Aviation Critical Safety Items

1. Aviation Critical Safety Items DCMA Aviation CSI Lead Aeronautical Systems Division 05 June 2007 1

2. Agenda • What is an Aviation Critical Safety Item • Aviation CSI Authority • Aviation CSI Identification • DCMA Assistance • PA Instructions/Guidance • Summary / Questions

3. What is an Aviation CSI • Critical Safety Item (CSI). A part, assembly, installation equipment, launch equipment, recovery equipment, or support equipment for an aircraft or aviation weapons system that contains a characteristic any failure, malfunction, or absence of which could cause a catastrophic or critical failure resulting in the loss or serious damage to the aircraft or weapons system, an unacceptable risk of personal injury or loss of life, or an uncommanded engine shutdown that jeopardizes safety.

4. Fatigue Sensitive Part Critical Characteristic Critical Safety Item Flight Critical Part Qualification Flight Safety Part Life Limited Part Critical Item Code Category I Part Approved Source Approved Part Qualified Item Tracked Part Frozen Part Tested Part Prime Part Flight Safety Critical Aircraft Part Mission Critical Part Qualified Manufacturers List Safety Critical Item Fracture Critical Traceable Qualified Suppliers List Qualified Parts List Fracture Critical Item Critical Item Procurement Requirement Document Durability Critical Part Flight Essential Part Terminology

5. What is an Aviation CSI • Damage is considered serious or substantial when it would be sufficient to cause a “Class A” accident or a mishap of severity categoryI. • The determining factor in CSIs is the consequence of failure, not the probability that the failure or consequence would occur. • “Critical Safety Item”, “Flight Safety Critical Aircraft Part”, “Flight Safety Part”, “Safety of Flight Item”, and similar terms are synonymous.

6. DoD NSNs 4.9 Million DLA NSNs 3.9 Million What Is A CSI Universe of Aviation Spare Parts CAIs CSIs (2-4%) CAI Failure = Mission, Performance, Readiness, or Safety Impact CSI Failure = Catastrophic Consequences (e.g. Class A Mishap)

7. P.L. 108-136, Sec 802 … FY 2004 National Defense Authorization Act • That the head of the design control activity for aviation critical safety items establish processes to identify and manage aviation critical safety items and modifications, repair, and overhaul of such items. • That the head of the contracting activity for an aviation critical safety item enter into a contract for such item only with a source approved by the design control activity in accordance with section 2319 of title 10, United States Code. • That the aviation critical safety items delivered, and the services performed with respect to aviation critical safety items, meet all technical and quality requirements specified by the design control activity.

8. Who Identifies CSIs • Determined By Service Engineering Support Activity (ESA), Based on • Engineering Failure Analysis, Field Failure Analyses, History, etc. • CSI’s are not identified by DCMA • CSI’s are not the same as SOF Exclusive Authority Of ESA DFARS 209.270-4

9. Where To Look CSI’s May Be Identified In The Following Area’s: • Contract - Part Item Description • Technical Data Packages • i.e. Drawings, Specs, Statement of Work • Contract Data Requirements List • Quality Assurance Letter of Instruction • Defense Supply Center Richmond Database • http://www.dscr.dla.mil/UserWeb/vg/VG.htm • CSI Data Viewer • FMEA/FMECA Data

10. DCMA Can Assist Elevate through Buying Office to ESA when: • Have reason to believe an item should be identified as CSI • Have reason to believe an item is incorrectly identified as a CSI • Recommending authorization for a supplier to perform material review board actions on minor non conformances (MRB)

11. Product Assurance CSI Instructions Primes/OEMs with Legacy Systems • CSI’s Identified with Critical Characteristics designated • Surveillance Strategy will require that a 0.4 Quality Release Level (QRL) be used. • CSI’s Identified with NO Critical Characteristics designated • Surveillance Strategy will require that applicable Process Evaluation be performed on CSI Items on a risk based approach. • Important Processes to be considered during the development of the surveillance strategy is Hyperlinked within the Instructions

12. Product Assurance CSI Instructions Alternate Source • CSI’s Identified with Critical Characteristics Designated • Surveillance Strategy will require that a 0.4 Quality Release Level (QRL) be used. • CSI’s Identified with NO Critical Characteristics Designated • Significant Characteristic evaluation shall be performed • Criteria for consideration during the identification of Significant Characteristics/Processes Provided in DCMA Instructions

13. Contractor to notify PCO and ACO of nonconformance's to: Replenishment parts identified as CSIs Systems, subsystems, assemblies, etc that impact safety Repair, maintenance, logistics, or overhaul that impact safety Notification within 72 hours after discovery/receipt of credible information of situation Summary Chronology Potentially affected systems POC Other relevant info Flow down to Subcontractors Prime contractor responsible for notification Subcontract to provide notice to higher contractors Concurrently notify PCO/ACO if known to Subcontractor Facilitate communications between Gov’t and Sub Neither Admission of Responsibility nor Release of Liability Notification Requirements for Critical Safety ItemsDFARS Case 2004-D008 - Synopsis (Comments Being Dispositioned)

14. Summary • CSI’s are not Identified By DCMA • Designated by the Service ESA • CSI’s characteristics are not the same as Safety of Flight. • Elevate CSI concerns to the ESA through the Buying Office • Questions?