Chapter 10.3

Design Modifications

Table of contents

Paragraph

1 General1

1.1 Introduction. 1

1.2 Applicability. 2

2 Policy on the modification of Service aircraft and equipment2

3 Classification of 4Design3 Modifications (DMs)2

4 4Design3 cover modifications. 2

5 Modification procedures. 2

6 Responsibilities. 2

6.1 IPT responsibilities. 2

7 DM brief and cost analysis sheets. 4

7.1 Modification Brief Sheet – Design Stage. 4

7.2 Modification Brief Sheet – Classification Stage. 4

7.3 Modification Cost Analysis Sheet6

8 References. 8

List of tables

Table 1.  Modification Brief Sheet – Design Stage.4

Table 2.  Modification Brief Sheet – Classification Stage.4

Table 3.  Modification Cost Analysis Sheet.6

List of figures

Figure 1.  DML/DIL Process. 3

1 General

1.1 Introduction

This chapter contains the policy and instructions for in-service design changes to an aircraft or associated equipment 4that is contracted with the aircraft or equipment Design Organization (DO).  These changes are defined as Design Modifications (DMs).3 This chapter is to be read in conjunction with Chapter 10.0.1, Chapter 10.1, Chapter 10.2 and Chapter 10.2.1.

DMs provide a43change to the build standard of materiel.  Changes are incorporated into the technical publications and the modifications are fully supported with spares and special tools, etc.

4Local Technical Committees (LTC) and Configuration Control Boards (CCB) form a structured3process for modification proposals; ensuring that they are relevant, cost-effective and will not conflict with previously approved proposals.

A substantial change of design, which materially affects the operation or function of an aircraft or equipment, or the interchangeability of equipment, 4may be3 treated as the introduction of a new mark number for aircraft, or a new mark number and/or part number for equipment, and is authorized by the appropriate modification committee; 4Def Stan 05-123, Part 3, Section 7 refers3.

1.2 Applicability

This chapter is applicable to all Military Air Environment materiel subject to DM, except that specifically excluded by separate contractual arrangements, eg weapons and some multi-national projects.

2 Policy on the modification of Service aircraft and equipment

Changes to materiel are normally to be made by DM action in accordance with the general requirements in Def Stans 05-57 and 05-12343.

A Service Modification (SM) may be superseded by a 4DO3cover modification to maintain configuration control of the drawing set.  A 4DO3cover modification is invariably to be sought when spares are affected.

The expeditious embodiment of modifications, once kits are available, is of prime importance to achieve maximum operational capability, reliability and maintainability from aircraft and equipments.  The embodiment of modifications at all 4levels3of maintenance is to be given a high priority and is to be actively managed.

3 Classification of 4Design3 Modifications (DMs)

The coding system for the classification of modifications is detailed at Chapter 10.2.1.

4 4Design3cover modifications

SMs can be useful to satisfy short term or limited applicability requirements, but where there is a need to make the modification a permanent change, to update publications and to ensure long term provisioning of spares, a 4Design3cover modification may be sought.

A 4Design3cover modification incorporates details of the SM in the equipment Configuration Status Record, formerly the Master Record Index.

1 Where the SM satisfies the design standards that the 4DO3is contracted to maintain, the 4DO3may adopt the SM design and produce a cover modification which ‘is satisfied by’ the SM.

2 Where the SM does not satisfy the contracted design standards, the 4DO3will redesign the modification, possibly at a significant cost to the Integrated Project Team (IPT).

5 Modification procedures

The Engineering Authority (EA) within the IPT manages the DM procedure.  In addition to this chapter, further advice is given in the 4Acquisition Operating Framework (AOF)3document – Configuration Management.  Refer to Def Stan 05-57 for access to the Modification Proposal Form.

6 Responsibilities

6.1 IPT responsibilities

The IPT is responsible for:

1 Editing the Draft Modification Leaflet (DML) or, when necessary, altering a published Topic 2 modification leaflet in accordance with the DML/Draft Information Leaflet (DIL) update process at Figure 1.  IPT personnel involved in technical editing duties are to read and should understand the requirements of Def Stan 05-123 4Part 3, Section 6 and JSP 8863.

