (Expiration Date)

CAGE STS Name Specification/Process Prime/

OEM

DOD NADCAP AS9100

ISO

9001:2008+

Figure 1. Sub-Tier Supplier Qualifications

8.9.1. For raw material STS, provide CAGE, STS Name and material specification/process only.

8.9.2. For STS(s) of castings or forgings, substantiate that the source(s) are currently OEM or DOD approved. If not approved by the OEM or DOD provide a rationale proving to the ESA that the casting or forging source is capable of manufacturing the replacement part to the established OEM or DOD quality standards.

8.9.3. For laboratory testing STS, provide CAGE, STS Name, specification/process, ISO/IEC 17025 or NADCAP certification only.

8.9.4. Provide copies of the current STS’s certificates or approval letter(s) and all conditions and restrictions imposed for the significant industrial processes with the expiration date highlighted.

8.9.4.1. It should be noted that ESA may specify additional testing.

8.9.4.2. If the approval does not have a defined expiration date, enter IND for indefinite.

8.9.5. Provide a copy of ISO 9001:2008, AS9100, or equivalent certifications for the STS used to perform work on Critical Items.

8.9.6. Provide a copy of NDI Level III certificate for all certified employees for all NDI Methods for the PS or/and STS.

8.9.7. For assemblies, identify all sub-assembly component sources. All Critical Item sub-components must only be supplied by government approved suppliers.

8.9.8. For STS providing proprietary industrial process support, provide a letter of support, capability and an expiration date.

8.10. Element H, QUALITY HISTORY.

Note: Nonconformance is not necessarily perceived as an increase in risk when considering alternate source qualification. In fact, identification of nonconformance can illustrate a successful quality assurance program.

8.10.1. If the PS and STS facilities have not experienced any quality deficiencies within the last three (3) years, provide a statement stating such.

8.10.2. Else, provide a PS and all STS quality history summary of Deficiency Reports experienced for the last three (3) years including but not limited to, internal deficiencies, commercial deficiencies, FAA Service Bulletins, MRB actions, Quality Deficiency Reports (QDR), Laboratory Quality Review Orders (LQRO), Offeror Report of Nonconformance (ORON), Supplier Report of Nonconformance (SRON), Material Deficiency Reports (MDR), statistical reports of nonconformance and nonconforming material rejection reports for the subject and/or similar item(s).

8.10.2.1. The Company President, Facility General Manager or the Quality Assurance Manager must coordinate on the summary. If the government source inspections were conducted, the Government Quality Assurance Representative will coordinate on the summary.

8.10.2.2. The summary will include the following data: P/N, Nomenclature, feature, deficiency, quantity, date and corrective action. It can be provided for the entire company or the specific part number or NSN.

8.10.3. Provide all corrective action requests and corrective action plans or resolutions for identified deficiencies.

8.10.4. Provide the PS’s and the STS’s scrap rates.

8.11. Element I, SIMILAR ITEM TECHNICAL DATA. For Category II SARs Only

NOTE: This information may include repair manuals, technical orders, drawings (casting, forging, detail, assembly, source controlled, masters, airfoil data, schematics, etc.), specification, configuration (revision), parts list and Quality Assurance Document (QAD), etc.

as applicable.

8.11.1. For Government Similar Item Technical Data, provide:

8.11.1.1. The similar item RDL and the front page of the all similar item technical data or a copy of the sales receipt detailing the data purchased.

8.11.1.2. If not located within the United States or Canada, provide a copy of the export control license.

8.11.2. For Proprietary Similar Item Technical Data, provide:

8.11.2.1. The similar item RDL, the latest legible revision of all drawings and specifications required to clean, inspect, repair, assemble and test the similar item.

8.11.2.2. If proprietary similar item data cannot be provided, submit a statement declaring that the data cannot be submitted, RDL and a copy of the title page, the licensing agreement or ownership statement ensuring the most current data was used to perform the required work. The images may be redacted to only reveal the technical data number, title, revision and proprietary statement.

