afi21-101.pdf

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

AIR FORCE INSTRUCTION 21-101

AIRCRAFT AND EQUIPMENT

MAINTENANCE MANAGEMENT

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for downloading or ordering on the e-Publishing website at www.e-publishing.af.mil.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AF/A4LM

Supersedes: AFI 21-101, 1 May 2015 AFI 21-110, 16 Jun 2016 AFI 21-123, 3 Feb 2017 AFI 21-124, 12 Jan 2017 AFI 21-136, 3 Feb 2017

Certified by: SAF/AQD (Ms. Angela L. Tymofichuk)

Pages: 336

This publication implements Air Force Policy Directive (AFPD) 21-1, Maintenance of Military Materiel. It is the basic Air Force Instruction (AFI) for all weapon system and support equipment maintenance management guidance. It provides the minimum essential guidance and procedures to safely and effectively maintain, service, and repair weapon systems and support equipment.

This publication applies to all military and civilian members of the Regular Air Force (RegAF), Air Force Reserve (AFR) and Air National Guard (ANG) and those with contractual obligation to comply with Air Force publications. Supplements and addendums are written in accordance with (IAW) AFI 33-360, Publication and Forms Management. Supplements must identify and document Major Command (MAJCOM), AFR, and ANG required deviations (applicability, variance, exception and differences in organizational placement of responsibilities/processes) in their supplement and addendums with the abbreviation “(DEV)”. Place the “DEV” entry after the Paragraph number and directly preceding the affected text, such as (AMC) (DEV) Use the... or (ADDED-AMC) (DEV) Use the...). All supplements and addendums are submitted to the Air Force Maintenance Division (AF/A4LM) @ usaf.pentagon.af-a4.mbx.a4lm-maintenance-policy@mail.mil for approval and are published in the e-Publishing website. The authorities to waive wing and unit level requirements in this publication are identified with a Tier (“T-0, T-1, T-2, T-3”) number following the compliance statement. See AFI 33-360 for a description of the authorities associated with the Tier numbers. Submit requests for waivers through the chain of

16 JANUARY 2020

Corrective Actions applied on, 15 September 2020

Maintenance http://www.e-publishing.af.mil/ mailto:usaf.pentagon.af-a4.mbx.a4lm-maintenance-policy@mail.mil mailto:usaf.pentagon.af-a4.mbx.a4lm-maintenance-policy@mail.mil

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command to the appropriate Tier waiver approval authority, or alternately, to the requestor’s commander for non-tiered compliance items. For questions on interpreting this instruction, first contact your MAJCOM maintenance functional activity. Refer recommended changes and questions about this publication through your MAJCOM, AFR or ANG, to the Office of Primary Responsibility (OPR) using the Air Force (AF) Form 847, Recommendation for Change of Publication; route AF Forms 847 from the field through the appropriate functional chain of command. Ensure all records created as a result of processes prescribed in this publication are maintained in accordance with AFI 33-322, Records Management and Information Governance Program, and disposed of in accordance with the Air Force Records Disposition Schedule located in the Air Force Records Information Management System. The use of the name or mark of any specific manufacturer, commercial product, commodity, or service in this publication does not imply endorsement by the AF.

SUMMARY OF CHANGES CORRECTIVE ACTION

This corrective action revises the following paragraphs: 10.3.1.; 10.3.3.3.3.; 10.11.1.;

10.11.2.1.1.; 10.12.; 10.13.1.; 10.13.1.1., 10.13.6.1 and 11.8.3.15. Additionally, this corrective action deletes para, 6.10.1.3.3.1.

SUMMARY OF CHANGES

This publication has been substantially revised and must be completely reviewed in its entirety. Significant changes include the addition of Maintenance Cyber Discipline requirements, Decentralized Materiel Support, incorporation of four AFIs superseded above and establishes a Wing Avionics Manager Position requirement. Additionally, eTool and World Wide Identification (WWID) management procedures were expanded to provide standardized enterprise requirements. MAJCOMs/ANG designated to establish Special Certification Roster (SCR) prerequisites to optimize workforce alignment to mission requirements.

