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

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

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

4. 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

5. 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

6. 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

7. 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.

8. 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

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

10. 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
Army Pamphlet
Navy Commander, Naval Air Forces Instruction (COMNAVAIRFORINST)

11. 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
Commercial contract terms and conditions

12. 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 through -8 clause, minimally

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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)

19. 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

20. 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

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

22. 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

23. 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

24. 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

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

26. 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

27. 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

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

29. 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

30. 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

31. 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

32. 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

33. 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

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

35. 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

36. 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

37. 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

38. 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

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

40. 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

41. 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

42. 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

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

44. 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

45. 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

46. 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

47. SOF Performance Requirements
Training
Experience
Qualifications
Certifications
PERFORMANCE

48. 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

49. 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

50. Questions

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

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

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

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