T-38_Structural_Re-Engineering_Industry_Day_Brief_FINAL.pdf

LIFE CYCLE MANAGEMENT CENTER

Industry Day 1 Overview

Industry Day 2 Overview

Lt Skyler Means, Lead PJM

AFLCMC/WLDMB

Eric Flygare, Lead Engineer

AFLCMC/WLDEB

30 October 2018

Industry Day for T-38 Structural Component Re-

Engineering Effort

Disclaimer

THIS BRIEFING IS FOR INFORMATION ONLY. NO U.S. GOVERNMENT COMMITMENT TO SELL,

LOAN, LEASE, CO-DEVELOP OR CO-PRODUCE DEFENSE ARTICLES OR PROVIDE DEFENSE

SERVICES IS IMPLIED OR INTENDED.

DISCLOSURE NOTICE - THIS INFORMATION IS FURNISHED ON THE CONDITION THAT IT WILL

NOT BE RELEASED TO ANOTHER NATION WITHOUT SPECIFIC AUTHORITY OF THE

DEPARTMENT OF THE AIR FORCE OF THE UNITED STATES, THAT IT WILL BE USED FOR

MILITARY PURPOSES ONLY, THAT INDIVIDUAL OR CORPORATE RIGHTS ORIGINATING IN THE

INFORMATION, WHETHER PATENTED OR NOT, WILL BE RESPECTED, THAT THE RECIPIENT

WILL REPORT PROMPTLY TO THE UNITED STATES ANY KNOWN OR SUSPECTED COMPROMISE,

AND THAT THE INFORMATION WILL BE PROVIDED SUBSTANTIALLY THE SAME DEGREE OF

SECURITY AFFORDED IT BY THE DEPARTMENT OF DEFENSE OF THE UNITED STATES. ALSO,

REGARDLESS OF ANY OTHER MARKINGS ON THE DOCUMENT, IT WILL NOT BE DOWNGRADED

OR DECLASSIFIED WITHOUT WRITTEN APPROVAL OF THE ORIGINATING U.S. AGENCY.

NOTHING STATED IN THIS BRIEFING OR RELATED DISCUSSIONS IS CONTRACTUALLY BINDING.

ALL COMMUNICATIONS OR INFORMATION WHICH PERTAINS TO THIS EFFORT IS FOR

DISCUSSION PURPOSES ONLY.

ANY OFFEROR COSTS INCURRED PRIOR TO RECEIPT OF A CONTRACT SIGNED BY THE

GOVERNMENT CONTRACTING OFFICER ARE THE RESPONSIBILITY AND RISK OF THE

OFFEROR.

Agenda

Administrative Items & Ground Rules IPT Introductions Conference Overview and Objectives Program Overview and Requirements Proposed Schedule Contract Strategy Summary Q & A

Administrative Items

Facilities Restrooms

Emergency procedures Emergency exits Shelter in Place

Lunch: Approximately 1100–1230 Local restaurants

• Popeyes, Burger King on-base

• Jimmy Johns outside West gate

• Kneaders, Chic-fil-A, Five Guys and more on Antelope Drive out South gate

Ground Rules

Government seeks feedback per Draft PWS/IMS The agenda packet contains the questions/topics the government is interested in getting feedback on If you have not yet responded to contracting, we encourage you to complete and turn-in at your one-on-one or before you depart for the day

Any questions after Industry Days shall be directed by email to the Contracting Officer

This brief, notes, non-proprietary questions and Government responses will be posted on FedBizOpps

Program Team

2Lt Skyler Means Structural Re-Engineering PJM

MATRIX SUPPORT

Leron Lechtenberg Engineering

Matthew Morgan Engineering

Eric Flygare Lead Engineer

Casey Hodson

PCO

CONTRACTING FINANCEENGINEERING

Kelly Ross Budget Analyst

Amber Weber Chief, T-38 Sustainment Section

Maj Joseph Clapsaddle T-38 Branch Chief

LOGISTICS

Cresencio Rivera Logistics Mgmt Specialist

Donald Chesmer Equipment Specialist

Carlos Pontes Equipment Specialist

Gary Ash Equipment Specialist

Industry Day Objectives

Provide Industry with an overview of the T-38 Structural Component Re-Engineering requirements

