LESSON 4 Safety of Flight 15November2013 Lesson 4: Safety Stock

F/A-18D Hornet Crash Photographs courtesy of the U.S. Navy

Lesson Introduction Given a contract with Safety of Flight (SOF) requirements, you will be able to recognize requirements of an SOF surveillance plan.

Lesson Objectives Upon completion of this lesson, you should be able to: Identify contractual SOF surveillance requirements. Differentiate between a SOF Standard Platform List and a Local SOF List. Relate the Quality Assurance Specialist (QAS) responsibilities for coordination with the Government Flight Representative (GFR) and the Government Ground Representative (GGR) in the development of a Local SOF List. Identify SOF Quality Assurance (QA) surveillance strategies. Recognize SOF QA documentation requirements. Recognize SOF training requirements. Lesson 4: Safety Stock

Lesson Topics This lesson covers the following topics: SOF Surveillance Requirements Roles and Responsibilities SOF Standard Platform and Local SOF List Differences SOF QA Surveillance Strategies SOF QA Documentation SOF QAS Training Requirements

WIIFM? This lesson introduces: SOF policy How a SOF Standard Platform List differs from a Local SOF List The QAS’s responsibilities towards ensuring SOF requirements

Definition Safety of Flight (SOF) Refers to the absence, failure, unsatisfactory/defective condition (where no backup exists) of an item, feature, or characteristic of an aircraft system installation, rigging, operation, test, or closure of any aircraft area that will cause a catastrophic result. The basic designation of SOF is primarily based on the high consequence of failure.

SOF Surveillance Requirements Lesson Topics: SOF Surveillance Requirements Roles and Responsibilities Standard and Local SOF Platform List Differences SOF QA Surveillance Strategies SOF QA Documentation SOF QAS Training Requirements

Topic 1: SOF Surveillance Requirements SOF requirements are imposed by DCMA, based on Military Service documents, and guided by Federal Acquisition Regulations (FARs).

Surveillance Requirements SOF is: A DCMA-imposed requirement NOT found in Public Law, FAR, Defense Federal Acquisition Regulation Supplement (DFARS), or other Department of Defense (DoD) requirements Based on Military Services documents Air Force Technical Order 00-20-1 Army Pamphlet 738-751 Navy Commander, Naval Air Forces Instruction (COMNAVAIRFORINST) 4790.2

Authority FAR 52.246-2 through -8 FAR 52.212-4 An SOF program will be instituted for contracts with aircraft and containing the contract quality clauses granting the Government's right of access and authority Contract addendum required FAR 52.212-4 Commercial contract terms and conditions

Question and Answer Which item is NOT true regarding SOF surveillance requirements? DCMA-imposed Not found in public law Do not pertain to rotary aircraft Contract includes a FAR 52.246-2 through -8 clause, minimally

Roles and Responsibilities Lesson Topics: SOF Surveillance Requirements Roles and Responsibilities Standard and Local SOF Platform List Differences SOF QA Surveillance Strategies SOF QA Documentation SOF QAS Training Requirements

Topic 2: Roles and Responsibilities Platform Team Manager (PTM) SOF Standard Platform List Point of Contact (POC) Contract Management Office (CMO) Commander/Director First Line Supervisor (FLS) SOF Coordinator CMO Platform POC Aviation Program Team (APT) POC CMO QA Personnel

Roles and Responsibilities (1 of 5) Platform Team Manager (PTM) Manage the SOF Standard Platform List process Notify the field via Tasking Memorandum SOF Standard Platform List POC Manage requests to modify/revise the list Coordinate with the customer prior to modifying/revising list Coordinate with PTM when aircraft design changes occur that could affect SOF

Roles and Responsibilities (2 of 5) CMO Commander/Director Appoints in writing: SOF coordinator - CMOs with multiple SOF programs APT QA POC - with the necessary SOF experience and knowledge Assign a CMO Platform POC for each SOF program

Roles and Responsibilities (3 of 5) First Line Supervisor (FLS) Ensures QA personnel possess the necessary competency Ensures proficiencies are assessed and documented for newly-assigned QA personnel Reviews changes to Standard Platform or Local List to identify gaps requiring additional training SOF Coordinator Is the central POC for SOF issues within the CMO Assures consistency among the CMO SOF programs Includes documented review of all SOF Program Plans