8.11.3. For Non-Proprietary or Non-Government Similar Item Technical Data, provide RDL, the latest legible revision of drawings and specification required to clean, inspect, repair, assemble and test the similar item.

8.12. Element J, SIMILARITIES AND DIFFERENCES BETWEEN SUBJECT AND

SIMILAR ITEMS.

8.12.1. For QWC 8, provide a comparison matrix between the manufacturing and repair process.

8.12.2 For CAT II SARs Only, provide a comparison matrix identifying the specific similarities and differences in materials, coatings, design features, industrial processes, operating environment, etc. between the subject and similar item. Multiple similar items can be used to illustrate the capability necessary to perform work on the subject item.

8.12.3. For Proprietary industrial processes supported by a STS place an * next the process.

Ensure Element G has a support letter for that process.

8.13. Element K, PURCHASE ORDERS AND SHIPPING DOCUMENTS. The contract performance documentation provided for CSI shall be within three (3) years and within seven

(7) years for CAI, as evidenced by latest shipping document. The threshold should apply on the date the SAR is received by the Small Business Office. All financial information must be removed, else the SAR may be returned. Highlight the date on all documents in this section and ensure all items are accounted for. The data provided in this section should be from the same contract(s) as those provided in SAR Elements L and M.

8.13.1. For QWC 8, provide the purchase order and shipping documents for the manufactured subject item.

8.13.2 For Cat I or II, provide copies of at least one purchase order(s), all amendments and shipping documents from the Prime/OEM, DOD, foreign government, or other commercial customers for the Subject or Similar item.

8.13.3. For Cat III, provide a statement stating no repair(s) has been conducted for the Subject item.

8.13.4. If a contract was terminated, state the reason for the termination.

8.14. Element L, TRAVELERS AND PROCESS/OPERATION SHEETS (POS). The data provided in this section pertaining to the repair history should be from the same contract(s) as those provided in SAR Elements K and M.

Note: Travelers that may be enclosed in this section are not to be considered a replacement for detailed POS. Lack of detailed POS(s) pertaining to repair is cause for disapproval of the PS’s

SAR.

8.14.1. The subject item travelers and/or POS must have the Name, Address and CAGE for the PS on the top of every page. The following requirements must be met:

8.14.1.1. The documentation must be from the actual repair provider.

8.14.1.2. The traveler and POS must include all part numbers that are covered by the production documentation.

8.14.1.3. The traveler must include a detailed step-by-step account of the proper sequenced procedures necessary for the repair.

8.14.1.4. The traveler must include the operation number, process description, location, STS Name and CAGE; repair software data file name, etc. necessary to control the repair operations and must be signed or stamped off by in-process operator and/or inspector.

For Proprietary Travelers and POS, the process description may be redacted.

8.14.1.5. The traveler must track the disposition of all parts during the entire repair operation to include rejects and laboratory samples.

8.14.2. Any sub-vended process listed in the traveler must identify the STS by name and CAGE at each applicable operational step with clearly identified process or procedure.

8.14.3. For Category I, provide copies of the actual subject item traveler and POS used for the repair submitted.

8.14.4. For Category II provide copies of the actual similar item(s) repair traveler and POS and detailed proposed subject item traveler and POS to be used.

8.14.5. For Category III, provide the proposed subject item detailed traveler and POS sheets to be used.

8.15. Element M, REPAIR PROCESS SHEETS (RPS) and INSPECTION METHOD SHEETS (IMS). The RPS and IMS should include the nomenclature, part number, characteristics inspected, special instructions, zone, tolerances and actual measurements, inspection tooling/method, frequency and inspector's stamp. RPS and IMS may be included as an integral part of the POS(s) in SAR Element L. The data provided in this section should be from the same contract(s) as those provided in SAR Elements K and L.

8.15.1. The subject item IMS or RPS must have the Name, Address and CAGE for the PS on top of every page. The following requirements must be met:

8.15.1.1. The documentation must be from the actual PS.

8.15.1.2. The IMS or RPS must include part number(s), dimensions and proper units.

8.15.1.3. The IMS or RPS must include a detailed step-by-step account of the proper sequenced procedures necessary to inspect the subject and/or similar item.

