Source_Qualification_Statement.pdf

SOURCE QUALIFICATION REQUIREMENTS

(FA R 9.202 (a), DFARS 209.270-4, PGI 209.202)

NATIONAL STOCK NUMBER: 1560-01 -527-3968

NOUN: -33 Wing Assembly

PART NUMBER: 2-23000-33

APPLICATION: T-38

SOURCE QUALIFICATION STATEMENT

(FAR 9.202, (a), DFARS 209.270-4, PGI 209.202)

SECTION A. ITEM IDENTIFICATION

1. STOCK NUMBER (NSN): 1560-01-527-3968

2. PART NUMBER: 2-23000-33

3. NOUN: -33 Wing Assembly (commonly known as wing torque box)

4. APPLICATION: T-38 aircraft

SECTION B:

1. JUSTIFICATION FOR ESTABLISHING A QUALIFICATION REQUIREMENT

A. Part Criticality:

The -33 Wing Assembly is the complete wing torque box assembly (does not include wing tips, leading edges, control surfaces, landing gear etc.) on the T-38 aircraft. The -33 Wing Assembly performs a critical function and is essential for mission success. Complete pre-award qualification testing is necessary to ensure the product will operate in the flight environment of the T-38. Failure to perform pre-award qualification testing has a high probability of resulting in loss of the aircraft and the pilot crew. Due to the importance of the subject item, post-award qualification testing is not conducive to the mission.

B. Part Complexity:

The -33 Wing Assembly involves complex processing and must meet the requirements of drawing 2-

23000-33. Completion of the specified pre-contract award qualification requirements will ensure the government that the offeror is capable of producing the item in compliance with applicable technical specifications/data. Completion of the requirements will establish the technical capability of the offeror to support the government's requirements for this item. Contract award on this item, without verification of the offeror’s technical capability, will result in a critical supply position if the offeror is unable to successfully produce the assembly.

C. Form, Fit, Function, and Interface:

The qualification requirements specified herein are necessary to verify the structural and/or functional integrity and/or fit, form, and interface of the T-38 -33 Wing Assembly.

2. REASON WHY QUALIFICATION REQUIREMENT MUST BE DEMONSTRATED PRIOR TO

ANY CONTRACT AWARD

A. Completion of the specified pre-contract award qualification requirements are necessary to assure the government that the offeror is capable of producing the -33 Wing Assembly in compliance with the

NATIONAL STOCK NUMBER: 1560-01 -527-3968

NOUN: -33 Wing Assembly

PART NUMBER: 2-23000-33

applicable technical specification/data within the schedule and economic constraints of our contracts.

There are significant technical and schedule risks which can only be minimized by a completion of the requirements prior to contract award.

B. Qualification Requirement Cost Estimate: Estimated likely costs for testing and evaluation, which will be incurred by the potential offering party to become qualified are $36,800.00. This number is based on a $100/hour bulk rate.

C. Qualification Time Completion Estimate: It is the estimate of the engineering support activity that completion of the qualification effort should require 60 days. This is based on the complexity of the -

33 Wing Assembly and the need to assemble a number of various programmatic and technical experts to provide for this level this estimating. It is also noted that due to the number of people involved on a part-time basis with the review of the -33 Wing Assembly data package, the final response will take a significant commitment in resources and expertise to the potential offering party.

For planning purposes, the following table provides a rough guidance as to the type of expertise involved and the number of hours involved to meet a 60 day completion:

Function Hours

Program Management, Supply

Chain Management, Planning, and Scheduling

Lead Engineer 72

Stress Engineering 32

Manufacturing Engineering 72

QA Engineer/Authority 16

Technicians 64

NDI Authority 16

Total 368

D. Government Risk:

The following paragraphs explain the government risk when buying this part/assembly from an unqualified source.

