LESSON 4 Safety of Flight 15 November 2013

LESSON 4 Safety of Flight 15 November 2013

F/A-18 D Hornet Crash Photographs courtesy of the U. S. Navy Module 7, Lesson 4: Safety of Flight 2

Lesson Introduction Given a contract with Safety of Flight (SOF) requirements, you will be able to recognize requirements of an SOF surveillance plan. Module 7, Lesson 4: Safety of Flight 3

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. Module 7, Lesson 4: Safety of Flight 4

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 Module 7, Lesson 4: Safety of Flight 5

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 Module 7, Lesson 4: Safety of Flight 6

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. Module 7, Lesson 4: Safety of Flight 7

SOF SURVEILLANCE REQUIREMENTS Lesson Topics: 1) SOF Surveillance Requirements 2) Roles and Responsibilities 3) Standard and Local SOF Platform List Differences 4) SOF QA Surveillance Strategies 5) SOF QA Documentation 6) SOF QAS Training Requirements Module 7, Lesson 4: Safety of Flight 8

Topic 1: SOF Surveillance Requirements SOF requirements are imposed by DCMA, based on Military Service documents, and guided by Federal Acquisition Regulations (FARs). Module 7, Lesson 4: Safety of Flight 9

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 (Do. D) 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 Module 7, Lesson 4: Safety of Flight 10

Authority FAR 52. 246 -2 through -8 § § 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 Module 7, Lesson 4: Safety of Flight 11

Question and Answer Which item is NOT true regarding SOF surveillance requirements? A. B. C. D. DCMA-imposed Not found in public law Do not pertain to rotary aircraft Contract includes a FAR 52. 2462 through -8 clause, minimally Module 7, Lesson 4: Safety of Flight 12

ROLES AND RESPONSIBILITIES Lesson Topics: 1) SOF Surveillance Requirements 2) Roles and Responsibilities 3) Standard and Local SOF Platform List Differences 4) SOF QA Surveillance Strategies 5) SOF QA Documentation 6) SOF QAS Training Requirements Module 7, Lesson 4: Safety of Flight 13

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 Module 7, Lesson 4: Safety of Flight 14

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 Module 7, Lesson 4: Safety of Flight 15

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 Module 7, Lesson 4: Safety of Flight 16

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 Module 7, Lesson 4: Safety of Flight 17

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) Module 7, Lesson 4: Safety of Flight 18

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 Module 7, Lesson 4: Safety of Flight 19

STANDARD AND LOCAL SOF PLATFORM LIST DIFFERENCES Lesson Topics: 1) SOF Surveillance Requirements 2) Roles and Responsibilities 3) Standard and Local SOF Platform List Differences 4) SOF QA Surveillance Strategies 5) SOF QA Documentation 6) SOF QAS Training Requirements Module 7, Lesson 4: Safety of Flight 20

Topic 3: Standard and Local SOF Platform List Differences SOF STANDARD PLATFORM LIST LOCAL SOF LIST Module 7, Lesson 4: Safety of Flight 21

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 Module 7, Lesson 4: Safety of Flight – – Fuel System Closure Egress Systems Pitot/Static System Software – Major Structural Mates – ALRE – Transmission Beams 22

SOF Standard Platform List 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 -5/SOF_Platform_Lists. htm Module 7, Lesson 4: Safety of Flight 23

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 Module 7, Lesson 4: Safety of Flight 24

Local SOF List Development QAS GG Foundation List R Local SOF List Template Unplanned Work Current Work R F G Available Technical Information Local SOF List Module 7, Lesson 4: Safety of Flight 25

Question and Answer When is the SOF Standard Platform List used? A. B. C. D. When available/approved For fixed-wing aircraft only For rotary-winged aircraft only When Local SOF List unavailable Module 7, Lesson 4: Safety of Flight 26

SOF QA SURVEILLANCE STRATEGIES Lesson Topics: 1) SOF Surveillance Requirements 2) Roles and Responsibilities 3) Standard and Local SOF Platform List Differences 4) SOF QA Surveillance Strategies 5) SOF QA Documentation 6) SOF QAS Training Requirements Module 7, Lesson 4: Safety of Flight 27

Topic 4: SOF QA Surveillance Strategies Subcontractor Facilities Determination Other SOF Surveillance Module 7, Lesson 4: Safety of Flight 28

SOF QA Surveillance Strategies (1 of 3) Subcontractor Facilities § § Determination § 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 Other SOF Surveillance Module 7, Lesson 4: Safety of Flight 29

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 Module 7, Lesson 4: Safety of Flight 30

SOF QA Surveillance Strategies (3 of 3) Subcontractor Facilities DCMA SOF policy requires surveillance strategies address unplanned work requirements when items are distributed through… …Over and Above Work Requests (OAWR) Determination …Work to Facilitate Other Maintenance (FOM) …Breaks of Inspection (BOI) …Grounding Conditions Other SOF Surveillance …Service/Safety Bulletins …Technical/Service Bulletins Module 7, Lesson 4: Safety of Flight 31