8.15.1.4. If a sampling plan is used, provide the sampling plan and the approval letter.

8.15.2 For QWC 8, provide manufacturing subject item MPS and IMS with the manufacturing data and proposed blank RPS and IMS for subject item.

8.15.3. For Category I, provide the actual subject item RPS and IMS with the repair data.

Blank Subject RPS and IMS do not meet this requirement.

8.15.4. For Category II, provide the actual similar item RPS and IMS with the repair data and proposed RPS and IMS for subject item. Blank similar item RPS and IMS do not meet this requirement.

8.15.5. For Category III, provide proposed detailed RPS and IMS for subject item.

8.16. Element N, PRIME/OEM CONTRACTOR'S QUALITY RATING SYSTEM REPORT.

8.16.1. If the company has not repaired the item(s) for a Prime/OEM and thus no quality rating is available, provide a statement stating that no quality rating is available.

8.16.2. Provide the PS's quality system report or rating from the Prime/OEM responsible for the subject item. If no rating is available for the subject part from Prime /OEM, provide alternate quality ratings from another prime contractor, OEM and/or commercial customer.

8.17. Element O, LICENSEE AGREEMENT (If applicable).

8.17.1. If there is no proprietary data or process used, provide a statement stating as such.

8.17.2. For an item with an RMSC Code of V or where proprietary data is used, provide an ownership statement or a copy of the licensee agreement between the PS and the data owner.

8.17.2.1. If an ownership statement or a copy of the entire licensee agreement cannot be provided, at a minimum provide a redacted portion showing the details of Material Review Board (MRB) activity, data rights, configuration control, source control, etc.

8.17.3. If a STS will be supporting a proprietary process, the PS will provide a letter of support from the STS. The letter should state the duration of the proprietary process support, availability and capacity.

8.18. Element P, VALUE ADDED (By Prime OR OEM).

8.18.1. If there is no Prime/OEM value added, provide a statement stating as such.

8.18.2. Provide a statement identifying any value added provided by the Prime, OEM or any Proprietary Industrial Process STS in the repair of the subject or similar item(s).

8.19. Element Q, GOVERNMENT/PRIME CONTRACTOR SURVEYS. This section can include any available DOD technical evaluations of the PS's repair capability, quality assurance procedures, industrial resources, material purchasing and STS controls.

8.19.1. If no onsite inspection, site survey or self-assessment has been performed within the last seven (7) years, provide a statement stating as such.

8.19.2. If applicable, provide a copy of the latest onsite inspection, site survey, self-assessment (survey, findings and corrective actions) or DOD site survey acceptance letter performed within the past seven (7) years.

8.20. Element R, PRE-QUALIFICATION TEST PLANS. Not Applicable.

8.21. Element S, TEST RESULTS. Not Applicable.

8.22. Element T, MASTER TOOLING CERTIFICATIONS.

8.22.1. Provide a list for all equipment/tooling requiring calibration to include the part number, serial number, location and date of calibration and expiration for each item.

8.22.2. If no master tooling is required, provide a statement stating as such.

8.22.3. Provide certification of access to and the right to use any required master tooling, special tooling/test equipment, Mylars (stable base drawings), glass layout, and loft data/contour data as applicable to the latest item technical data or drawing required for repair.

8.23. Element U, GOVERNMENT QUALITY ASSURANCE COMPLIANCE. Provide a statement that the PS will comply with all government imposed quality assurance provisions, testing requirements, etc. as identified in the solicitation or contract for the subject item.

NOTE: Elements V-Z Left Blank Intentionally

8.24. Element AA, ESA/OEM APPROVAL LETTER. Provide a copy of the ESA/OEM approval letter or certificate with the expiration or issuance date circled.

