RFP KC-130J_IDIQ_Attachment_06_Drafting and Processing TEI (2023-06-23).docx

N62649XXXXXXX

Attachment 6 23 June 2023

ATTACHMENT (6)

DRAFTING AND PROCESSING TEMPORARY ENGINEERING INSTRUCTIONS (TEI) AT CONTRACT MAINTENANCE FACILITIES for

KC-130J

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

References

a) NAVAIR SWP4300-010

b) NAVAIR FORM 5600/2

c) DoDI 5230.24, Change 2, Date 1 Nov 2017

d) COMNAVAIRFORINST 4790.2D

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

1. Purpose of This Attachment:

This attachment provides guidance for the drafting and processing of Temporary Engineering Instructions (TEI) for repair work being performed at a contractor aircraft maintenance facility. This attachment is intended to meet the requirements of Ref (a), as applicable to contractor based maintenance.

2. Temporary Engineering Instruction Usage and Limitations:

2.1. Usage - A TEI shall be drafted by the contractor when instructions for correction of a defect are not provided by an existing Authoritative Engineering Document (AED), or when the severity of the defect is beyond the limits specified in an AED. Repairs, or acceptance of any defect outside the limits in an existing AED, shall not occur until a TEI addressing the defect is approved by FRC WESTPAC Engineering.

Examples of AED data that may be applied to accept or correct a defect without the need for a TEI include:

· The damage is within negligible size and location limits presented in a Structural Repair Manual (SRM).

· After required clean-up, the defect area remains within original equipment manufacturer (OEM) drawing or specification tolerance limits.

· Defect is within the scope of a standard repair task in the applicable Interactive Electronics Technical Manual (IETM).

· A repair to correct the defect is provided in a Local Engineering Specification (LES).

· A technical directive (TD) was issued to accept the defect.

2.2. A TEI may perform the following functions:

2.2.1. Provide repair instructions to correct a defect.

2.2.2. Document and justify unrepaired defects that are not covered by AED limits.

2.2.3. Deviate from existing repair instructions in an AED.

2.2.4. Provide supplemental instructions to an AED that lacks enough information to address a specific defect.

2.2.5. Amend, update, or revise an existing TEI.

2.3. Limitations.

2.3.1. A TEI shall be for one-time use on a specific defect for a specific bureau number (BUNO) aircraft. If a defect is discovered that was the same as one corrected by a previous TEI, but on a different aircraft, a new TEI shall be submitted for the new BUNO.

2.3.2. A TEI shall not be used to waive or alter flight critical requirements.

2.3.3. A TEI shall not be used to alter form, fit, or function of configuration controlled items.

2.3.4. FRC WESTPAC Engineering shall determine when the TEI will expire; either at 120 calendar days after approval, or upon completion of the work specified in the TEI for the specific BUNO.

2.3.5. A TEI shall be considered “Draft” until approved and signed by FRC WESTPAC Engineering.

NOTE: During the TEI process steps to design repairs, accept damage as-is, or justify a repair, strength and fatigue analysis may need to be performed by FRC WESTPAC Engineering, Continental United States (CONUS) Fleet Support Team (FST) Engineering, and/or the Original Equipment Manufacturer (OEM) Engineering. Strength and fatigue analysis may take significant time to complete. If analysis is required, the contractor will be notified by FRC WESTPAC Engineering of any anticipated delay and be provided a recurring status update of analysis progress.

3. Procedures – Refer to Flowchart in Appendix B.

3.1. The contractor identifies a defect.

NOTE: Cleanup work, including, but not limited to, corrosion removal, blending, paint removal, cutouts, scarf sanding, general cleaning, and Non-Destructive Investigation (NDI) may be required before accurate data describing a defect may be collected. If cleanup and NDI can be performed in accordance with the limits and procedures of an 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: If at any point during damage cleanup of a replaceable part, it becomes obvious that the part is beyond repair, cleanup work may be suspended and planning for replacement may be initiated. If part replacement per drawing(s) is possible, then replacement may proceed without a TEI. If replacement of the part will require deviation from drawings, or additional guidance is not available on the drawing(s), then a TEI shall be submitted. If unsure, consult with FRC WESTPAC to confirm decision to replace vice repair.

3.2. Data clearly describing location, severity, and extent of a defect shall be collected. Examples of relevant data are: part numbers, serial numbers, aircraft coordinates, measurements, non-destructive investigation (NDI) results, pictures, etc.

NOTE: If the contractor is unsure whether any particular defect is covered by an AED, they are encouraged to consult with FRC WESTPAC Engineering.

3.3. The defect will be assessed by the contractor, during which time the contractor will consult AED’s to see if the damage is within limits and/or an applicable repair is published.

3.3.1. If an AED covers the defect, the contractor shall perform corrective actions as specified by the AED and a TEI is not required.

3.3.2. If an AED does not have applicable damage limits, the defects are beyond damage limits, or the AED does not provide corrective action for the defect, continue with the TEI process.

3.4. The contractor shall initiate development of the draft TEI.

3.4.1. If the contractor is unable to determine all appropriate corrective action (ex: design repair, accept damage as-is, etc.) to include in the draft TEI, 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 TEI. The method for documenting consultation with FRC WESTPAC Engineering is at the contractor’s discretion.

3.4.2. FRC WESTPAC Engineering consultation with FST: 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 FRC in 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.

