ATLAS_3_-_KC-135_MLG_USS_Redesign_SOO_Amendment_01.pdf

KC-135 MAIN LANDING GEAR UPPER SIDE STRUT REDESIGN SOO

DISTRIBUTION D. Distribution authorized to Department of Defense and U.S. DoD contractors only administrative or operational use, 9 Feb. 2017. Refer other requests for this document to OO-ALC/417 SCMS, Hill AFB, Utah 84056-5826.

STATEMENT OF OBJECTIVES (SOO)

FOR

KC-135 MAIN LANDING GEAR UPPER SIDE STRUT REDESIGN

PURPOSE:

This Statement of Objectives (SOO) provides the Government’s key objectives and contract deliverables for the KC-135 Main Landing Gear (MLG) Upper Side Strut Redesign.

SCOPE:

This project is intended to mitigate the diminishing sources of manufacture issues for the KC-135 MLG Upper Side Strut. This solution at a minimum will omit the swaging and welding processes from the manufacture of this item.

PERIOD AND PLACE OF PERFORMANCE:

The period of performance (POP) is estimated to be three years; however, it is expected that the offeror will present its best solution and the corresponding POP to enable that solution. The place of performance is anticipated to be predominantly the offeror’s facility, although some visits to USAF facilities may be necessary.

BACKGROUND:

The KC-135 MLG Upper Side Strut (USS) is the upper segment of the side strut assembly. The side strut assembly provides lateral support to the main landing gear when extended. The MLG Upper Side Strut is a large high strength steel tube with semi-closed ends. The MLG Upper Side Strut is produced using swaging and welding in the manufacturing process. The swaging process is used to produce semi closed ends using dies to hammer a round workpiece into a smaller diameter. Welding is used to attach the up-lock fitting to the outer diameter of the strut.

The process of swaging has become uncommon for manufacturing large high strength steel parts such as the MLG Upper Side Strut. The previous source for the swaging process has removed the capability from their facility. Only one source has been identified to have the capability to swage a component this large. That source has never made this part before and is not qualified to swage this part. The welded up-lock fitting additionally complicates manufacture and increases lead time and risk of defect parts due to the variability and reliability of high strength steel welding. For these reasons, the most recent procurement contractor has requested to terminate their contract. Due to obsolescence, additional sources are not expected to develop in the future.

DISTRIBUTION D. Distribution authorized to Department of Defense and U.S. DoD contractors only administrative or operational use, 9 Feb. 2017. Refer other requests for this document to OO-ALC/417

SCMS, Hill AFB, Utah 84056-5826.

An engineering solution is needed in order to mitigate the diminishing sources of manufacture issues. This solution at a minimum will omit the swaging and welding processes from the manufacture of this item.

PRIMARY OBJECTIVES:

The purpose of this task is to seek engineering services in support of resolving current diminishing sources of manufacture issues with the MLG Upper Side Strut. The resolution is to be a redesign of the MLG Upper Side Strut that incorporates readily available manufacturing methods. This effort will involve non-recurring engineering activities required to redesign, qualify, and implement a new MLG Upper Side Strut that will allow for continued support of the KC-135 through retirement.

TASK 1 - PROGRAM ECONOMICS/DEFICIENCY IDENTIFICATION:

The contractor will provide engineering services to determine program economics with a recommended funding and detailed implementation strategy, including all aspects of integrated product team involvement from cradle-to-grave. The contractor will identify and quantify all current reliability/performance weaknesses and provide analysis to demonstrate how this assessment was made.

These shall address areas of manufacturing, procurement, special processing, raw materials, forgings, corrosion, wear, fatigue susceptibility, strength, stress corrosion cracking, tooling, assembly methods, etc.

Deliverables:

1. Analysis of Alternatives report detailing a redsigned upper side brace that does not require swaging or welding in the manufacutring process, to resolve identified weaknesses or unidentified weaknesses, and evaluation of the understood problems and assumptions about causes and potential solutions. Draft implementation strategies shall be included for each alternative. CDRL A013, A012

2. Economic Analysis report for potential alternatives including material availability, timeline for manufacture, and return on investment (ROI).

CDRL A013

TASK 2 - PRELIMINARY DESIGN REVIEW (PDR):

The contractor will generate PDR documentaion which outlines the recommended design solution, process improvments, preliminary analysis, and conceptual level Technical Data Package (TDP). An initial Modified Airworthiness Certification

Criteria Compliance Report (MACC-CR) shall be delivered which provides all necessary qualification testing and analysis for USAF certification.

Deliverables:

1. PDR documentation, CDRL A013

a. Briefing materials

b. Meeting minutes

c. Action items

2. Preliminary Analysis:

a. Structural analysis report and analysis computer generated files will be per 417 SCMS/GUEA "LANDING GEAR STRUCTURAL ANALYSIS REQUIREMENTS" specification drawing 201612106. Analysis reports and computer generated analysis files will be delivered to the 417 SCMS/GUEA with unlimited rights.

CDRL A013, A017

b. Any other data, engineering tools, or computer files used or developed in this engineering effort will be delivered. Including, but not limited to, source code, spreadsheets, script files (i.e.