8.25. Element AB, NOVATION LETTER. Provide a copy of the novation letter submitted to the PCO for the given NSN.

9. SOURCE RESUBSTANTIATION REQUEST (SRR). Only Approved Source that have produced CSI within three (3) years or CAI within seven (7) years can submit a SRR. SRR elements are listed in Table 3 and defined in section 8.

9.1. SRR DETERMINATION.

9.1.1. SRR packages can be requested for two different types of sources, producing and qualified.

9.1.2. Producing Sources

9.1.2.1. A producing source is defined as an approved source that has been on a contract with the USAF. If a source is producing and delivering for the USAF, there is no need for resubstantiation.

9.1.2.2. If a source stops production and within three (3) years for CSI or seven (7) years for CAI from the last time the item was produced by that source, the source may resubstantiate. If a PS lapses past this timeframe, a full SAR submittal will be required for approval.

9.1.2.3. The ESA may request resubstantiation of producing sources if any of the criteria listed in Section 14 of this document are observed.

9.1.3. Qualified Sources

9.1.3.1. A qualified source is defined as an approved source that has not delivered the subject item(s) to the USAF.

9.1.3.2. A qualified source may resubstantiate within three (3) years for CSI and seven

(7) years for CAI from the time of qualification. If a PS lapses past this timeframe, a full SAR submittal will be required for approval.

9.2. SRR Requirements. SRR elements are listed in Table 3 and defined in section 8. Filled in block designates a mandatory requirement.

ELEMENT SOURCE RESUBSTANTIATION REQUEST SRR DOCs REMARKS

A COVER LETTER

B

TECHNICAL DATA RIGHTS

CERTIFICATION STATEMENT (CRITICAL)

Include all NSN and PN

C BROCHURE & CORRESPONDENCE

D QUALITY ASSURANCE DOCUMENTATION * *Site Survey meets requirement E SUBJECT ITEM TECHNICAL DATA For all NSN and PN.

F SUBJECT ITEM SPECIFICATIONS For all NSN and PN.

G

SUB-TIER SUPPLIER LIST (FROZEN FOR

CSI)

H QUALITY HISTORY Include all NSN and PN.

K

PURCHASE ORDERS &SHIPPING

DOCUMENTS

Per cognizant engineer request

L

TRAVELERS & PROCESS/OPERATIONS

SHEETS (POS) (FROZEN FOR CSI)

M

MANUFACTURE PROCESS SHEETS AND/OR

INSPECTION METHOD SHEETS (IMS)

(FROZEN FOR CSI)

N

PRIME CONTRACTOR’S QUALITY RATING

SYSTEM REPORT

Only submit once for all the SARs.

O LICENSEE AGREEMENT (IF APPLICABLE) Include all NSN and PN.

P VALUE ADDED (BY PRIME OR OEM)

For all NSN and PN. Only submit once for all the SARs.

Q

GOVERNMENT/PRIME CONTRACTOR

SURVEYS

Submit once per CAGE.

T MASTER TOOLING CERTIFICATIONS

U

GOVERNMENT QUALITY ASSURANCE

COMPLIANCE

Include all NSN and PN.

The ESA may request additional data on SRRs; required within three (3) working days from ESA request. See Section 11.2

Table 3. Source Resubstantiation Request Package Requirements

10. WAIVER, SAR or SRR SUBMITTALS. Waiver, SARs or SRR packages should be submitted to:

10.1. AFSC/SB

Staff Drive, Ste 1AG85A Tinker AFB, OK 73145-3009

10.2. If in Solicitation:

AFSC/SB

Solicitation Number: (Solicitation Number) Staff Drive, Ste 1AG85A Tinker AFB, OK 73145-3009

10.3. The PS shall retain the SAR package or a copy until the approval expires.

11. SAR, WAIVER AND RESUBSTANTIATION EVALUATION.

11.1. The ESA will evaluate the approval request, SAR, Waiver or Resubstantiation packages, submitted using the LPS Form 815 (815), Propulsion Sustainment Directorate Source Request Review. The ESA will tailor the 815 to the type of approval request and category identified in the approval request package. ESA will scan all CD(s) for viruses prior to inserting them into the assigned government computer system.