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

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

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

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

3.5.2.1. TEI Enclosure (1) – Damage Description: Provide a detailed description of the defect including 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 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 TEI Enclosure (1) is shown in Appendix D.

3.5.2.2. TEI Enclosure (2) – Detailed Instructions: Include all steps to complete the repair process or other corrective action. Include drawings and figures as required. Leverage and reference existing AED to the maximum extent possible. Safety warnings and cautions may be included to safeguard artisans that will be performing the work at contractor’s discretion. Format of this enclosure is at contractor’s discretion. Example of a completed TEI Enclosure (2) is shown in Appendix D.

3.5.2.3. TEI Enclosure (3) – Justification: 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 this Enclosure. Format of this enclosure is at contractor’s discretion. Example of a completed TEI Enclosure (3) is shown in Appendix D.

3.5.2.4. TEI Enclosures (4) and Subsequent – Optional for any use at the contractor’s discretion.

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

3.6. Draft TEI Submittal: After the draft TEI 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 TEI 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.

3.7. Draft TEI Review Process:

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

3.7.2. In some cases, FRC WESTPAC Engineering will need to consult with the cognizant Fleet Support Team (FST) Engineering located in the continental United States (CONUS) to approve the draft TEI. If CONUS FST coordination is required, the contractor will be notified of any anticipated delay and be provided a recurring status update of review progress.

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

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

3.8.2. Signed and approved: The TEI 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.

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

3.9. Approved TEI Implementation:

3.9.1. Prior to starting work per the approved TEI, 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), Performance Work Statement (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).

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

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

CONFIGURATION ITEMS - Items designated by Department of Defense 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

DEFECT - Any nonconformance of the unit or product with specified requirements. Defects will normally be grouped into one or more of the following classes but may be grouped into other classes or subclasses within these classes:2

DEFECT, CRITICAL - A defect that constitutes a hazardous or unsafe condition, or as determined by experience and judgment could conceivably become so, thus making the aircraft unsafe for flight or endangering operating personnel.2

DEFECT, MAJOR - A defect, other than critical, that could result in failure or materially reduce the usability of the unit or part for its intended purpose.2

DEFECT, MINOR - A defect that does not materially reduce the usability of the unit or part for its intended purpose or is a departure from standards but which has no significant bearing on the effective use or operation of the unit or part.2

DEVIATION - To depart from established policy or procedures. A deviation differs from an engineering change in that an approved engineering change requires corresponding revision of the documentation defining the affected item, whereas a deviation does not contemplate revision of the applicable specification or drawing. 2 (Abridged)

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 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

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

UNREPAIRED DEFECT – A defect that is left as-is or only has surface treatment/cosmetic corrective action applied. 1

Definition References 1 Specific to this Instruction.

2 Ref (d), Appendix A

APPENDIX B – TEI PROCESS FLOW CHART

APPENDIX C – TEI COVER PAGE AND DATA REQUIREMENTS

TEI Cover Sheet Data Requirements:

1. TEI 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 TEI.

1.2. Company name. Recommend to abbreviate.

1.3. Calendar year the TEI is generated.

1.4. Unique serial number for each TEI in a calendar year.

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

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

2. Model, See Appendix A for definition.

3. BUNO, See Appendix A for definition.

4. Part Number

5. Serial Number (If applicable).

6. 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.

7. Part Nomen: Part Nomenclature. Give a short description of the part with defect.

8. Subject: Short description of the issue and/or repair presented in the TEI.

9. Priority: Options for this field:

9.1. Urgent – Approval expected (but not guaranteed) within 3 working days.

9.2. Routine – Approval expected (but not guaranteed) within 10 working days.

9.3. Low – Approval expected (but not guaranteed) within 15 working days.

10. References: List references, use Temporary Engineering Instruction field or an enclosure if more space is required.

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

12. Defect Classification: See Appendix A for definitions.

13. Work Stop: Check this box if the aircraft is at work stop while waiting for this TEI to be approved. Checking this box will indicate maximum priority on the TEI and should be used only when warranted.

14. Contractor: Name of contractor generating TEI and performing work.

15. Engineer: Contractor engineer that created the TEI.

16. Phone No: Phone number of engineer.

17. Approved By: Contractor Approving Engineer

18. Phone No: Phone number of approving engineer.

19. Statement of problem: Brief background and description of defect/problem/repair. Use TEI Enclosure (1) for detailed description.

20. Standard Enclosures: Check these boxes when including these standard enclosures in the TEI.

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

22. Temporary Engineering Instructions: Provide instructions to repair defect or solve problem here. Most of the time this field is too small to provide all instructions, so utilize TEI Enclosure (2).

23. FRC WESTPAC Engineering Endorsement Section

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

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

23.3. Logbook Entry Required: Checked by FRC WESTPAC Engineer if the TEI requires recording in the aircraft logbook.

23.4. Expires in 120 Calendar Days: If the FRC WESTPAC Engineer checks this box, the TEI shall expire 120 calendar days from FRC WESTPAC Engineer signature date.

23.5. Expires Upon Completion of Work: If the FRC WESTPAC Engineer checks this box, the TEI expires after the work in the TEI is complete on that specific BUNO.

24. Distribution Statement per Ref (c): The following statement is required: “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 TEI WITH ENCLOSURES

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