Tension Regulator Source Qualification.docx

SOURCE PRE-QUALIFICATION REQUIREMENTS FOR THE C-5 SLAT ACTUATOR REPAIR

RMSC C: The part requires engineering source approval by the design control activity in order to maintain the quality of the part. Existing unique engineering skills, and repair knowledge by the qualified source(s) require repair of the part by the approved source(s). The approved source(s) retain repair knowledge, or technical data that are not economically available to the government, and the data or knowledge is essential to maintaining the quality of the part. An alternate source must qualify in accordance with the design control activity's procedures, as approved by the cognizant government engineering activity, AFLCMC/WLSEAB (C-5 Galaxy Division).

SECTION A: ITEM IDENTIFICATION

SECTION B: JUSTIFICATION FOR ESTABLISHING A QUALIFICATION REQUIREMENT

The C-5 aileron control system contains spoiler mixer tension regulators which differ slightly in appearance and buildup but are identical in operation. The main function of the tension regulators is to maintain constant tension on cables regardless of temperature or structural deflection. The tension regulator does this with moveable sectors connected on a common shaft by means of springs and interconnections. All aileron and flight spoiler movement is controlled via cables running through one of these tension regulators.

C-5 aileron spoiler mixer tension regulator repairs require strict control of processes to ensure adherence to quality control and testing requirements. Special tooling is required for the repair capability, and special equipment is required for testing of the C-5 aileron spoiler mixer tension regulators once repaired. Consistent repair processes are needed to ensure that the C-5 aileron spoiler mixer tension regulators is repaired and remain operable.

Catastrophic failure of the C-5 aileron spoiler mixer tension regulators could place the aircraft and crew in an extremely hazardous situation due to potential loss of control of ailerons or spoilers. In the event of one of the aileron spoiler mixer tension regulator the other pilot’s side cable system should maintain limited control. Flight safety histories indicate that aircrew task saturation as a result of component failures dramatically increases the risk of an aircraft mishap if they occur in critical phases of flight. If this failure occurs under these conditions, there is a risk of loss of life and/or aircraft.

SECTION C: QUALIFICATION REQUIREMENTS

Source approval information: Listed below are the minimum requirements necessary to become a qualified bidder on the equipment listed above. Prospective contractors should report in accordance with MIL-HDBK-831.

a) Potential bidders shall provide a summary of the company’s capabilities, including a detailed factory layout, a list of the machinery, fixtures, tooling and test and inspection equipment.

b) Potential bidders shall demonstrate the ability and possess experience in the repair of similar critical aircraft parts, which are currently in use on large commercial or military transport aircraft. Potential bidders shall provide the following information:

1. Contract Number

2. Procuring Agency

3. Contract Value

4. Number of assets shipped

5. Summary explanation of why part is similar to include drawings or pictures from various angles

c) Potential bidders shall provide a detailed quality plan implementing ISO 9001 (or equivalent). Evidence of independent, 3rd party certification that the quality program satisfies ISO 9001 requirements may be submitted in lieu of the actual quality plan.

d) Potential bidders shall provide a detailed overhaul process plan within the context of USAF overhaul manuals 9H2-4-184-3 and 9H2-4-189-3 describing repair, inspection and testing procedures and shall provide for:

1) Traceability of batch/lot for material, heat treatment and all test/inspections.

2) Identification of material, plating, and painting sources. Sources for raw materials shall be documented for each type of material incorporated in the assembly. No material, plating or painting waivers will be granted.

3) Identification of source for special tooling identified in TO 16R1-2-24-3 Table 2-and Table 3

4) Identification of any requested alternate tooling/test equipment for evaluation of suitability, to include specifications, drawings and/or specification sheets as applicable and written justification of why the tooling/test equipment meets or exceeds the capabilities of the tooling within the USAF overhaul manual.

5) Identification of any process where the potential bidder wishes to deviate from the USAF overhaul manual with a detailed, written justification detailing why the alternate process is equivalent or superior to those within the USAF overhaul manual.

6) Identification of sources and qualifications for potential outsourced processes.

e) Potential bidders shall perform a minimum of 75% of the repair workload in-house.

f) A sub-vendor qualification and quality assurance process to ensure conformance to specifications on work performed by subcontractors.

g) The Air Force may not qualify potential bidders who have had quality problems when delivering similar or identical items to the government. Potential bidders who have repaired similar items for the commercial market shall also be considered for qualification and shall provide commercial brochures and at least five (5) references with phone numbers

SECTION D: ESTIMATE OF THE TEST AND EVALUATION COSTS

No testing will be required for qualification. Development of a Source Approval package estimated cost is $0.

SECTION E: GOVERNMENT CONTRACT

The Government Point of Contact for the technical requirements specified for qualification is AFLCMC/WLSEAB, 235 Byron Street Suite 19A, Robins AFB, GA 31098.