Roles and Responsibilities (4 of 5) CMO Platform POC Identifies contracts for aircraft manufacture and Overhaul, Maintenance, Modification, and Repair (OMMR) Establishes and manages SOF Program Plan Understands roles/responsibilities during non-duty hours regarding approved mishap/supplier aircraft impoundment procedures Coordinates with the Government Ground Representative (GGR)/Government Flight Representative (GFR) to identify trends with Foreign Object Damage (FOD)

Roles and Responsibilities (5 of 5) APT POC Participates on the Annual GFR survey Accomplishes Aircraft Operations Inspection (AOI) Self-Assessment annually CMO QA Personnel Performs scheduled SOF activities in accordance with established SOF Program Plan and as defined in DCMA SOF Policy Understands roles/responsibilities during non-duty hours regarding approved mishap/supplier aircraft impoundment procedures

Standard and Local SOF Platform List Differences Lesson Topics: SOF Surveillance Requirements Roles and Responsibilities Standard and Local SOF Platform List Differences SOF QA Surveillance Strategies SOF QA Documentation SOF QAS Training Requirements

Topic 3: Standard and Local SOF Platform List Differences SOF STANDARD PLATFORM LIST LOCAL SOF LIST

FOUNDATION LIST Foundation List “List of aircraft systems, subsystems, and items that typically contain SOF characteristics. All SOF items noted on the SOF Standard Platform Lists and the Local SOF Lists are based on the criteria located in the Foundation List.” DCMA-INST 308, Safety of Flight Minimum items considered when developing SOF lists: All aircraft: Powerplant Flight Controls Landing Gear Final Closure Rotary Wing Main/Tail Rotor Power Train Fuel System Closure Egress Systems Pitot/Static System Software Transmission Beams Major Structural Mates ALRE

SOF Standard Platform List Required use if available/approved Based on the Foundation List Developed by service engineers, supplier engineers, and DCMA QA Identifies all established SOF characteristics for contract-associated aircraft https://home.dcma.mil/guidebook/226/226-5/SOF_Platform_Lists.htm

LOCAL SOF PLATFORM LIST Local SOF List LOCAL SOF PLATFORM LIST Based on the Foundation List Used when no SOF Standard Platform List available Developed by QAS, available technical directives, and assistance of/coordination with GFR/GGR

Local SOF List Development QAS GGR GFR Available Technical Information Local SOF List Foundation List Unplanned Work Current Work Local SOF List Template

Question and Answer When is the SOF Standard Platform List used? When available/approved For fixed-wing aircraft only For rotary-winged aircraft only When Local SOF List unavailable

SOF QA Surveillance Strategies Lesson Topics: SOF Surveillance Requirements Roles and Responsibilities Standard and Local SOF Platform List Differences SOF QA Surveillance Strategies SOF QA Documentation SOF QAS Training Requirements

Topic 4: SOF QA Surveillance Strategies Subcontractor Facilities Determination Other SOF Surveillance

SOF QA Surveillance Strategies (1 of 3) Subcontractor Facilities Determination Other SOF Surveillance Conducted where subcontractor encloses SOF items/systems within an aircraft (A/C) section (installed at another facility) and items/systems are not reopened and inspected Delegation issued to advise supporting CMO of requirement  Prime CMO provides the local SOF List as part of the delegation

SOF QA Surveillance Strategies (2 of 3) Subcontractor Facilities Determination Other SOF Surveillance SOF surveillance strategy based on SOF Platform List (Standard or Local) All SOF items require 100% product examination in accordance with DCMA SOF policy If an escape occurs, the QAS performs a complete process review in conjunction with CAR follow-up to validate supplier’s root cause analysis Independent inspection of fuel cells is required Determine hold points with caution; DO NOT direct supplier to insert Government hold points into its planning documents

SOF QA Surveillance Strategies (3 of 3) Subcontractor Facilities DCMA SOF policy requires surveillance strategies address unplanned work requirements when items are distributed through… Determination …Over and Above Work Requests (OAWR) …Work to Facilitate Other Maintenance (FOM) …Breaks of Inspection (BOI) Other SOF Surveillance …Grounding Conditions …Service/Safety Bulletins …Technical/Service Bulletins

Question and Answer What is provided to the receiving CMO if SOF surveillance is delegated? Standard SOF surveillance strategy Alternate SOF surveillance strategies Foundation List Appropriate Local SOF List

SOF QA Documentation Lesson Topics: SOF Surveillance Requirements Roles and Responsibilities Standard and Local SOF Platform List Differences SOF QA Surveillance Strategies SOF QA Documentation SOF QAS Training Requirements