Chapter 1—MANAGEMENT OVERVIEW, SUPPORTING CONCEPTS AND

REQUIREMENTS. 12

1.1. Introduction

1.2. Organization

1.3. Maintenance Concept

1.4. Aircraft Maintenance Tactics, Techniques and Procedures (TTP)

1.5. Aircraft and Equipment Readiness

1.6. Maintenance Discipline

1.7. Communications Security (COMSEC)/Controlled Cryptographic Item (CCI) Accountability

Table 1.1. Tiered Interface Examples

AFI21-101 16 JANUARY 2020 3

1.8. Environmental Compliance

1.9. Publications

1.10. Maintenance Training

1.11. Modification Management

1.12. Maintenance Information Systems (MIS)

1.13. General Safety Guidance

1.14. Duty Shifts and Rest Periods

1.15. Communications

1.16. Maintenance Repair Priorities

Table 1.2. Maintenance Repair Priority Designators

1.17. Associate Unit Program/Total Force Integration (TFI)

1.18. Performance-Based Activities

1.19. Changes to Technical Orders

Chapter 2—ROLES AND RESPONSIBILITIES 25

2.1. General

2.2. Wing Commander (WG/CC) Responsibilities

2.3. Wing Vice Commander (WG/CV) Responsibilities

2.4. Maintenance Group Commander (MXG/CC) Responsibilities

2.5. Deputy Maintenance Group Commander (MXG/CD)

2.6. MXG Superintendent Responsibilities

2.7. Wing Weapons Manager (WWM)

2.8. Squadron Commander (SQ/CC) Responsibilities

2.9. Maintenance Supervision Responsibilities

2.10. Flight Supervision

2.11. Production Superintendent (Pro Super)

2.12. Section NCOIC/Chief

Chapter 3—AIRCRAFT MAINTENANCE SQUADRON (AMXS). 46

3.1. General

3.2. Maintenance Supervision Responsibilities

4 AFI21-101 16 JANUARY 2020

3.3. Aircraft Maintenance Unit (AMU)

3.4. AMU OIC/SUPT Responsibilities

3.5. Production Superintendent (Pro Super)

3.6. Flightline Expediter

3.7. Aircrew and Maintenance Debrief Section

Table 3.1. Landing Status Codes

Table 3.2. System Capability Codes

Table 3.3. Deviation Cause Codes

3.8. Aircraft Section

3.9. Specialist Section

3.10. Weapons Section

3.11. Support Section

3.12. AMU Decentralized Materiel Support (DMS)

Chapter 4—MAINTENANCE SQUADRON (MXS) 62

4.1. General

4.2. Maintenance Supervision Responsibilities

4.3. MXS Production Superintendent (Pro Super)

4.4. Accessories Flight

4.5. Aerospace Ground Equipment (AGE) Flight

4.6. Armament Flight

4.7. Avionics Flight

4.8. Fabrication Flight

4.9. Maintenance Flight

4.10. Munitions Flight

4.11. Propulsion Flight

4.12. Test, Measurement, and Diagnostic Equipment (TMDE) Flight

Chapter 5—MAINTENANCE OPERATIONS (MXO). 90

5.1. General

5.2. Maintenance Operations

AFI21-101 16 JANUARY 2020 5

5.3. Maintenance Training (MT)

5.4. Programs and Resources (P&R)

Chapter 6—QUALITY ASSURANCE (QA) 103

6.1. General

6.2. Responsibilities

6.3. QA Superintendent (QA SUPT) Responsibilities

6.4. Chief Inspector Responsibilities

6.5. Quality Assurance Inspector Responsibilities

6.6. Quality Assurance Inspector Training

6.7. Maintenance Standardization and Evaluation Program (MSEP)

6.8. LEAP QA Database

6.9. QA Product Improvement Programs (PIP)

6.10. Technical Order Distribution Office (TODO)

6.11. One-Time Inspections (OTI) program