2 Deciding whether an amendment proposal from the 4DO3to a DML or a published Topic 2 modification leaflet is acceptable and, if so, how to implement it.

3 Declaring how the support costs for an operational modification are likely to change as a function of the modification.  The modification cost analysis sheet at Table 3 should be used to identify the specific costs for each modification.

Figure 1.  DML/DIL Process

7 DM brief and cost analysis sheets

As the modification develops, brief sheets should be used to keep the MC apprised of progress.  The modification cost analysis sheet should be used to inform financial decisions.

7.1 Modification Brief Sheet – Design Stage

Table 1.  Modification Brief Sheet – Design Stage.

Modification  Number	……………………	Platform/Equipment	…………………….
Question:		Brief
1.   State why this modification is essential.
2.4 Detail who is liable for costs.3
3.   Does the proposal stem from a fault?  If so, quote references to relevant Serious Fault Signals, MOD Form 760, accident and incident reports.
4.   Do you agree the proposal in respect of: a.   Equipment type, mark, and reference number? b.   Title? c.   Origin? d.   Evidence? If not, state proposed amendments.
5.   Is a TI necessary?
6.   Have you any comments on individual costs quoted in the design section of the proposal?
7.   Is the Release To Service likely to be affected?
8.   Will the modification affect the equipment or platform Safety Case?
9.   Are there any particular requirements or implications for information systems?
10.  Is the modification likely to be adopted by another IPT?  If so, how are the costs to be shared?
Design Cost?		£………………………………….
Specialist Officer:  Name, Rank, Appointment
Sponsor:  Name, Rank, Appointment

7.2 Modification Brief Sheet – Classification Stage

Table 2.  Modification Brief Sheet – Classification Stage.

Modification Number	…………………….	Platform /Equipment	…………………….
Question		Brief
1.   Have you assessed, in conjunction with the relevant EA and 4DO,3 the spares implication of this modification by considering: a.  The cost of the modification sets and labour for spares held in Service and on order? b.  Who should modify the spares? c.  The cost of Service-supplied items for modification sets if no surplus assets are available? d.  Can any of the modification set components be supplied from available Service assets? Has this been discussed at LTC level?
2.   If major spares cannot be modified, have you assessed: a.  The costs of new post-modification spares to support the modified fleet? b.  The cost of spares made redundant after the modification programme? c.  Any financial liability resulting from cancellation of pre-modification spares orders?
3.   Taking account of the embodiment backlog, priorities, opportunities, resources and the contractor's forecast delivery dates: a.  When will embodiment start? b.  When will embodiment be complete? c.  What is the planned programme?
4.   What consequential or cover modifications will be required for: a.  Aircraft fit? b.  Government Furnished 4Assets3? c.  Simulators? d.  Training rigs? e.  Test equipment?
5.   If Service embodiment, and special tools are required, state: a.  Number of tools required. b.  Allocation of tools.
6.   Which of the following are required:  DML, CWP-type DML, other type of DML or an information leaflet? (See Note)
7.   What AP amendments will be required?
8.   Will the Release To Service need amending?
9.   Do you agree with the proposed modification set delivery dates and places?
10.  What modification classification is required?
11.  Will the modification be adopted by another IPT?  If so, how are costs to be shared?
12.  Will this modification affect any other embodiment programme? If so, what are the effects and consequent programme changes required?
Total Sponsorship Cost:
Specialist Officer:  Name, Rank, Appointment
Sponsor:  Name, Rank, Appointment

Note:

An information leaflet is issued when users are not required to embody the modification but need to be aware of its effects.  An information leaflet may also include the information required to enable units to accept, inspect or approve the work done by CWPs.

7.3 Modification Cost Analysis Sheet

The modification cost analysis sheet should be used to itemize the separate elements and consequential costs of pursuing a modification.

Table 3.  Modification Cost Analysis Sheet.

Classification

Privacy Marking (note 1)

Firm …………………

Equipment …………………..

Modification No……………..

1.

This submission represents:

Part of a package of modifications

c

(complete Blocks 1 & 2)

Part of an independent modification

c

(complete Blocks 1 & 2)

A change to previous sponsorship

c

(complete Blocks 1 & 2)

A complete independent modification

c

(complete Block 2)

BLOCK 1

2.

