RFP KC-130J_IDIQ_Attachment_05_Drafting and Processing LMR (2023-06-23).docx

ATTACHMENT (5)

DRAFTING AND PROCESSING LOCAL MANUFACTURING REQUESTS (LMR) AT CONTRACT MAINTENANCE FACILITIES for

KC-130J

Integrated Maintenance Plan (IMP) Planned Maintenance Interval (PMI)

References:

a) COMNAVAIRFORINST 4790.2D

b) NAVAIRINST 4200.56, dated 24 Apr 2013

c) JACG Aviation Source Approval and Management Handbook, dated 16 Mar 2011

d) Joint Deficiency Reporting System, https://jdrs.mil/

e) MIL-STD-882E, dated 11 May 2012

f) DoDI 5230.24, Change 2, dated 1 Nov 2017

g) SECNAVINST 4410.23, dated 29 Aug 2020

Appendices:

A. Definitions and Abbreviations B. LMR Process Flow Chart C. LMR Cover Page Format and Data Requirements D. Example of a Completed LMR with Enclosures

1. Purpose of This Attachment: This attachment provides guidance for the drafting and processing of Local Manufacturing Requests (LMR) for one-time or limited quantity part manufacturing at a contractor aircraft maintenance facility that is providing logistics services. This attachment is intended to meet the requirements of reference (a) Section 3.1.2.3 together with references (b) and (c) per FRCWESTPACINST 4408.1B, as applicable to contractor based, one-time or limited quantity part manufacturing.

2. LMR Usage and Limitations

2.1. Usage

2.1.1. A draft LMR may be generated by the contractor for local manufacture of part-numbered aircraft part(s) at contractor facilities.

2.1.2. Manufacturing of part-numbered aircraft parts shall not be performed by the contractor until an LMR is approved by FRC WESTPAC Engineering.

2.1.3. An LMR is not required for Repair Parts as defined by Appendix A of this attachment.

2.1.4. Parts with “M” in first position of their Source, Maintenance, and Recoverability (SM&R) code per reference (g) shall require an LMR.

2.1.5. A single LMR may be used for manufacture of:

2.1.5.1. A single part.

2.1.5.2. A family of parts with a common base part number and multiple dash numbers that only vary by one, or limited number of, characteristic(s). An example is multiple bushings that are all the same except for varying outer diameter and wall thickness.

2.1.5.3. Two parts with same base part numbers and different dash numbers that are mirrored opposites, with the same form, fit, and function.

2.1.5.4. All parts that make up one specific assembly, including combining parts into the final assembly. If an assembly contains a large number of parts, consult with FRC WESTPAC Engineering to confirm whether parts need to be broken up into multiple LMRs.

2.2. Limitations

NOTE: Local manufacture of a limited quantity of reserve stock parts should only be done temporarily to address non-availability via contractor’s supply channels. Quantity of reserve stock parts to be manufactured shall be coordinated with the FRC WESTPAC Production IPT Lead prior to submitting the LMR.

NOTE: Reserve stock parts shall be tagged with the following: “Check with FRC WESTPAC CTPL for changes to Engineering Drawings or newly released Technical Directives affecting this part prior to install.”

2.2.1. An LMR shall be for one-time or limited quantity manufacture of parts for the following applications. “Limited quantity” is defined as a quantity of parts expected to be consumed by one or more of the following applications:

2.2.1.1. A specific aircraft bureau number (BUNO) in an FRC WESTPAC managed depot overhaul program.

2.2.1.2. A reserve stock of frequently replaced parts that shall be used only on aircraft in a specific FRC WESTPAC managed depot overhaul program (not single BUNO specific).

2.2.1.3. A specific FRC WESTPAC in-service repair (ISR) requirement.

2.2.2. Parts manufactured under the FRC WESTPAC LMR process shall not enter the US Navy supply system nor be used for any purpose other than determined per Paragraph 2.2.1 of this enclosure. Excess, unused parts manufactured under the LMR process shall be dispositioned per FRC WESTPAC Supply Department direction.

2.2.3. All US Naval Aviation parts are assigned a criticality by a cognizant Fleet Support Team (FST) Technical Authority (TA) engineer per reference (b). In ascending order of criticality, parts may be classified as Non Critical (NC), Critical Application Item (CAI), or Critical Safety Item (CSI). Contractors may be limited to a level of criticality part that they may locally manufacture. The level of criticality part a contractor is allowed to manufacture is at the discretion of the cognizant FST TA. The FST TA may wish to visit contractor manufacturing facilities for a capability assessment prior to allowing local part manufacturing. Any subcontractors utilized in the LMR process may receive individual assessment and authorization from the FST TA. Recommend that the contractor coordinate with FRC WESTPAC Engineering early in the program to establish part criticality manufacturing limitations.

