Flight Control Cylinder Assembly (P/N: 212-076-005-109)

SOURCE PRE-QUALIFICATION REQUIREMENTS RMSC C: This part requires engineering source approval by the control activity to assure the integrity of the part. Alternative sources must pre-qualify by submitting a Source Approval Request (SAR) according to the design control activity's procedures and receive approval from the applicable government engineering activity, AFLCMC/WIUED Engineering office, the Systems and Integrity Section. SECTION A: ITEM IDENTIFICATION Below listed items can be Overhauled and Repaired by the same contractor: Stock Number (NSN) Part Number Nomenclature Tech Order 1615-01-421-4776 212-076-005-109 Cylinder Assy NAVAIR 03-30ET-45 1680-01-094-6453 SYLC 50114 Linear Actuator NAVAIR 03-75BA-19/ T.O. 8D1-13-49-3 SECTION B: JUSTIFICATION FOR ESTABLISHING A QUALIFICATION REQUIREMENT Flight Control Cylinder Assembly (P/N: 212-076-005-109) translates input from the pilot/copilot's collective input into the swashplate and ultimately the main rotor blades. The main rotor cyclic and collective controls are powered by two separate and completely independent hydraulic systems, referred to as System 1 and System 2. In addition to powering the cyclic and collective controls, System 1 is also used to power the tail rotor pitch control. Each system includes a non-pressurized reservoir, a transmission-driven pump, an integrated valve and filter assembly, pressure operated shut-off valve, directional flow check valves, pressure switch, spring-loaded piston type accumulator, and interconnecting hoses and tubes. Two quick disconnect couplings are also provided in each system, to allow use of an external hydraulic power source for ground operation of the systems. P/N serves as the hydraulic output actuator, from System 2, to apply pilot/copilot's forces into the collective system (i.e. swashplate). This item is a Critical Safety Item (CSI) and Critical Application Item (CAI) with catastrophic failure consequences. This item is identified as a Flight Safety Part on the drawing, with multiple critical characteristics identified. Failure of any of these dynamic components could result in the loss of aircraft, severe injury or loss of life. Linear Actuator (P/N: SYLC50114) is an electro-mechanical force input device used to direct air flow in the Air Management System. The air management system provides inlet air to each engine power section and carries away exhaust gases. The system consists of twin series of ducts and valves, within the engine cowling and extending aft from the air inlet fairings above each power section and includes the exhaust ducts and the induction baffle installations. The control valve in each air passage is located downstream from the induction baffle, and has an electrical actuator controlled by a three-position ONAUTO- OFF switch marked PART SEP and ENGINE No. 1 or No. 2. The electrical circuits are connected through breakers ENG 1 PART SEP and ENG 2 PART SEP to the 28V DC essential bus, with interconnections to caution panel PART SEP OFF and through emergency switches to the fire extinguishing system and the engine low rpm warning system. This item is a Critical Safety Item (CSI) and Critical Application Item (CAI) with catastrophic failure consequences. This item is identified as a Flight Safety Part on the drawing, with multiple critical characteristics identified. Failure of any of these dynamic components could result in the loss of aircraft, severe injury or loss of life. Sources must have quality procedures and processes to insure that each item is in compliance with the drawing. Outstanding quality and thoroughness of the overhaul and repair is required. The overhaul of these components will require the contractor to conduct inspection/functional checkout and disassembly/assembly to restore them to a serviceable condition end item that shall efficiently serve their intended purpose using the USAF Overhaul and Repair technical manuals listed in Section A above. Therefore, repair and overhaul sources must qualify in accordance with the appropriate Government engineering activity, AFLCMC/WIUED Engineering office, Robins AFB, GA. Additionally, the qualification procedures must be approved by AFLCMC/WIUED Engineering office. NAVAIR 03-30ET-45 and NAVAIR 03-75BA-19/T.O. 8D1-13-49-3 provide essential information to accomplish repair and maintenance functions on the noted items. SECTION C: QUALIFICATION REQUIREMENTS Source approval information: Listed below are the minimum requirements necessary to become a qualified bidder on the equipment listed above. The repair and overhaul of these dynamic components will require the restoration of the unserviceable assets to serviceable condition using USAF and Navy overhaul and repair technical orders. The extent of overhaul or repair work required shall be determined by the initial inspection/functional checkout and the disassembly/assembly required in order to restore these items to a serviceable condition end item if being overhauled, or required to return these items to a serviceable end item if being repaired, that shall efficiently serve their intended purpose. 