The package/modification, including any consequential modifications at paragraph 4 of Table 2 on the brief sheet:

Has already been sponsored

c

(complete Part A)

Needs to be sponsored now:

For the first time

c

(complete Part B)

Because of a change

c

(complete Parts A &  B)

3.

Part A – Already Sponsored

Modification No/ Stage

Estimated Cost

Sponsored by

…………..…………

£  .….…………………

Appt …………..………………………

…………..…………

£  .….…………………

Modification Sheet Ref …..…………

…………..…………

£  .….…………………

Date …………..…………

Total

£  .….…………………

Submit for financial approval (note 2)

4.

Part B – To be Sponsored Now

Modification No/ Stage

Estimated Cost

Reasons for any change

…………..…………

£  .….…………………

.….……………….….…………

…………..…………

£  .….…………………

.….……………….….…………

…………..…………

£  .….…………………

.….……………….….…………

…………..…………

£  .….…………………

.….……………….….…………

Total

£  .….…………………

Submit for financial approval (note 2)

BLOCK 2

5.

Complete as appropriate

Complete Modification

c

Design Stage

c

Production Stage

c

Long Lead Items

c

Other ………………………………………………………………

a.

Design Costs

(1)

Preparation

£ ………………..

(2)

Trial installation

£ ………………..

(3)

Flight trials

£ ………………..

(4)

Ground/Bench tests

£ ………………..

(5)

Design incorporation  (total)

£ ………………..

including DML

£ ………………..

Publication amendments

£ ………………..

(6)

Proof Installation

£ ………………..

Total Design

£ ………………..

b.

Production Costs

(1)

Changes in production

@      £ …………

£ ………………..

(2)

Modification sets for in-service fleet

@      £ …………

£ ………………..

(3)

Return to Works

@      £ …………

£ ………………..

(4)

On repair or recondition

@      £ …………

£ ………………..

(5)

Retrofit before delivery

@      £ …………

£ ………………..

(6)

Scrap: In production

£ ………………..

Retro before delivery

£ ………………..

(7)

Contractor’s production and embodiment tooling

£ ………………..

Total Production

£ ………………..

c.

Effect on Spares (3)

(1)

Modification Sets for spares

@      £ …………

£ ………………..

(2)

Service supplied items and Government Furnished Equipment to convert all modification sets to kits

@      £ …………

£ ………………..

(3)

Redundant spares and tooling

£ ………………..

(4)

Cancelled spares orders

£ ………………..

Total Spares

£ ………………..

d.

Embodiment Costs

(1)

Service tooling

@      £ …………

£ ………………..

(2)

CWP Manpower

@      £ …………

£ ………………..

(3)

Test equipment

@      £ …………

£ ………………..

Total Embodiment

£ ………………..

(4)

Service man-hours (4)

…………@………… = £………………..

(Service man-hours are to be declared, but excluded from sum sponsored)

e.

Modification of FsAST (Applicable/Non-applicable)

(1)

Modification Sets (inc spares)

@      £ …………

£ ………………..

(2)

Service supplied items and Government Furnished Equipment

@      £ …………

£ ………………..

(3)

Investigation task

£ ………………..

(4)

Design & Development

£ ………………

(5)

Design Incorporation

£ ………………

(6)

Installation

£ ………………

Total Production

£ ………………..

Total Cost of Block 2

£ ………………..

Submit for financial approval (note 2)

Sponsor

…………………

Signature

…………………

Name

…………………

Rank

Date

…………………

…………………

Appointment

Notes:

1

Use ‘Commercial’ when CWP man-hour rate is shown.

2

Submit results of the modification cost analysis for financial approval in accordance with the appropriate 43 financial and accounting BP.

8 References

This chapter refers to the following publications and websites:

1 4Acquisition Operating Framework (AOF) – Project and Programme Management – What is Configuration Management?3

2 4JSP 886 – The Defence Logistics Support Chain Manual.3

3 Def Stan 05-57 – Configuration Management of Defence Materiel.

4 Def Stan 05-123 – Technical Procedures for the Procurement of Aircraft, Weapons and Electronic Systems.

5 43

6 Topic 2 – General Orders and Modifications.