Matlab, Mathcad, etc.), macros, databases, scanned documents, copies of referenced materials, video, photos, and audio.

c. Preliminary prototype manufacturing plan. CDRL A017

2. AOA and EA Update

a. Analysis of Alternatives Report, including all assumptions, justifications, and methodologies used. CDRL A013

b. Economic Analyses Report, including all assumptions, justifications, and methodologies used to demonstrate economic viability. CDRL A013

3. Conceptual level TDP per MIL-STD-31000, CDRL A009

4. Initial MACC-CR, CDRL A013

TASK 3 - CRITICAL DESIGN REVIEW (CDR):

The contractor will generate CDR documentation which will include but not be limited to: material changes, processing requirements/improvments, developmental design drawings, and final (SPO approved) MACC. As required, additional tructural analysis will be performed to prove CDR design airworthiness.

Deliverables:

1. CDR documentation, CDRL A013

a. Briefing materials

b. Meeting minutes

c. Action items

2. Analysis:

a. Analysis and analysis computer generated files will be per 417

SCMS/GUEA "LANDING GEAR STRUCTURAL ANALYSIS

REQUIREMENTS" specification drawing 201612106. Analysis reports and computer generated analysis files will be delivered to the 417 SCMS/GUEA with unlimited rights. CDRL A013, A017

b. Any other data, engineering tools, or computer files used or developed in this engineering effort will be delivered. Including, but not limited to, source code, spreadsheets, script files (i.e.

Matlab, Mathcad, etc.), macros, databases, scanned documents, copies of referenced materials, video, photos, and audio. CDRL A017

3. Updated Implementation Plan

a. Updated Analysis of Alternatives outlining the final solution with all assumptions, justifications, and methodologies used to down-select the final solution from other alternatives, including performance, economic, logistical, and reliability/maintainability considerations. CDRL A013

b. Updated Economic Analyses outlining the final solution with all assumptions, justifications, and methodologies used to demonstrate economic viability. CDRL A013

c. A detailed Integrated Product Team (IPT) master plan of all steps, milestones, factors, and required forms and approvals for advancement from design through implementation. CDRL A012

4. Developmental level TDP per MIL-STD-31000, CDRL A009

5. Final MACC-CR, CDRL A0013

TASK 4 - PROTOTYPE MANUFACTURE AND QUALIFICATION BY

TESTING:

Upon CDR approval, the contractor will generate a qualification test plan (QTP), procure test prototypes, perform a test readiness review (TRR), perform structural analysis validation testing, perform qualification testing and generate a qualification test report (QTR). Additionally, the structural analysis shall be updated as necessary to reflect any changes that prove to be necessary based on the validation and qualification testing.

Deliverables:

1. Qualification Test Plan (QTP), CDRL A006

2. Test Readiness Review (TRR), CDRL A013

a. Briefing materials

b. Meeting minutes

c. Action items

3. Qualification Test Report (QTR), CDRL A007

5. Final Structural Analysis (as required based on qualification testing and FEA validation checks):

c. Analysis reports and analysis computer generated files will be per

417 SCMS/GUEA "LANDING GEAR STRUCTURAL

ANALYSIS REQUIREMENTS" specification drawing 201612106. Analysis reports and computer generated analysis files will be delivered to the 417 SCMS/GUEA with unlimited rights.

CDRL A013, A017

d. Any other data, engineering tools, or computer files used or developed in this engineering effort will be delivered. Including, but not limited to, source code, spreadsheets, script files (i.e.

Matlab, Mathcad, etc.), macros, databases, scanned documents, copies of referenced materials, video, photos, and audio. CDRL A017

3. Test Asset Prototypes

TASK 5 - IMPLEMENTATION AND TECHNICAL DATA:

The contractor will assist the government with approval efforts for the Configuration Control Board (CCB). The contractor will provide all necessary technical order updates for the manufacture, repair, and overhaul of any redesigned components. The contractor will continue engineering and logistics support to the IPT for the process outlined in the implementation master plan described above. Additionally, the contractor will provide the Government with two (2) untested prototype parts per the CCB approved technical data package to support validation and verification of technical orders, assembly processes, and fit-check of the component into the next higher assembly and aircraft. The final production level TDP will incorporate all project findings and engineering updates required to produce the redesigned upper side brace.

Deliverables:

1. CCB documentation, including all Airworthiness documentation, CDRL A013

2. System Safety Evaluation Report, CDRL A013

3. Type 2D Production level TDP per MIL-STD-31000, A009

4. Technical Order Validation and Verification Report, CDRL A013

5. Technical Order (T.O.) source data in Word (.doc) and Adobe PDF (.pdf) format, along with Standard Generalized Markup Language (SGML) for Aircraft System T.O.s, as required by the KC-135 System Program Office (SPO). Illustration files will be delivered in Computer Graphics Metafile (.cgm), vector images with a minimum resolution of 300 DPI, or as required (e.g. .TIFF, vector). CDRL A010

6. Fit Check Test Plan, CDRL A006

7. Fit Check Test Report, CDRL A007

8. Structural Analysis Report Updates (as required), CDRL A0013

9. Operational Utility Evaluation (OUE) prototypes

OPERATING CONSTRAINTS:

Any solution must be form/fit/function/interface compliant, and the implementation strategy must be as allowed per the funding constraints associated with the USAF supply chain (typically, this means normal attrition is the implementation strategy).