NOTE: A public release copy of the 815 can be found on the following site:

http://www.tinker.af.mil/429scms.saspo/index.asp. The 815 can be modified by the ESA in accordance with the established QR.

11.2. The ESA will identify any issues, missing data or discrepancies, found during the evaluation of the approval request package. The ESA will provide the PS a list of issues that need to be resolved.

11.2.1. The PS will be given three (3) working days or and agreed upon time frame to provide either the data required to eliminate the issues identified or provide a date the data will be submitted.

11.2.2. If the PS provides a Data Submission Date (DSD), then the ESA will determine if the established deadline allows for the approval request package to sit in abeyance until the DSD. If the DSD is acceptable, the ESA will continue the evaluation once the data is provided within the set DSD. If the DSD is not met, then ESA will complete the evaluation and forward a disapproval letter. The PS will be encouraged to resubmit the SAR, waiver or RSS package once all identified issues have been resolved.

11.2.3. If the PS provides the required data, the ESA will complete the evaluation. If the issues were not resolved, the ESA will forward a disapproval letter with a list of issues that need to be resolved. If the issues were resolved, the ESA will approve the approval request package and inform AFSC/SB of the results.

11.3. If the ESA evaluation determines that the approval request package met the requirements established in the QR, then the ESA will approve the source and update the approved source list.

11.4. All transactions required to evaluate the approval request will be documented on the 815.

All necessary artifacts will be recorded on the 815 and retained in an ESA designated information system.

11.5. Once all the approval request requirements have been met, the ESA will issue an approval letter with expiration date in accordance with section 12.

12. SAR, WAIVER AND RESUBSTANTIATION APPROVAL DURATION. ESA source approval expiration is defined Table 4. The expiration date will be based on the date affixed on the Propulsion ESA approval letter.

APPROVAL DURATION MATRIX

Criticality Approval Duration Reference CSI Three (3) Years AFI 20-106 CAI Seven (7) Years AFMCI 23-113/SAM Table 4. Propulsion approval duration

13. Self-Assessment Checklist (SAC) and Site Survey Checklist (SSC). The ESA may require a SAC and then a SSC, after determining if one has been conducted by the USAF or another Military Service.

13.1. SAC. The SAC is similar to the Site Survey checklist found in the SAM.

13.1.1. The ESA will forward the SAC to the PS with a 30 day deadline.

13.1.2. The PS will provide a completed SAC to the ESA with all the artifacts required to demonstrate compliance.

13.1.3. The ESA will review the SAC and determine if a follow-on site survey is required.

13.2. SSC. The SSC will use the SAC submitted by the PS to conduct a site survey of the PS facility. The primary focus of the site survey will be to resolve any issues that were discovered during the SAC. The site survey duration will be between one to three days.

14. LOSS OF QUALIFICATION APPROVAL. The PS should be aware that qualification approval may be lost per the conditions detailed in FAR Part 9.207 and the following:

14.1. Products or services, submitted for inspection or acceptance, that do not meet the requirement;

14.2. Products or services that were previously rejected and the defects were not corrected when submitted for inspection or acceptance;

14.3. An approved source fails to request resubstantiation following change of location or ownership of the plant where the product which met the qualification requirement was repaired (see the FAR clause at 52.209-1, Qualification Requirements);

14.4. If manufacture or repair is discontinued;

14.5. A condition of meeting the qualification requirement was violated; e.g., advertising or publicity contrary to FAR part 9.204(h)(5);

14.6. A revised specification imposes a new qualification requirement;

14.7. Manufacturing, design or repair changes have been incorporated in the qualification requirement;

14.8. Performance of a contract subject to a qualification requirement is otherwise unsatisfactory.

15. Phase II, Source Demonstration (SD). The SD phase will not start until Phase 1, SAR approval, is complete and the ESA has notified the PS that a SD will be required.