6.12. Functional Check Flights (FCFs) to include Operational Check Flights (OCFs)

6.13. Inflight Operational Checks

6.14. High Speed Taxi Checks

6.15. Weight and Balance (W&B) Program

Chapter 7—IMPOUNDMENT PROCEDURES 128

7.1. Aircraft and Equipment Impoundment

7.2. Specific Guidance

7.3. Impoundment Authorities

7.4. Impoundment Official Responsibilities

7.5. Mandatory Impoundments

7.6. Impoundment Procedures

7.7. Rules of Impoundment Specifically for Explosive-Related Events/Mishaps

Chapter 8—TOOL AND EQUIPMENT MANAGEMENT 133

8.1. Tool and Equipment Management

8.2. Guidelines for Program Management

6 AFI21-101 16 JANUARY 2020

8.3. General Program Guidelines

8.4. TMDE Management Guidelines

8.5. Tool Accountability

8.6. Tool and Equipment Marking and Identification

8.7. Locally Manufactured, Developed, or Modified Tools and Equipment

8.8. Tool Room Operations and Security

8.9. Lost Item/Tool Procedures

Chapter 9—MATERIEL MANAGEMENT SUPPORT 146

9.1. General

9.2. Decentralized Materiel Support

9.3. Supply Discipline

9.4. Readiness Spares Package Review

9.5. Bench Stock

9.6. Consumable Readiness Spares Package

9.7. Shop Stock

9.8. Operating Stock

9.9. Work Order Residue

9.10. Adjusted Stock Levels

9.11. Shelf-life Items

9.12. Equipment Items

9.13. Special Purpose Recoverable Authorized Maintenance (SPRAM)

9.14. Supply Assets Requiring Functional Check, Calibration, or Operational Flight Programming

9.15. Time Compliance Technical Order (TCTO) Kit Procedures

9.16. Supply Points

9.17. Local Manufacture

9.18. DIFM Management

9.19. Tail Number Bins (TNB)

9.20. CANN Actions

AFI21-101 16 JANUARY 2020 7

9.21. Bench Check and Repair Policy

9.22. Maintenance Turn-Around Record Update Processing

9.23. Buildup Items

9.24. DR Exhibits

9.25. Destruction of TOP SECRET Material

9.26. Certifying Items Associated With Explosives

Chapter 10—MUNITIONS POLICY AND WEAPONS LOAD CREW PROGRAM 155

10.1. AF Munitions Policy

10.2. Unit Committed Munitions List (UCML), Test/Training Munitions List

(TTML)

10.3. Weapons Load Crew Training Program (WLCTP)

10.4. Loading Standardization Crew (LSC)

10.5. Weapons Academic Instructor

10.6. Squadron Lead Crews

10.7. Training Facilities/Aircraft

10.8. Weapons Academics

10.9. Practical Training

10.10. Task Assignment List

10.11. Munitions Aircraft Loading Certification/Decertification

10.12. Proficiency Review Period

10.13. Minimum Required Proficiency Load

10.14. Load Crew Semi-Annual Evaluations (SAE)

10.15. Documenting Load Crew Certification/Decertification/Qualification

10.16. Weapons Task Qualification

10.17. Munitions Load Time Standards

Table 10.1. Fighter Aircraft Munitions Family Group and Munition Load Time Standards (in minutes)

Table 10.2. Bomber Aircraft Munitions Family Group and Munition Load Time Standards

Table 10.3. Remote Piloted/Special Mission Aircraft Munitions Family Group and Munition Load Time Standards

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Chapter 11—ADDITIONAL MAINTENANCE REQUIRMENTS AND PROGRAMS 174