1. The probability of an unqualified source producing an unsatisfactory part/assembly is high due to the item's complexity. An unqualified source may not possess technical skills or the ability to obtain such skills dealing with production control procedures, quality assurance provisions, and safety programs applicable to the item being procured or processes performed.

2. Historically, the most common failure modes of the subject part/assembly are fatigue and structural degradation, both phenomena leading to cracking. An unqualified source increases the risk of manufacturing and production errors which will exacerbate fatigue cracking and structural degradation, thus leading to future unplanned premature replacements of the part/assembly. Compounding this situation, fatigue cracking and structural degradation take years to manifest as fleet problems; thus, it is imperative that procurement from an unqualified source be avoided to ensure fleet safety, and to

NATIONAL STOCK NUMBER: 1560-01 -527-3968

NOUN: -33 Wing Assembly

PART NUMBER: 2-23000-33

eliminate future supply problems due to premature wing condemnations.

3. Source must be able to deliver in a timely manner. Any delay would result in grounded aircraft and mission delays/cancellation.

4. Inappropriate/unauthorized manufacturing processes used for sub-components, coupled with improper assembly and/or fastener installation, can result in premature failures of critical wing structure.

5. Logistic and economic risks/costs will be increased due to potential contract default of an unqualified source.

SECTION C. QUALIFICATION REQUIREMENTS: REQUIREMENTS THAT MUST BE

SATISFIED TO BECOME A QUALIFIED SOURCE.

1. Prequalification Notice. The offeror shall notify the contracting officer in the 748 SCMG, Hill AFB, UT (AFMC OL_H/PZAC) of intent to qualify as a source for this item. Because of the need for uninterrupted item support to military aircraft systems while keeping within the requirements of FAR

9.202 (a), the current acquisition need not and generally will not be delayed to provide an offeror an opportunity to qualify.

2. Manufacturing, Repair, Test, and Quality Assurance Capability. The offeror shall certify to the assembly/design control authority (416 SCMS/GUMBA, Hill AFB, Utah) that the required facilities and equipment to manufacture, repair, inspect, test, and package the item are available. When the offeror proposes to acquire these items, the offeror shall provide documented equipment orders or similar documentation for government inspection. The offeror shall make these facilities, equipment, tooling, and personnel available for evaluation and inspection by the government. The offeror shall submit a Quality Assurance Program Plan that describes, in detail, how ISO 9100, or equivalent as determined/approved by the design control authority, will be implemented throughout the parts procurement, manufacturing, and assembly process.

3. Data Verification. The offeror shall verify possession of a complete data package by providing a list of applicable drawings, procedures, and specifications, including change notices. The offeror may also be required to produce copies of the drawings or specifications. When the offeror proposes to use standards otherwise authorized by the government, documentation shall be submitted to the design control authority (416 SCMS/GUEAB) for approval. Approval is required before implementation of proposed process.

4. Manufacture, Repair, and, Process Verification. The offeror must demonstrate to the government their experience and ability to conform to all the requirements detailed in this document and to the latest revision of drawing 2-23000-33.

4.1. When requested by the government, the offeror shall provide copies of the manufacture, repair, and process control specifications for review and analysis. At the offeror's expense, data showing the results of all quality, performance, and environmental evaluations conducted by the offeror must be provided to show compliance with the requirements of the drawings and specifications. The offeror shall also identify special tooling requirements, sources for materials, and standards for internally used processes, as well as identify major sub-vendors and their processes, inspections and tests. The offeror

NATIONAL STOCK NUMBER: 1560-01 -527-3968

NOUN: -33 Wing Assembly

PART NUMBER: 2-23000-33

shall submit documentation that any source controlled components of the subject item shall be procured from approved sources. The offeror shall submit documentation of accomplishment of the above requirements to the government. In order to qualify for the production of the required forgings, the offeror shall provide data demonstrating that they can meet, or have met the requirements of SAE

AMS-A-22771, Aluminum Alloy Forgings, Heat Treated or SAE AMS-F-7190, Forging, Steel, For

Aircraft/Aerospace Equipment and Special Ordnance Applications.