15.1. This SD Phase of the qualification process is the substantiation of specific repair procedures, process control and the specialized sample testing. The SD will be performed by the ESA or designee after completion of the SAR package and prior to source approval. ESA will determine SD acceptance.

15.2. SD requirement may not be required by the ESA for the following:

15.2.1. If PS has been approved by the OEM and the PS can provide a copy of the certification or approval within three (3) years for CSI and seven (7) years for CAI.

15.2.2. If PS can provide a part-process matrix and provide certification(s) for all the significant industrial processes as defined in Appendix B and listed in 8.2.4.1.1.

15.3. After the SAR is approved, the PS shall notify the ESA, if the PS intends to proceed to source demonstration of the qualification process.

15.4. The ESA will advise the PS of the availability of USAF Source Demonstration asset(s).

The ESA will provide a Repair Program Plan (RPP) for a specific part to the PS. After notification that SD assets are available, the PS shall proceed as follows:

15.4.1. The PS shall submit a final RPP copy of all required production documentation and a shipping address for the SD asset(s) shipment.

15.4.2. After the ESA approves production documentation and the PS has completed all prototyping efforts, the PS will provide the ESA with a SD schedule and agenda.

12 July 2018 RQR-PSD-1

APPENDIX A

TECHNICAL DATA RIGHTS CERTIFICATION LETTER

I am an officer and employee of the above name legal entity with the responsibility for investigating the facts upon which this certification is made. To the best of my knowledge and information obtained from my recent investigation:

I certify that the technical data submitted as a part of my company's request for approval as potential source for the purpose of obtaining a contract were obtained by legal means by my company, without breach of any contractual or confidential relations pertaining to said technical data by my company, its current or recent employees; and

I certify that my company, its current or recent employees did not obtain or receive any technical data marked with a company's proprietary rights legend or a Government limited rights legend from any U.S. Governments agency or employee or other third parties that were used in the preparation of or were incorporated into the request for approval or its supporting technical data other than as described herein; and

I certify that my company has the legal right to use said technical data to manufacture/repair the below identified part for the United States Government. To the extent that said technical data are marked with a company's proprietary rights or a Government limited rights legend or are otherwise believed to be or have in the past been the proprietary data of another company, the following documents which are attached hereto and made a part of the certification have formed the basis for claiming legal right to use said technical data. Such documentation must clearly cover the data necessary for source approval.

THIS CERTIFICATION CONCERNS A MATTER WITHIN THE JURISDICTION OF AN

AGENCY OF THE UNITED STATES AND THE MAKING OF A FALSE, FICTITIOUS, OR

FRAUDULENT CERTIFICATION MAY RENDER THE MAKER SUBJECT TO

PROSECUTION UNDER THE TITLE 18, UNITED STATES CODE, SECTION 1001.

THIS CERTIFICATION APPLIES TO:

NSN______________________P/N__________________

Note: If SAR package is for multiple NSNs, all NSNs, Part Numbers, Nouns must be listed.

The list can be attached to the letter.

(Signature) (Date) (Typed or printed name & title)

This document must be signed by the Company President, Owner or Plant Manager

12 July 2018 RQR-PSD-1

APPENDIX B

SIGNIFICANT INDUSTRIAL PROCESSES

The following examples are typical processes considered significant in that they are capable of producing alterations to material structures, mechanical properties and ultimately, item reliability, if performed improperly and cannot normally be evaluated without destructive testing.

# SIGNIFICANT INDUSTRIAL PROCESSES NADCAP

1 Casting Processes NA 2 Forging Processes NA 3 Other Forming Processes NA 4 Disassembly Procedures NA 5 Blending/Reworking NA 6 Heat Treatment and Surface Hardening Processes 7102 7 Brazing 7102

Chemical Processes: Chemical Cleaning, Anodizing, Conversion/Phosphate Coatings, Paint/Dry Film Coatings, Stripping, Chemical Milling, Surface Treatment/Passivation and Etching (Nital/Pre- Penetrant/Temper/Macrostructure/Blue Etch Anodize)

9 Metal…