2.2.4. Deviations from part drawing/specifications presented in a draft LMR shall not alter form/fit/function of configuration controlled items.

2.2.5. An LMR shall expire upon completion of manufacturing the quantity of parts specified in the LMR.

2.2.6. An LMR shall be considered “Draft” until approved and signed by FRC WESTPAC Engineering.

3. Procedures – Refer to Flowchart in Appendix B.

NOTE: Cleanup work, including, but not limited to, corrosion removal, blending, paint removal, cutouts, scarf sanding, general cleaning, and Non-Destructive Inspection (NDI) may be required before accurate data describing a defect may be collected. If cleanup and NDI can be performed in accordance within the limits and procedures of an Authoritative Engineering Document (AED), then the work may be performed without prior FRC WESTPAC Engineering consultation (after any required contractual negotiation). If unsure of the extent of cleanup work required, or whether necessary cleanup work is authorized by an AED, consult with FRC WESTPAC Engineering.

NOTE: Making the determination to replace vice repair a part requires consideration of replacement complexity, part availability, cost/benefit analysis, etc. When unsure, consult with cognizant FRC WESTPAC departments to confirm a replace vice repair determination.

3.1. After performing required cleanup and assessment of a defect, the contractor identifies a part that requires replacement.

3.2. After decision to replace a discrepant part is made, contractor shall seek replacement part through their logistics channels.

3.2.1. If a replacement part is available in a timely manner, then continue with part order and do not submit an LMR.

3.2.2. If the part is not readily available, continue with the LMR process.

3.3. The contractor shall determine whether they have qualified artisans, processes, tools, etc. to physically manufacture the part.

3.3.1. If the contractor is unable to manufacture the parts, stop and consult with FRC WESTPAC for alternate part sources or solutions.

3.3.2. If the contractor is able to manufacture the part, continue with the LMR process.

3.4. The contractor shall consult with FRC WESTPAC Engineering to confirm the criticality of the part.

NOTE: There may be instances when a part has not yet been assigned a criticality in reference (d). In these cases, FRC WESTPAC Engineering will coordinate with the cognizant FST TA to have a criticality assigned. At FRC WESTPAC Engineering discretion, the contractor may proceed with the LMR process while the criticality assignment is pending.

3.5. FRC WESTPAC Engineering will follow guidance per reference (b) and consult reference (d) to confirm part criticality.

3.5.1. If part criticality is of a level that is beyond what the contractor is authorized to locally manufacture, FRC WESTPAC Engineering may consult the cognizant FST TA.

3.5.1.1. If the FST TA does not authorize manufacture, then stop and consult with FRC WESTPAC for alternate part sources or solutions.

3.5.1.2. If the FST TA does authorize manufacture, continue with the LMR process.

3.5.2. If part criticality is of a level that is already authorized for manufacture by the FST TA, continue the LMR process.

3.6. The contractor shall develop their internal manufacturing plan.

3.6.1. If the contractor has applied best effort but is unable to determine all appropriate manufacturing steps/processes to include in the manufacturing plan, they shall consult with FRC WESTPAC Engineering. Consultation with FRC WESTPAC Engineering may be by email, phone, or in person. The results of consultation with FRC WESTPAC Engineering may need to be documented and used as a reference in a LMR. The method for documenting consultation with FRC WESTPAC Engineering is at the contractor’s discretion.

3.6.2. If FRC WESTPAC Engineering is unable to provide adequate guidance to the contractor, FRC WESTPAC Engineering will consult with the appropriate FST located at other FRCs in the Continental United States (CONUS). During this consultation, FRC WESTPAC Engineering will act as a liaison between the contractor and CONUS FST. The contractor shall not contact CONUS FST Engineering directly unless first coordinated, or directed, by FRC WESTPAC.

3.6.3. FRC WESTPAC Engineering will provide guidance, or relay any guidance provided by the CONUS FST, to the contractor.

3.7. Once content for the draft LMR is adequately developed, the contractor shall submit the draft LMR package in the following format:

3.7.1. Cover Sheet: The FRC WESTPAC LMR cover sheet and data requirements are shown in Appendix C. The LMR Cover Sheet in blank, fillable Adobe Acrobat PDF format, may be provided to the contractor by FRC WESTPAC Engineering upon request. Format of the LMR cover sheet shall not be modified by the contractor unless authorized by FRC WESTPAC Engineering. The LMR Cover Sheet shall be limited to one page, so use of enclosures is expected. Example of a completed LMR cover sheet is shown in Appendix D.

