Trailing Edge Gearboxes Qualifications.pdf

Qualification for Requirements for the Overhaul of the C-5

Trailing Edge Flap Gearboxes

AMSC C: These parts require engineering source approval by the control activity to assure the integrity of the part. An alternative source must qualify according to the design control activity’s procedures as approved by the applicable government engineering activity, AFLCMC/WLSEAB (C-5 Galaxy Division)

Stock Number (NSN) Part Number Nomenclature 1680-00-412-2735 5901-101E LH 1A Flap Gearbox 1680-01-567-7001 5901-101G LH 1A Flap Gearbox 1680-00-412-2737 5901-102E RH 1A Flap Gearbox 1680-01-567-7002 5901-102G RH 1A Flap Gearbox 1680-00-412-2736 5901-103E LH 1B Flap Gearbox 1680-01-525-8910 5901-103F LH 1B Flap Gearbox 1680-00-412-2738 5901-104E RH 1B Flap Gearbox 1680-01-525-8911 5901-104F RH 1B Flap Gearbox 1680-00-248-8553 5901-105D LH 2A Flap Gearbox 1680-01-525-8906 5901-105E LH 2A Flap Gearbox 1680-00-248-8567 5901-106D RH 2A Flap Gearbox 1680-01-525-8908 5901-106E RH 2A Flap Gearbox 1680-00-248-8549 5901-107D LH 2B Flap Gearbox 1680-01-525-8905 5901-107E LH 2B Flap Gearbox 1680-00-248-8500 5901-108D RH 2B Flap Gearbox 1680-01-525-8904 5901-108E RH 2B Flap Gearbox 1680-00-443-6443 5901-109D LH 3A Flap Gearbox 1680-01-525-8912 5901-109E LH 3A Flap Gearbox 1680-00-454-6063 5901-110D RH 3A Flap Gearbox 1680-01-525-8916 5901-110E RH 3A Flap Gearbox 1680-00-443-6445 5901-111D LH 3B Flap Gearbox

SECTION B: JUSTIFICATION FOR ESTABLISHING A QUALIFICATION

REQUIREMENT

The C-5 flap system makes it possible for the aircraft to operate at relatively slow speeds for takeoff or landing, and high speeds for cruise. These individual Flap gearboxes are part of the C- 5 flap system that transmit rotational input from the flap power package to the flap actuators to physically drive the positioning their respective flaps.

C-5 flap gearbox repair requires strict control of processes to ensure adherence to very close tolerances when machining specified material. Special equipment is required to repair the precisely manufactured part surfaces.

Consistent repair processes are needed to ensure that the gearbox is manufactured such that the gearbox drives appropriately in flight.

Failure of C-5 Flap gearboxes could place the aircraft and crew in an extremely hazardous situation due to potential loss of appropriate flap actuation. This could lead to asymmetrical conditions between flaps. 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 item in Section A.

a. Potential bidder 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 bidder shall demonstrate the ability and have experience in repairing similar critical aircraft parts, which are currently in use on a military heavy cargo transport aircraft and shall provide the following:

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 to show whole part

c. Potential bidder 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 bidder shall provide a detailed manufacturing plan describing manufacturing and inspection and shall provide for:

1. Traceability plan for all test/inspections for repaired assets.

2. Identification of material sources, including forgings if applicable. Sources for raw materials must be documented for each type of material called for in the assembly. Any material substitutions must be approved, in writing by the Engineering Authority.

3. Identification of sources for outsourced processes shall be documented.

e. Potential bidder shall perform more than 75% of the repairing workload in-house.

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

g. Once qualified, bidders shall be subject to first article testing if they have not previously repaired this item within the last five years.

h. The Air Force may not qualify potential bidders who have had quality problems when delivering similar or identical items to the government.

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.