Exchange information prior to Formal RFP release Impart to Industry a clear understanding of these requirements Understand from Industry their concerns/risks and receive recommendations for PWS/RFP improvements

NOTE: Information provided/exchanged today may change based on feedback from these meetings and as the acquisition strategy is finalized

Program Objectives

Objective: Re-engineer select structural components to increase sources of supply beyond OEM to increase competition and reduce cost Purpose: Deliver Air Force Technical Data Packages

(TDPs) for select structural components to increase production options

Single Contractor Period of Performance (PoP): 3 years total Basic year of requirements with two (2), one year options of additional/similar workload Estimate PoP: Jun’19 through Jun’22

Anticipated Competitive Acquisition (possible Small Business (SB) set-aside)

Cost Plus Fixed Fee (CPFF) contract Trade Off

Program Overview

The acquisition strategy has not been approved. As such, all discussions should be considered as preliminary and “for information only” at this time.

Program Overview (Cont.)

Program Description Re-Engineer T-38 structural components Reverse Engineer versus Re-Engineer Reverse Engineer: Engineer an exact duplicate Re-Engineer: Retain Fit and Function. Re-Engineer

Form where necessary i.e. replace materials or legacy processes: bonding, surface treat, etc.

Targeting high priced bonded honeycomb structures Focus of the program is to reduce costs All technical data is proprietary to OEM and cannot be used for project

Parts Overview Item P/N Component Description

B at ch

1 3-11801-503 Door, MLG Inboard Wheel (LH) 2 3-11801-504 Door, MLG Inboard Wheel (RH) 3 2-25100-605 Aileron (LH) 4 2-25100-606 Aileron (RH)

B at ch

5 2-26100-505 Flap (LH) 6 2-26100-506 Flap (RH) 7 3-31415-3 Leading Edge, Vertical Stabilizer 8 3-24132-501 Wing Leading Edge (LH) 9 3-24132-502 Wing Leading Edge (RH)

10 3-23801-501 Trailing Section, Wing 11 3-31429-13 Trailing Edge, Vertical Stabilizer

Parts Overview (MLG Door)

MLG Door P/N 3-11801-503 (-504) Bonded honeycomb construction: 26”x25”x4” Piano hinge assembly Uplock attach points, brackets, rub strips LH and RH mirrored assemblies

Parts Overview (Aileron)

Aileron P/N 2-25100-605 (-606) 10”x32”x1.25” trailing edge:

Bonded honeycomb construction 18-25”x32”x3” overall structure:

ribs/spars/skins Hinge components

Parts Overview (Flap) Flap P/N 2-26100-505 (-506)

10”x46x1.5” trailing edge: Bonded honeycomb construction

24-33”x46x4” structure: ribs/spars/ skins Inboard hinge tube and second hinge/attach.

Parts Overview (Vertical LE)

Vertical Leading Edge P/N 3-31415-3 5-10”x58”x2” Bonded honeycomb construction Closeout ribs No internal structures

Parts Overview (Wing LE)

Wing LE P/N 3-24132-501 (-502) 6-15”x115”x4” Bonded honeycomb construction Internal composite tubing for control cables (no other internal features) Closeout ribs, various brackets Two access panels

Parts Overview (Wing TE)

Wing Trailing Edge P/N 3-23801-

15-19”x17”x2” Bonded honeycomb construction

No internal components

Parts Overview (Vertical TE)

Vertical Trailing Edge P/N 3-31429-13 11-19”x27”x2” Bonded honeycomb construction

No internal components

Parts Acquisition:

Contractor will acquire four components of each Item For mirrored components: 3 of one side, 1 of the other Option 1: Purchase new parts from DLA Option 2: Borrow parts from DLA (RPPOB program) Option 3: Coordinate with DoD to attain used parts

Scanning and Teardown:

Contractor to 3D scan/measure all four components Access to operational aircraft can be coordinated

Disassemble one component Destructive test to establish legacy strength properties

Component level design process Additive manufacturing not allowed Composite material not allowed

Component Structural Analysis:

Equivalent strength and stiffness analysis Mass properties analysis Loads Development

Component Level Testing:

Not required for Reverse Engineered components Testing required for Re-Engineer components/Processes

Waiver may be granted for previously approved systems

Deliverable – Government Owned Tech Data Package Seven major assemblies Mirrored parts do not require separate TDP Approx. 130 Sub-components (skins, ribs, hinges, etc.)