11.1. Facility Housekeeping and Contamination Control

11.2. Personal Wireless Communications Systems Management

11.3. MAJCOM/ANG Special Certification Rosters (SCR)

Table 11.1. Mandatory Special Certification Roster and Prerequisites

11.4. Aircraft Grounding

11.5. Ramp Inspection Program

11.6. Red Ball Maintenance

11.7. Maintenance Recovery Team:

11.8. Foreign Object Damage (FOD) Prevention Program

11.9. Dropped Object Prevention (DOP) Program

11.10. Aircraft Structural Integrity Program (ASIP)

11.11. Identification Friend or Foe (IFF) Program

11.12. Radar Warning Receiver/Radar Threat Warning Testing

11.13. Cannibalization Program

11.14. Hangar Queen Aircraft

11.15. Ground Instructional Trainer Aircraft (GITA)

11.16. Aircraft Inlet/Intake/Exhaust Certification

11.17. Engine Run Training and Certification Program

11.18. Engine Blade Blending Training and Certification Program

11.19. Engine Flexible Borescope Inspection Training and Certification Program

11.20. Flying Crew Chief (FCC) Program

11.21. Maintenance of Flash Blindness Protective Devices

11.22. WRM External Nestable Fuel Tank Build-Up

11.23. Protective Aircraft Shelters (PAS)

11.24. Combat Sortie Generation

11.25. Hot Refueling Procedures

11.26. Aircraft Rapid/Hot Defueling

11.27. 406 MHz Emergency Locator Transmitter Systems Program

AFI21-101 16 JANUARY 2020 9

11.28. Crashed, Damaged or Disabled Aircraft Recovery (CDDAR) Program

11.29. Aircraft Battle Damage Repair (ABDR)

11.30. Egress/Cockpit Familiarization Training

11.31. Aircraft Defensive Systems Loading Program

11.32. Aircraft and Equipment Decontamination

11.33. End-of-Runway (EOR) Inspection

11.34. Wing Avionics Manager (WAM)

11.35. Fire Extinguisher Requirements

11.36. Air Force Repair Enhancement Program (AFREP)

11.37. Calibration Limitation Approval Certification Program

11.38. Oil Analysis Program (OAP)

11.39. Air Force Engineering and Technical Services (AFETS)

11.40. Senior Leader Mission Generation (SLMG) Course

Chapter 12—MAINTAINING COMMERCIAL DERIVATIVE AIRCRAFT (CDA). 246

12.1. Background Information, Objective and Roles and Responsibilities

12.2. AF/A4L will:

12.3. The Program Manager (PM) will:

12.4. Lead Commands will:

12.5. Units will:

12.6. Maintenance Personnel Requirements

12.7. Deviations/Changes to Inspection Requirements, Time Change Intervals, and Component/Aircraft Overhaul

12.8. Air Force Modifications to CDA and Components

12.9. Certification Basis for CDA

Chapter 13—CENTRALIZED REPAIR FACILITIES (CRF). 249

13.1. Introduction

13.2. Organization

13.3. CRF Production Requirements

13.4. MGN Support

10 AFI21-101 16 JANUARY 2020

13.5. CRF Enterprise Information Management

13.6. Documentation

13.7. Metrics

Chapter 14—MAINTENANCE PLANS, SCHEDULING AND DOCUMENTATION

(PS&D). 251

14.1. Responsibilities:

14.2. Data Documentation

14.3. Configuration, TCTO, SI and TCI Management

14.4. ENGINE MANAGEMENT (EM)

14.5. Maintenance and FHP Planning Cycle

14.6. Contingency and Expeditionary Responsibilities

Chapter 15—AIRCRAFT SUN SHADE SUSTAINMENT 287

15.1. Purpose:

15.2. Scope:

15.3. Definitions

15.4. Headquarters Air Force

15.5. MAJCOM A4s will:

15.6. Owning Organization

15.7. New Procurements

15.8. Design Criteria/Standards of New or Replacement Aircraft Sun Shades

15.9. Current Aircraft Sun Shades

15.10. Sustainment and Accountability

15.11. Allied Support (Electricity, Water, Communications, Lighting)

15.12. Crew Shelters and Portable/Inflatable Shelters

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 299

Attachment 2—AIRCRAFT COMMANDER FEEDBACK ON FCC 331

Attachment 3—QUARTERLY FCC REPORT FORMAT 332

Attachment 4—ANNUAL FCC REPORT 333

Attachment 5—FCC SDAP REQUEST 334

AFI21-101 16 JANUARY 2020 11

Attachment 6—FOREIGN OBJECT DAMAGE (FOD) REPORT 335

Attachment 7—CRITICAL APPLICATION ITEMS & CRITICAL SAFETY ITEMS 336

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Chapter 1

MANAGEMENT OVERVIEW, SUPPORTING CONCEPTS AND REQUIREMENTS.

1.1. Introduction. This instruction prescribes basic aircraft and equipment maintenance management policy implementation and procedures used throughout the United States Air Force (USAF) to perform Mission Generation (MG) functions.

1.2. Organization. AF organizations are structured according to AFI 38-101, Air Force Organization, or as authorized by the Director of Manpower, Organization & Resources (AF/A1M). Contracted maintenance functions are not required to organize IAW AFI 38-101, but will implement the organization as outlined in their proposal as accepted by the government. For the definition of “Lead Command” see AFPD 10-9, Lead Command Designation and Responsibilities for Weapon Systems.