3.7.2. LMR Enclosures: There are three standard enclosures that may be included in a LMR if the contractor is unable to fit all required information on the LMR Cover Sheet. The three standard LMR enclosures shall always be numbered as described in this section. Additional LMR enclosures, starting from “Enclosure (4),” may be added at the contractor’s discretion.

3.7.2.1. LMR Enclosure (1) – Damage Description: Provide a detailed description of the defect that is leading to the part being replaced. Include the following as applicable: figures showing location of defect on the aircraft, pictures of the defect from a distance (for orientation) as well as close up, measurements of the defect, NDI results, and anything else that would be aid in fully understanding the defect by someone unable to be on site to see the defect in person. Format of this enclosure is at contractor’s discretion. Example of a completed LMR Enclosure (1) is shown in Appendix D.

3.7.2.2. LMR Enclosure (2) – Manufacturing Procedure:

3.7.2.2.1. LMR without deviation from AED: If no deviations from manufacturing reference AEDs are proposed, then LMR Enclosure (2) is not required and it may just be noted on the LMR Cover Sheet, Manufacturing Process section, that “The part shall be manufactured per XX”, where XX is the applicable AED(s). If desired, the contractor may utilize LMR Enclosure (2) to present manufacturing/quality-assurance steps, even if they are not deviations from an AED(s). Format of this enclosure is at contractor’s discretion. Example of completed LMR Enclosure (2) is shown in Appendix D.

3.7.2.2.2. LMR with deviation(s) from an AED: Any manufacturing steps or processes that deviate from manufacturing reference AED(s) shall be presented in order, either on the LMR Cover Sheet, Manufacturing Process section, or in LMR Enclosure (2). Reference original equipment manufacturer (OEM) drawings and specifications to the maximum extent possible. Recommend that safety warnings and cautions be included to safeguard artisans that will be performing the work. Format of this enclosure is at contractor’s discretion. Example of completed LMR Enclosure (2) is shown in Appendix D.

3.7.2.3. LMR Enclosure (3) – Justification: This enclosure is only required if deviating in any way from AED(s). Justification may include analysis or reference previously approved, similar or same, instructions. Due to often limited data available to contractors for analysis or historical research, the contractor may need to rely on FRC WESTPAC Engineering for justification. If relying on FRC WESTPAC Engineering for justification, note as such in the LMR. Format of this enclosure is at contractor’s discretion. Example of a completed LMR Enclosure (3) is shown in Appendix D.

3.7.2.4. LMR Enclosures (4) and subsequent – Optional for any use at the contractors discretion.

NOTE: Draft LMRs should be submitted as they are generated. Make every effort to avoid batch submittal (i.e. waiting until many draft LMRs are generated and submit to FRC WESTPAC Engineering all at once) as this will increase review turnaround time.

3.8. Draft LMR Submittal: After the draft LMR is generated by the contractor, it shall be signed by contractor engineering author(s) and approver(s) as applicable per contractor’s internal processes. Use of electronic signature with a Public Key Infrastructure (PKI) certificate or ink signatures are acceptable. The complete draft LMR shall be submitted to FRC WESTPAC Engineering electronically. Email is generally the accepted method for submittal, but other methods such as secure file transfer or workflow websites may be used with FRC WESTPAC approval.

3.9. Draft LMR Review Process:

3.9.1. FRC WESTPAC Engineering will review the draft LMR and perform justification research/analysis as required.

3.9.2. In some cases, FRC WESTPAC Engineering will need to consult with the cognizant FST Engineering located in CONUS to approve the draft LMR. If CONUS FST coordination is required, the contractor may be notified of any anticipated delay and be provided a recurring status update of review progress.

3.10. Final LMR Disposition. After review, FRC WESTPAC Engineering will return the LMR to the contractor with one of the following dispositions:

3.10.1. Unsigned for revision: If the LMR requires modifications or corrections before it can be approved, it will be returned electronically to the contractor unsigned with guidance to modify. The draft LMR may be resubmitted, with the same LMR number, after modifications are complete. When resubmitting a modified, unreleased, unsigned draft LMR, it is not necessary to add a revision annotation (ex: “Rev. A”) to the LMR number.

3.10.2. Signed and approved: The LMR is approved for use and will be returned to the contractor electronically with FRC WESTPAC Engineer signature. Note any comments or annotations added by FRC WESTPAC Engineering.