Question and Answer What is provided to the receiving CMO if SOF surveillance is delegated? A. Standard SOF surveillance strategy B. Alternate SOF surveillance strategies C. Foundation List D. Appropriate Local SOF List Module 7, Lesson 4: Safety of Flight 32

SOF QA DOCUMENTATION Lesson Topics: 1) SOF Surveillance Requirements 2) Roles and Responsibilities 3) Standard and Local SOF Platform List Differences 4) SOF QA Surveillance Strategies 5) SOF QA Documentation 6) SOF QAS Training Requirements Module 7, Lesson 4: Safety of Flight 33

Topic 5: SOF QA Documentation SOF Surveillance Plan Criteria Required SOF Surveillance Plan Content SOF Records SOF Corrective Action Request (CAR) Requirements Module 7, Lesson 4: Safety of Flight 34

SOF Surveillance Plan Documentation SOF Surveillance Plan is a separate document. Consolidates all correspondence, history, procedures, and processes Module 7, Lesson 4: Safety of Flight § § § § BOI OAWR Concurrent Notification letters Data Analysis On-the-Job Training (OJT) Impounding A/C during offshifts with no GFR/GGR 35

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 Module 7, Lesson 4: Safety of Flight 36

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 Module 7, Lesson 4: Safety of Flight 37

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 Module 7, Lesson 4: Safety of Flight 38

SOF Records SOF documentation requirements: § § Standard DCMA Product Examination Policy documentation Aircraft serial/tail number Module 7, Lesson 4: Safety of Flight 39

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 Module 7, Lesson 4: Safety of Flight 40

Question and Answer What documentation is part of the SOF QA Records? (Select all that apply. ) A. Surveillance Local Platform List B. DCMA Product Examination Policy documents C. Corrective Action Reports D. Aircraft serial/tail number Module 7, Lesson 4: Safety of Flight 41

SOF QAS TRAINING REQUIREMENTS Lesson Topics: 1) SOF Surveillance Requirements 2) Roles and Responsibilities 3) Standard and Local SOF Platform List Differences 4) SOF QA Surveillance Strategies 5) SOF QA Documentation 6) SOF QAS Training Requirements Module 7, Lesson 4: Safety of Flight 42

Topic 6: SOF QAS Training Requirements OJT Meet DCMA CSE QA Systems Core Fall Protection Requirements Aircraft Skill Set Module 7, Lesson 4: Safety of Flight 43

SOF Training Requirements (1 of 3) OJT Meet DCMA CSE QA Systems Core Fall Protection Requirements For example: § § § Module 7, Lesson 4: Safety of Flight Aircraft Skill Set CMQ 101 Blueprint Reading Root Cause Analysis 44

SOF Training Requirements (2 of 3) OJT Meet DCMA CSE QA Systems Core Fall Protection Requirements § § § Proficiency assessment/OJT - Specific to platforms assigned Aircraft Skill Set 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 Module 7, Lesson 4: Safety of Flight 45

SOF Training Requirements (3 of 3) OJT § AERO 101, 201, 302 Meet DCMA CSE QA Systems Core § Basic Metallurgy § Applicable Aircraft Core Plus Courses Fall Protection Requirements Aircraft Skill Set Module 7, Lesson 4: Safety of Flight 46

SOF Performance Requirements Training Experience s n o i t a c i f i l a u Q PERF s ORM n o i t a c i f ANCE i t r Ce Module 7, Lesson 4: Safety of Flight 47

Question and Answer Which of these are SOF training requirement(s)? I. OJT, CSE, and Fall Protection II. DCMA QA Systems Core requirements III. Aircraft Structures and System requirements A. B. C. D. I II I, II and III Module 7, Lesson 4: Safety of Flight 48

Summary Having completed this lesson, you should now be able to: § § § § Module 7, Lesson 4: Safety of Flight 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 49

Questions Module 7, Lesson 4: Safety of Flight 50

Review Question 1 What documentation contains the quality clauses granting the Government’s right of access and authority? A. FAR Part 12 (52. 212 -4) B. FAR 52. 246 -2 through -8 C. Air Force Technical Order 00 -201 D. Navy COMNAVAIRFORINST 52. 212 -4 Module 7, Lesson 4: Safety of Flight 51

Review Question 2 If it is available, which SOF Platform List is used by default? A. B. C. D. Local Standard Alternate Foundation Module 7, Lesson 4: Safety of Flight 52

Review Question 3 With whom does the QAS coordinate efforts to develop the Local SOF List? A. B. C. D. GFR GGR GFR and GGR ASO/ACO Module 7, Lesson 4: Safety of Flight 53

Review Question 4 What is the minimum level for a Corrective Action Request (CAR) on a SOF characteristic? A. B. C. D. I II IV Module 7, Lesson 4: Safety of Flight 54