1.3. Maintenance Concept. Per AFPD 21-1, organizational, intermediate and depot maintenance capabilities for operational readiness shall be maintained to ensure effective and timely response to peacetime operations, mobilizations, national defense contingencies and other emergencies. Note: Guidance for the use of Additive Manufacturing to build replacement parts is prescribed in AFI 63-101/20-101, Integrated Life Cycle Management.

1.3.1. As a minimum each capability will be able to:

1.3.1.1. Organizational: launch and recover sorties, maintain and repair materiel coded for organizational level repair.

1.3.1.2. Intermediate: repair materiel coded for organizational and intermediate level repair in back shops, centralized repair facilities, or both.

1.3.1.3. Depot-level Maintenance: Provides the capability to maintain materiel coded for organizational, intermediate and depot levels of maintenance. Includes maintenance requiring the overhaul, upgrading, or rebuilding of parts, assemblies, or subassemblies, and the testing and reclamation of equipment as necessary.

1.3.2. Organizational and intermediate-level maintenance is organized into two mutually exclusive networks, the Mission Generation Network (MGN) and the Repair Network (RN).

The MGN is optimized for mission generation at the wing level and consists of authorized “on- equipment” and “off-equipment” maintenance capabilities required to launch, recover, configure, inspect and repair AF systems and equipment. The RN supports the MGN by providing the maintenance required to fulfill operational needs outside the capability or capacity of MGN activities. The interface between the two networks takes place when the MGN activity relinquishes control of reparable assets to the RN activity (such as, supply counter turn-in) or changing an end item Purpose Identifier Code (PIC) from an operational activity to a repair network activity (such as, depot maintenance).

1.3.2.1. Most MGN units possess a complement of equipment and supplies necessary to perform on-equipment and off-equipment maintenance.

1.3.2.2. RN units may reside at bases that perform mission generation. RN requirements and processes are identified in AFI 20-117, Repair Network Management.

AFI21-101 16 JANUARY 2020 13

1.3.3. MAJCOMs assigned combat coded fighter aircraft will coordinate with Mission Design Series (MDS) lead and using commands and the MAJCOM Operations Directorate (MAJCOM/A3) to develop and document standardized MDS and Primary Aerospace Vehicle (Aircraft) Authorized (PAA) specific utilization rate standards in their supplements to this instruction. At a minimum the rates will:

1.3.3.1. Consider aggregated and analyzed unit generation capability data to identify and document standard MDS turn patterns by PAA in their supplements to Chapter 14 of this instruction.

1.3.3.2. Account for standard avionics and weapons training configurations.

1.3.3.3. Account for standard Technical Order (TO) driven turn time inspections and Average Sortie Duration.

1.3.3.4. Include a process for supporting units in assessing shortfalls and developing action plans.

1.3.4. Requests for Assistance. If a maintenance activity requires assistance for evaluation, repair, or both, beyond unit capability, requests are made IAW AFI 21-103, Equipment Inventory, Status and Utilization Reporting; TO 00-25-107, Maintenance Assistance; and TO 00-20-14, AF Metrology and Calibration Program, or automated process as approved by the MDS Program Manager (PM) (for example, C-130 Automated Inspection, Repair, Corrosion and Aircraft Tracking (AIRCAT), F-16 Technical Assistance Request). All requests for assistance must be coordinated through the originating MAJCOM and Lead Command as applicable. (T-2)

1.4. Aircraft Maintenance Tactics, Techniques and Procedures (TTP). TTPs are developed from lessons learned and best practices that provide valuable reference documents to improve maintenance processes and procedures. Maintenance leaders should utilize the maintenance fundamentals TTP volumes (Aircraft, Munitions and Missile) to effectively and efficiently support mission generation. Maintainers who attend the USAF Advanced Maintenance and Munitions Operations School are trained in advanced operational, expeditionary and tactical maintenance management concepts stemming from the alumni’s development and formalization of TTPs. Maintenance Group Commander (MXG/CC) should identify their Advanced Maintenance and Munitions Operations School graduates and utilize them as advisors and instructors to enhance mission capability. AFTTP 3-4.21V1, Aircraft Maintenance, can be found at: https://cs2.eis.af.mil/sites/10070/Documents/AFTTP3-4.21V1ACMX.pdf. For additional information on Advanced Maintenance and Munitions Operations School and TTP development see Air Force Manual (AFMAN) 21-111, Advanced Maintenance and Munitions Operations School.