4.2. The offeror will be performing many manufacturing processes which require strict adherence to their Quality Assurance Program Plan, thus ensuring that the manufactured -33 Wing Assembly has the desired fatigue life. The -33 Wing Assembly is approximately 250 inches tip to tip and 72 inches fore and aft. This assembly has many critical fastener holes. The offeror must demonstrate the ability to properly and accurately place holes within the drawing tolerances and demonstrate the drilling, reaming and countersinking of holes with at least 125RHR (Roughness Height Reading or equivalent) finish. The offeror must demonstrate their ability to drill, ream and countersink holes perpendicular to surface where fastener heads will bear. The offeror must demonstrate the ability to drill, ream, and countersink holes in both thick and thin skin. The manufacturer of the lower and upper wing skins must demonstrate ability to manufacture the skin taper, the surface smoothness, and the smooth radii specified in drawing 2-23502-9 and 3-23301-5.

4.3. The -33 Wing Assembly has hole cold working and shot peening processes to improve fatigue life.

The offeror must show experience with these processes and document the quality assurance processes that will ensure the requirements of the technical data package are met. The offeror can obtain vendor products for this manufacturing effort. The offeror is responsible for their sub-vendor products and must show that the sub-vendor has the capability to meet the requirements defined by drawing 2-

23000-33.

5. Test and Evaluation and/or Verification. The offeror, at their own expense shall prepare and submit to

AFMC OL_H/PZAC for their prior approval, a qualification test plan/procedures detailing how the offeror intends to verify compliance with all performance, environmental, mechanical and quality assurance requirements identified by the provided technical data package.

5.1. The integrity of the -33 Wing Assembly shall be ensured by Non-Destructive Inspection (NDI) practices and Material Review Board (MRB) process that meet or exceed the T-38 Technical

Order/drawing requirements. A description of the offeror's NDI capabilities and MRB current policies/procedures shall be part of the offeror's Quality Assurance Plan. The offeror must define their capability to perform ultrasonic, radiographic, dye penetrant, magnetic particle, visual, and surface and fastener hole eddy current inspections. During manufacture, the -33 Wing Assembly may have a discrepancy which requires a repair which utilizes NDI procedures. In addition to NDI, the offeror's ability to design, analyze, and implement repairs shall be demonstrated. The offeror must define their capability to perform analysis including durability and damage tolerance using linear-elastic fracture mechanics, and static strength and stress.

6. Qualification Capabilities. The government will assess the offerors expertise and capabilities in manufacturing wing assemblies. These capabilities are critical to an offeror’s ability to become source qualified, as well as give the government confidence in the offeror’s ability to successfully produce, inspect, and test the -33 Wing Assembly. The following criteria must be met to become an approved source:

NATIONAL STOCK NUMBER: 1560-01 -527-3968

NOUN: -33 Wing Assembly

PART NUMBER: 2-23000-33

A. Contractor shall describe in detail their proposed process for manufacturing a 2-23000-33 wing and/or their process in the manufacture of complete military supersonic fighter/trainer aircraft wing assemblies that have at least 7.33g operational maneuvering capability.

B. Contractor shall describe in detail their experience and proposed process for controlling stringent manufacturing tolerances including hole diameter, hole location, surface finish, surface profile, and critical interfaces (e.g. 2-23207-517 (W.S. 64.8 Rib), 2-23220-501 (W.S. 125 Rib), 2-23277-11 & 2-

23278-15 (Aileron Hinges)).

C. Contractor shall describe in detail their experience and proposed process with manufacturing a wing skin that involves forming, hole cold working, and shot peening processes to improve fatigue life (e.g. 3-23502-9 (Lower Wing Skin) & Upper Wing Skin (3-23301-7).

D. Contractor shall describe in detail their experience and proposed process utilizing loft data for defining aircraft surfaces during manufacturing and assembly.