Topic 5: SOF QA Documentation SOF Surveillance Plan Criteria Required SOF Surveillance Plan Content SOF Records SOF Corrective Action Request (CAR) Requirements

SOF Surveillance Plan Documentation SOF Surveillance Plan is a separate document. BOI OAWR Concurrent Notification letters Data Analysis On-the-Job Training (OJT) Impounding A/C during off- shifts with no GFR/GGR Consolidates all correspondence, history, procedures, and processes

SOF Surveillance Plan Criteria Electronic control panel serving as a table of contents and contains links to all the information/documents in the plan Must ensure a repeatable and consistent approach Coordinated with the GFR and GGR Clearly identified and kept separate from other surveillance plans

Required SOF Surveillance Plan Content Contains the applicable SOF Standard/Local Platform List Details for handling unplanned SOF surveillance A copy of the supplier notification letter Contractor Notification Letter for Standard Platform List with SOF Items Contractor Notification Letter for Local SOF List Details of plan for SOF Data Collection and Analysis Location of surveillance and data analysis records List and status of SOF trained QA personnel OJT documentation

Required SOF Surveillance Plan Content (cont.) Copy of most current GFR notification letter QA personnel responsible for GFR annual survey, Foreign Object Damage (FOD) lost tool surveillance, and, if applicable, aircraft impound procedures during off shifts Procedure of unique aspects that occur locally on the SOF program/facility Process concurrent fuel cell inspection Host Nation Ministry of Defense (MOD) involvement

SOF Records SOF documentation requirements: Standard DCMA Product Examination Policy documentation Aircraft serial/tail number

SOF CAR Requirements Characteristics: Always issued at a MINIMUM of Level II Clearly identified as SOF CAR Repeats within 1 year for SOF – Level III required Exception fuel cells Initial response time of NOT MORE THAN 5 days Hold point bypassed – Level II required

Question and Answer What documentation is part of the SOF QA Records? (Select all that apply.) Surveillance Local Platform List DCMA Product Examination Policy documents Corrective Action Reports Aircraft serial/tail number

SOF QAS Training Requirements Lesson Topics: SOF Surveillance Requirements Roles and Responsibilities Standard and Local SOF Platform List Differences SOF QA Surveillance Strategies SOF QA Documentation SOF QAS Training Requirements

Topic 6: SOF QAS Training Requirements Aircraft Skill Set OJT CSE Fall Protection Meet DCMA QA Systems Core Requirements

SOF Training Requirements (1 of 3) Aircraft Skill Set OJT CSE Fall Protection Meet DCMA QA Systems Core Requirements For example: CMQ101 Blueprint Reading Root Cause Analysis

SOF Training Requirements (2 of 3) Aircraft Skill Set OJT CSE Fall Protection Meet DCMA QA Systems Core Requirements Proficiency assessment/OJT - Specific to platforms assigned using the specific SOF List as the OJT guide Confined Space Entry (CSE) training required to enter fuel tanks Fall protection required for all hazards over 4 feet

SOF Training Requirements (3 of 3) Aircraft Skill Set OJT CSE Fall Protection Meet DCMA QA Systems Core Requirements AERO101, 201, 302 Basic Metallurgy Applicable Aircraft Core Plus Courses

SOF Performance Requirements Training Experience Qualifications Certifications PERFORMANCE

Question and Answer Which of these are SOF training requirement(s)? OJT, CSE, and Fall Protection DCMA QA Systems Core requirements Aircraft Structures and System requirements I II III I, II and III

Summary Having completed this lesson, you should now be able to: Identify SOF and latest DCMA policy Highlight important definitions Understand QAS roles and responsibilities Provide details of SOF surveillance planning Illuminate SOF surveillance techniques Identify SOF CAR requirements Identify unique SOF training requirements Understand the purpose of the resource page Lesson 4: Safety Stock

Questions

Review Question 1 What documentation contains the quality clauses granting the Government’s right of access and authority? FAR Part 12 (52.212-4) FAR 52.246-2 through -8 Air Force Technical Order 00-20-1 Navy COMNAVAIRFORINST 52.212-4

Review Question 2 If it is available, which SOF Platform List is used by default? Local Standard Alternate Foundation

Review Question 3 With whom does the QAS coordinate efforts to develop the Local SOF List? GFR GGR GFR and GGR ASO/ACO

Review Question 4 What is the minimum level for a Corrective Action Request (CAR) on a SOF characteristic? I II III IV