1.5. Aircraft and Equipment Readiness. Aircraft and equipment readiness is the maintenance mission. The maintenance function ensures assigned aircraft and equipment are safe, serviceable, and properly configured to meet mission needs. Maintenance actions include, but are not limited to, inspection, repair, overhaul, modification, preservation, refurbishment, troubleshooting, testing, analyzing condition, performance and maintenance documentation. All levels of supervision need to place emphasis on safety, quality, and timeliness in the performance of maintenance. The concept of quality maintenance must be fostered by each supervisor and technician to ensure the integrity and skill of each maintainer is not degraded. To the greatest https://cs2.eis.af.mil/sites/10070/Documents/AFTTP3-4.21V1ACMX.pdf

14 AFI21-101 16 JANUARY 2020

extent possible, maintenance is accomplished on a preplanned scheduled basis. Planning provides the most effective and efficient use of people, facilities, and equipment, reduces unscheduled maintenance, and allows for progressive actions toward maintaining and returning aircraft and equipment to safe operating condition. Exploiting repair network capability and maintaining visibility of repair cycle assets throughout the maintenance cycle are also critical elements of the equipment maintenance program.

1.5.1. Preventive Maintenance. AF units implement and manage the tasks specified in the scheduled recurring maintenance program for their assigned aircraft and associated support equipment (SE). Preventive maintenance is achieved through the inspection requirement concepts described in TO 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policy, and Procedures, and applicable weapon system -6 TO

1.5.2. MAJCOMs that conduct Mission Generation Assessments or similar weapon system logistic evaluations in order to validate unit readiness will:

1.5.2.1. Provide units a standardized assessment report containing, at a minimum, positive, negative and areas for improvement feedback to facilitate crosstell to like units.

1.5.2.1.1. Analyze unit generation processes to capture and communicate best practices.

1.5.2.1.2. Analyze unit generation performance to identify and communicate noteworthy trends.

1.5.2.2. Directorates of Logistics, Engineering & Force Protection (MAJCOMs A4s) will semi-annually report their top three trends and causal factors to the Logistics Board to facilitate debate to identify and mitigate potential limiting factors. Submit MAJCOM top three trends to the AF/A4LX workflow no later than 30 days prior to each Logistics Board meeting for consolidation at: usaf.pentagon.af-a4.mbx.a4-elg-workflow@mail.mil.

1.6. Maintenance Discipline. It is the responsibility of all maintenance personnel to comply with all written guidance to ensure required repairs, inspections, and documentation are completed in a compliant, safe, timely, and effective manner. Supervisors are responsible for enforcing and establishing a climate that promotes maintenance and supply discipline. Unless expressly stated otherwise in a particular instruction, waiver, or deviation in this AFI granted by the appropriate authority, all Airmen must follow AFIs. (T-1) AFIs do not provide optional guidance, and failure to comply with AFIs can result in disciplinary action as described in AFI 1- 1, Air Force Standards. Civilian personnel who violate punitive publications may also be subject to disciplinary action. See AFI 33-360 for more detailed information on the use of punitive language in publications.

1.6.1. Compliance Terminology. For the purposes of this instruction, the following definitions apply:

1.6.1.1. Shall, Must, Will - Indicates mandatory requirements. Note: “Will” is also used to express a declaration of purpose for a future event.

1.6.1.2. Should - Indicates a preferred method of accomplishment.

1.6.1.3. May - Indicates an acceptable or suggested means of accomplishment.

mailto:usaf.pentagon.af-a4.mbx.a4-elg-workflow@mail.mil mailto:usaf.pentagon.af-a4.mbx.a4-elg-workflow@mail.mil

AFI21-101 16 JANUARY 2020 15

1.6.2. Use of TOs and TO Supplements. All personnel will enforce compliance with technical data. (T-1) Use of prescribed technical data to maintain aircraft and equipment is mandatory and will be conducted and managed IAW TO 00-5-1, Air Force Technical Order System. (T-1)

1.6.3. AFTO Form 492, Maintenance Warning Tag. The Air Force Technical Order (AFTO) Form 492, Maintenance Warning Tag, is used as prescribed in technical data, local procedures, or both, to flag a condition that could cause damage or injury if ignored. Refer to TO 00-20-1 for additional guidance. Note: The AFTO Form 492 is replacing the AF Form 1492, Warning Tag referenced in AFMAN 91-203, Air Force Occupational Safety, Fire, and Health Standards. Use of the AF Form 1492 is authorized until supplies are exhausted.