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. At a minimum, vendors will be required to have the special tooling and the special test equipment called out in T.O.s listed below: Technical Order Noun Special Tools and Test Equipment NAVAIR 03-30ET-45 Cylinder Assy Listed in TO NAVAIR 03-30ET-45 NAVAIR 03-75BA-19/ T.O. 8D1-13-49-3 Linear Actuator Listed in TO NAVAIR 03-75BA-19 Alternates to the special tooling and/or test equipment may be used, provided the potential bidder can demonstrate that they have an equivalent piece of equipment that can accomplish the same task without damage to the components. Alternate tools/equipment must be identified by part number and potential bidders must specify by part number which piece of equipment the alternate is replacing. Alternate tools/equipment must receive approval from the applicable government engineering activity, AFLCMC/WIUED Engineering office before such tools/equipment is used to overhaul/repair any flight safety critical components. b. Potential bidders shall demonstrate the ability and have experience in repair and overhaul of similar critical safety of flight dynamic components, which are currently in use on commercial or military helicopters. Potential bidders shall provide the following information on the similar items: 1. Contract Number 2. Procuring Agency 3. Contract Value 4. Number of assets shipped c. Potential bidders shall provide a detailed quality plan implementing ISO 9002 (or equivalent). d. Potential bidders shall provide a detailed repair and a detailed overhaul plan describing repair, overhaul and inspection procedures and shall providefor: 1.Traceability of batch/lot for repaired / overhauled material 2.Identification of material sources. Sources for raw materials must be documented for each type of material. No material waivers will be granted. 3.Identification of sources for process not done in house shall be documented. di. Potential bidders shall perform a minimum of 75% of the repair and overhaul workload in-house. Testing shall not be sub-contracted to a third party facility. dii. After qualification the repair and overhaul plan processes, vendor sources, quality procedures etc. shall not be changed without the approval of AFLCMC/WIUED, obtained through the contracting officer. diii. Potential bidders shall provide sub-vendor qualification and quality assurance process to ensure conformance to requirements on work performed by subcontractors. div. Potential bidders must show compliance with Unique Identification requirement in accordance with DFARS 211.274-2, DFARS 252-211.7003, and Military Standard (MIL-STD)-130N, Department of Defense Standard Practice/Identification Marking of U.S. Military Property. dv. This qualification process shall be waived for companies who have already passed pre-qualification. Bell Helicopter Textron (CAGE 97499) is currently qualified to repair, overhaul and test the items listed below: Actuator Cylinder Assembly e. 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 produced 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. Potential Bidders shall be ISO 9001:2008 certified. SECTION D: ESTIMATE OF THE TEST AND EVALUATION COSTS This is a requirement of FAR 9.202(a)(1)(ii) and 10USC2319(b)(3) (The following categories may not apply in all cases. The product engineer should identify the costs applicable to the project and indicate N/A on all sections that do not apply.) Section 1. Shipping, if required, use DD Form 1654, Evaluation of Transportation Cost Factors to develop the information. Refer any questions to the Procurement Contracting Officer for cost estimation. N/A Section 2. Dimensional/Electronic Verification. Contact the science/engineering laboratory to obtain cost estimates (bids) for tests such as: a. Chemical N/A b. Metallurgical N/A (1) Destructive N/A (2) Non-Destructive N/A c. Dimensional N/A d. Electronic N/A e. Mechanical N/A f. Non-Destructive Inspection N/A Section 3. Nuclear Hardness [This includes cost of shock, vibration, and Electro-Magnetic Pulse (EMP)]. Contact Systems Engineering Integration and Test Division for hourly rate. N/A Section 4. Form, Fit, Function and Interface. Contact your organizational Production Management Specialist (PMS) to obtain information on the same or similar item where work has been accomplished in the past using AFMC Form 206, Temporary Work Request. N/A Section 5. Original Equipment Manufacturer (OEM) Qualification Testing (If required) N/A a. Laboratory Costs (Costs are directly dependent on the type of testing to be accomplished and the location and duration of the testing. For example, landing gear laboratory testing is normally accomplished on a dynamometer and costs vary from $25,000 to $500,000 depending on the depth of testing. Aircraft and missile testing will vary as the requirement dictates and the cost will have to be identified by the source of testing). $16,627.91 b. Flight/Data Reduction & Analysis Costs. N/A Section 6. Travel to Contractor or Test Site (if required) N/A a. Lodging N/A b. Per Diem N/A c. Rental Cars N/A d. Incidentals (Verified) N/A Total: N/A Section 7. SAR Package Development/Evaluation Cost: A potential new source's development of a Source Approval (SAR) package may cost as much as $16,627.91. In addition, the cost incurred for Government evaluation of their SAR may be as much as N/A. Evaluation cost may be borne by the government if it is in the best interest of the Government to qualify alternate sources. SECTION E: GOVERNMENT CONTRACT The Government Point of Contact for the technical requirements specified for qualification is AFLCMC/WIUE, 235 Byron Street Suite 19A, Robins AFB, GA 31098-1670. The Government Point of Contact for the technical requirements specified for qualification is: Byron Givens Rotary Wing Systems and Integrity Branch Chief AFLCMC/WIUE 478.926-7500 Byron.Givens@us.af.mil