E. Contractor shall describe in detail their experience and proposed process manufacturing and procuring Critical Safety Items (CSI) and managing CSI requirements at all levels of manufacture and assembly.

F. Contractor shall describe in detail their experience and proposed process fabricating, controlling and inspecting bonded metallic and non-metallic composite structure (e.g. 23801-505 (Trailing

Section Panel)).

G. Contractor shall describe in detail their experience and proposed process controlling interchangeable and replaceable (I&R) interfaces capable of being readily installed, removed, or replaced without alteration, misalignment, or damage to adjoining items (e.g. 3-23241-507 (15%

Spar), 2-23220-501 (W.S. 125 Rib), 2-23277-11 & 2-23278-15 (Aileron Hinges)).

H. Contractor shall describe in detail their experience and proposed process manufacturing, inspecting and testing high-strength forgings and fatigue critical parts and assemblies (e.g. 3-23242-

507 (15% Spar), 2-23252-509 (44% Spar), & 3-23282-7 (66% Spar)).

7. Source Qualification Waiver Requirements. Sources who meet any of the following source

Qualification Waiver Criteria (QWC) may apply for a waiver of all or part of the qualification requirements by submitting written justification via e-mail to the Contracting Officer, Lowell Cook, at lowell.cook.3@us.af.mil. If a waiver is granted and the offeror is awarded a contract, the offeror may still be required to provide a post-contract award first article exhibit to verify production capability. This waiver will be granted only if the design control authority can establish the qualification of the offeror from written inputs from the offeror. Additionally, the current acquisition need not and will not be delayed in order to provide an offeror with an opportunity to meet the requirements for qualification waiver. To qualify for a waiver consideration, the offeror must meet the requirements defined in QWCl or QWC2 below:

QWCl: The offeror submits written certification that they have produced a -33 Wing

Assembly which has been supplied to the government or original equipment manufacturer (DD Form mailto:lowell.cook.3@us.af.mil

NATIONAL STOCK NUMBER: 1560-01 -527-3968

NOUN: -33 Wing Assembly

PART NUMBER: 2-23000-33

250, Material Inspection and Receiving Report, Purchase Order, invoice, etc.). This criterion is valid only if:

A. The production line is still in place at the original location B. The production line has produced a -33 Wing Assembly within the last 36 months

QWC2: The potential source has current (within last 36 months) experience in the manufacture of complete military supersonic fighter/trainer aircraft wing assemblies that have at least 7.33 g operational maneuvering capability. The potential source must have used various metal fatigue life improvement methods and must have specific experience with hole cold working and shot peening processes.

8. Time Limitation. An offeror may not be denied the opportunity to submit and have considered, an offer for a contract if the offeror can demonstrate to the satisfaction of the contracting and cognizant engineering activities that the offeror (or its product) meets these standards for qualification or can meet them before the date specified for award of the contract. The award will not be delayed to provide the offeror with an opportunity to demonstrate their ability to meet the standard specified in the source qualification statement.

9. Evaluation of Proposals Not Previously Qualified. The offeror must be fully qualified in order to be eligible for a contract award. Therefore, the offeror must fulfill all of the requirements stated, in writing, in this source qualification statement (SQS) before the date specified for award of the contract. The government reserves the right to award a contract at the time specified for award, to a qualified source, even though other sources may not have finished qualifying.

10. Successful offerors. Successful offerors shall be identified as an approved source for this item. However, successful completion of the qualification requirements does not guarantee any contract award. If the offeror is deemed qualified and awarded the contract, a post-contract award first article exhibit may be required to verify production capability. The cost for qualification testing and evaluation could be substantial and must be funded by the potential offeror.

11. Instructions. Source Qualification Statements shall be a maximum of 50 pages and delivered via e- mail to the

Contracting Officer, Leslie Trice, at leslie.trice@us.af.mil.