3.10.3. Signed and disapproved: The LMR is not approved for use and no revision is expected. The disapproved LMR will be returned to the contractor electronically by FRC WESTPAC Engineering and will include justification for disapproval. FRC WESTPAC Engineering may also provide guidance for alternate corrective action as required.

3.11. Approved LMR Implementation:

3.11.1. Prior to starting work per the approved LMR, the contractor shall ensure cost and man-hours are handled as described in the Correction of Discrepancy (COD) section of the Statement of Work (SOW), PWS and/or DCMA Over and Above Procedures Memorandum of Understanding (MOU). Any impact to delivery date shall be communicated to the appropriate Type/Model/Series (T/M/S) FRCWP Integrated Product Team Lead (IPTL), Contracting Officer Representative (COR), and applicable Administrative Contracting Officer (ACO).

3.11.2. (Not shown on flowchart in Appendix B) If problems are encountered when performing the instructions in an approved LMR, a revised LMR may be submitted to FRC WESTPAC Engineering. If submitting a revision of a signed, released LMR, the revised LMR shall either include a revision annotation after the original LMR Number (ex: Rev A), or shall be assigned a new LMR number.

APPENDIX A - DEFINITIONS AND ABBREVIATIONS

AED - AUTHORITATIVE ENGINEERING DOCUMENT – Technical data officially released by a cognizant US Department of Defense (DoD) Command and/or controlled through a US Navy Technical Publications Library (TPL). Authoritative engineering documents include, but are not limited to, technical publications, manuals, interactive electronic technical manuals (IETM), structural repair manuals (SRM), Original Equipment Manufacturer (OEM) drawings, FRC repair drawings, local engineering/process specifications (LES/LPS), and technical directives (TD).1

AIRCRAFT COORDINATES – Horizontal and vertical coordinates on an aircraft, usually defined by aircraft specific water line (WL), butt line (BL), frame/fuselage station (FS, or STA), etc. May also be component specific such as wing station (WS), nacelle station (NS), etc.1

AIRCRAFT PART – A part-numbered component installed on aircraft from the factory or through a technical directive (TD) with established engineering drawings, effectivity, etc.1

BUNO - BUREAU NUMBER - An unhyphenated serial number, not exceeding six digits, used to identify individual airframes within the naval aircraft inventory. Each number is unique to a particular airframe. Assignment is controlled by the Chief of Naval Operations (CNO).2

CAI - CRITICAL APPLICATION ITEM - An item that is essential to weapon system performance or operation, or the preservation of life or safety of operating personnel, as determined by the military Services.3

CONFIGURATION ITEMS - Items designated by DoD components for configuration management. They may differ widely in complexity, size, and kind. Examples are an aircraft, ship, mobile test unit, navigation system, embedded computer, computer program, facility, electronic system, test meter, or a round of ammunition.2

CRITICALITY – A determination of the degree of importance that an aircraft part has based on consequences should the part fail. Consequences of part failure based on reference (e), Table I, are assessed by a Technical Authority (TA) per reference (b) to determine degree of importance. See: NC, CAI, CSI.1

CSI - CRITICAL SAFETY ITEM - A part, assembly, installation equipment, launch equipment, recovery equipment, or support equipment for an aircraft or aviation weapons system that contains a characteristic that any failure, malfunction, or absence of which could cause a catastrophic or critical failure resulting in the loss or serious damage to the aircraft or weapons system, an unacceptable risk of personal injury or loss of life, or an uncommanded engine shutdown that jeopardizes safety. Damage is considered serious or substantial when it would be sufficient to cause a Class A accident or a mishap of severity Category I. The determining factor in Critical Safety Items is the consequence of failure, not the probability that the failure or consequence would occur.3

IETM - INTERACTIVE ELECTRONIC TECHNICAL MANUAL - A technical manual prepared in digital form and designed for interactive display to the maintenance technicians or system operator end users by means of an electronic viewer, such as, the Naval Air Systems Command (NAVAIR) Standard IETM Viewer (NSIV) software application designed to be viewed on a Portable Electronic Maintenance Aide (PEMA) laptop.2

T/M/S – TYPE/MODEL/SERIES – Each Navy aircraft is designated by a combination of significant letters and numbers. Examples: FA-18E, UH-1Y, MV-22B.2

NON CRITICAL – NC – Part classification which does not meet the criticality threshold for a Critical Application Item (CAI) or Critical Safety Item (CSI).1

REPAIR PART – A repair specific component, often not assigned a part number, such as patch, doubler, fitting, or filler specifically directed to be made, fabricated, formed, manufactured, or otherwise produced ad hoc per an applicable Technical Directive or TEI.1