3D models and 2D drawings Bill of Material, Detailed notes, manufacturing instructions

Deliverable – First Article (FA) One FA reqd for each assembly/mirrored assembly Seven FA units total

Proposed Schedule

Option Year 1

QTR:

Production

(DLA)

Test 1

Tooling/FA Dev FAT

Lead Time 1 Production 1

Q1 Q2 Q3 Q4

Basic Year

Concept Decision

CDR 1

RFP Rel

Option Year 2

PDR

2019FY:

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

2020 2021 2023 2024

Industry Days

Award

SRR

LEGEND

Program Milestone

Gov’t Milestone Draft TDP 1 Delivery

Teardown 1

Test 2

PDRSRR Draft TDP 2 Delivery

Teardown 2

CDR 2

Gov’t

CCB 1

Final TDP 1 Delivery

Tooling/FA Dev FAT SRR Final TDP 2 Delivery

CCB 2Source Selection

Logistics Update TO 1Stock list 1 Update TO 2Stock list 2

6 months 6 months

Lead Time 2

Production Contracts after Re-Engineering Air Force maintains data rights to all technical data All components will be Source Controlled Acquisition Method Code – 2 Acquisition Method Suffix Code – C Contractors will be approved via Source Approval Request

First Article will be required for all contracts

Estimated Production

Estimated DLA production contract quantities after Re-Engineering contract

Item P/N Component Description Est. Future Quantities

(10 yrs)

B at ch

1 3-11801-503 Door, MLG Inboard Wheel (LH) 414 2 3-11801-504 Door, MLG Inboard Wheel (RH) 377 3 2-25100-605 Aileron (LH) 63 4 2-25100-606 Aileron (RH) 70

B at ch

5 2-26100-505 Flap (LH) 102 6 2-26100-506 Flap (RH) 120 7 3-31415-3 Leading Edge, Vertical Stabilizer 176 8 3-24132-501 Wing Leading Edge (LH) 116 9 3-24132-502 Wing Leading Edge (RH) 86

10 3-23801-501 Trailing Section, Wing 160 11 3-31429-13 Trailing Edge, Vertical Stabilizer 100

Summary

Reverse and/or re-engineering of 11 select bonded honeycomb structural components

Government is interested in additional qualified sources

MAPA Division

Briefer: Casey Hodson Comm: 801-777-8416 casey.hodson@us.af.mil

T-38 Select Structural Component Re-Engineering

Contract Overview

30 October 2018

Contract Strategy

Contract type Requirements “C” contract Past Performance/Price Trade Off FFP, CPFF, CR, and NSP Pricing Arrangements Period of Performance (PoP): Estimated as 3 years total Basic Period is 12 months Option Period One is 12 months Option Period Two is 12 months

Anticipated Competitive Acquisition Possible Small Business Set-Aside

Contract Strategy Draft CLIN structure

CLIN NARRATIVE CLIN

TYPE

Basic Year

0001 Contractor Travel CR 0002 Data NSP 0003 Technical Data Package for Batch #1 - Draft CPFF

Option Year 1

1001 Contractor Travel CR 1002 Data NSP 1003 Technical Data Package for Batch #1 - Final CPFF 1004 Technical Data Package for Batch #2 - Draft CPFF 1005 First Article Test for Batch #1 FFP

Option Year 2

2001 Contractor Travel CR 2002 Data NSP 2003 Technical Data Package for Batch #2 - Final CPFF 2004 First Article Test for Batch #2 FFP

Acquisition Timeline Estimate

MILESTONE DATE

Industry Day Oct 18 Release Draft RFP Nov 18 Release RFP Dec 18 Proposals Due Feb 19 Contract Award May-Jun 19 Post Award Conference Jun 19

These dates are subject to change, these are only estimated dates.

Summary

Single contract to Re-engineer the select structural components

Contractor will be required to deliver Technical Data Packages (TDPs) and First Article Testing

(FAT)

At this time, we’ll take a short break before the Q & A period

Break (Please be back within 15 minutes)

Q&A