TA – TECHNICAL AUTHORITY - Formerly known as Basic Design Engineer, this term refers to the engineer delegated authority by a NAVAIR Level II Deputy Warranting Officer or their designee with the responsibility and accountability to exercise the inherently governmental function of ensuring the safety, reliability, and performance of Naval aviation products within a specified technical domain.3

TD - TECHNICAL DIRECTIVE - A document authorized and issued by Commander, Naval Air Systems Command to provide technical information necessary to properly and systematically inspect or alter the configuration of aircraft, engines, systems, or equipment subsequent to establishment of each respective baseline configuration. TDs include all types of changes and bulletins and consist of information that cannot be disseminated satisfactorily by revisions to technical manuals. Naval Air Technical Data And Engineering Service Center controls assignment of TD numbers.2

Definition References 1 Specific to this attachment.

2 Reference (a), Appendix A 3 Reference (b)

APPENDIX B - LMR PROCESS FLOW CHART

N62649XXXXXXX

Attachment 5 23 June 2023

APPENDIX C – LMR COVER PAGE AND DATA REQUIREMENTS

LMR Cover Sheet Data Requirements:

1. LMR No: The format of this number is at the contractor’s discretion but shall include the following information as a minimum:

1.1. Identify the document as a LMR.

1.2. Company Name. Recommend to abbreviate.

1.3. Calendar year the LMR is generated.

1.4. Unique serial number for each LMR in calendar year.

1.5. Revision annotation (ex: Rev A), when applicable.

1.6. Example for “Imaginary Aircraft Co.”: LMR-IAC-2018-003

2. Model, See Appendix A for definition.

3. BUNO, See Appendix A for definition.

4. Part Number

5. Seq. Number: Sequence Number of the aircraft in contract depot overhaul program. Numbering may be at contractor discretion and usually includes an abbreviation for the contractors company name. For example, the first aircraft inducted at “Imaginary Aircraft Co.” may be IAC-001, the next inducted in the program would be IAC-002, and so on.

6. Part Nomen: Part nomenclature, give a short description of the part being manufactured.

7. Priority: Options for this field:

7.1. Urgent – Approval expected within 3 working days.

7.2. Routine – Approval expected within 10 working days.

7.3. Low – Approval expected within 15 working days.

8. References: List references, use Manufacturing Process field or an enclosure if more space is required.

9. Need By Date: Provide reasonable date the approved LMR is required to meet schedule. This date in conjunction with the Priority field allows FRC WESTPAC engineering to prioritize more effectively.

10. Contractor: Name of contractor generating LMR and performing manufacturing.

11. Engineer: Contractor engineer that created the LMR.

12. Phone No: Phone number of engineer.

13. Approved By: Contractor Approving Engineer

14. Phone No: Phone number of approving engineer.

15. Background: Brief background and description of defect/problem that is leading to part replacement. Use LMR Enclosure (1) for detailed description.

16. Standard Enclosures: Check these boxes when including these standard enclosures in the LMR.

17. Additional Enclosures: List any additional enclosures in the LMR. Numbering of additional enclosures should always start at (4) to avoid confusion with the LMR standard enclosures (1) through (3).

18. Manufacturing Process (Utilize LMR Enclosure (2) if unable to fit all desired information in this section.):

18.1. LMR without deviation from AED: If no deviations from manufacturing reference AEDs are proposed, detailed manufacturing process steps are not required and it may just be noted in this section that “The part shall be manufactured per XX”, where XX is the applicable AED(s). If desired, the contractor may utilize this section, or LMR Enclosure (2), to present all manufacturing/quality-assurance steps, even if they are not deviations from an AED.

18.2. LMR with deviations from an AED: Any manufacturing steps or processes that deviate from manufacturing reference AED(s) shall be presented in order in this section or LMR Enclosure (2). Reference original equipment manufacturer (OEM) drawings and specifications to the maximum extent possible. Recommend that safety warnings and cautions be included to safeguard artisans that will be performing the work.

19. FRC WESTPAC Engineering Endorsement Section

19.1. Comments: FRC WESTPAC Engineer may provide comments and/or justification for approving the LMR.

19.2. Approved / Disapproved Check Boxes: Checked by FRC WESTPAC Engineer as appropriate.

19.3. Criticality Check Boxes.

20. Distribution Statement per reference (f): The following statement is required on the cover sheet per reference (f): “DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors; Administrative / Operational Use, February 24, 2019. Other U.S. requests for this document shall be referred to Fleet Readiness Center Western Pacific.”

APPENDIX D – EXAMPLE OF COMPLETED LMR WITH ENCLOSURES

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