1.7. Communications Security (COMSEC)/Controlled Cryptographic Item (CCI) Accountability. The Air Force COMSEC/Central CCI Authority is the Cryptologic and Cyber Systems Division, Joint Base San Antonio-Lackland, Texas.

1.7.1. Installed COMSEC/CCI accountability will be accomplished IAW AFMAN 17-1302- O, Communications Security (COMSEC) Operations and AFI 23-101, Air Force Material Management. (T-1) Ensure all serially controlled and serially tracked COMSEC/CCI information is entered into the Maintenance Information System (MIS) IAW TO 00-20-2, Maintenance Data Documentation. (T-1)

1.7.1.1. Maintain serial number inventory accountability for all COMSEC/CCI issued or removed to Facilitate Other Maintenance (FOM) in Tail Number Bin (TNB) IAW Paragraph 9.19 Tail Number Bins of this instruction.

1.7.1.2. Questions concerning COMSEC/CCI accountability can be directed to the Cryptologic and Cyber Systems Division’s COMSEC Policy Office Air Force Life Cycle Management Center (AFLCMC/HNCLS).

1.7.2. Maintenance Cybersecurity Discipline.

1.7.2.1. Maintaining positive maintenance cyber discipline practices of Department of Defense (DoD) Information Technology (IT) is critical to sustaining the mission.

Department of Defense Instruction (DoDI) 8500.01, Cybersecurity, defines both hardware and software that is physically part of, dedicated to, or essential in real-time to the mission assurance of special purpose weapon systems. DoD IT is the most common IT encountered in flightline environments, and includes (but is not limited to) electronic tools (eTools), aircraft and associated support equipment. The culture of positive cybersecurity awareness and actions necessary to sustain cyber resiliency is required by all maintenance personnel to mitigate allusive cyber threats and optimize enduring mission generation capabilities.

1.7.2.1.1. All users perform an integral role in prevention, detection, and reporting suspected corrupted software of DoD IT which includes Information Systems (IS) and Platform Information Technology (PIT), which is an electronic platform with information technology for a specific function. See Table 1.1

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Table 1.1. Tiered Interface Examples.

TIER Type of Interface Examples Applicable TOs

1 On-Board EC-130, XX-135, E-3, E-8 Device TO 2 Directly Connected F-22 PMA, F-35 PMA, Viper

MLV, CAPRE, CETS, DTADS

Device TO

3 Indirectly Connected Test Eqpt., Support Eqpt., ATS, ATE, AIS, VDATS

TO 33-1-38

4 Not Connected eTools TO 00-5-1

1.7.2.1.1.1. All users must consult airframe Security Classification Guides, TO 33- 1-38, Cybersecurity for Automatic Test Equipment and Support Test Equipment (ATE/STE). TO 33-1-38 provides guidance for Cybersecurity Incident Reporting and refers users to applicable technical manuals, instructions and publications when determining the classification of cybersecurity incidents and vulnerability documents. (T-1)

1.7.2.1.2. Authorized and unauthorized uses of IT and PIT. All users must have the ability to distinguish between authorized and unauthorized uses. (T-1)

1.7.2.1.2.1. Authorized uses must be vetted through a formal cybersecurity assessment process and be directed in specific TO guidance. (T-1) The governing TOs or equivalent publications specifically define authorized uses.

1.7.2.1.2.2. Unauthorized uses include: connecting any hardware, uploading or downloading software, or media not explicitly defined by TOs. This includes but is not limited to: personal devices, phones, tablets, computers, Universal Serial Bus drives, and similar devices.

1.7.2.1.2.3. DoD IT, derivative AF Publications, and TOs provide users guidance on Automated Computer Program Identification Number System devices acquired from local Communications Squadrons and media obtained from DoD contractors.

1.7.2.1.2.4. All users will follow the applicable TO when directly or indirectly connecting computers and equipment to the aircraft or support equipment, and when uploading or downloading data. (T-1)

1.7.2.1.2.5. All users will immediately discontinue use, report, and turn into the appropriate functional authority IT and PIT (WAM, Wing Cybersecurity Office, and the Mission Defense Teams/Cyber Squadron, if assigned) that are suspect for containing malicious software, malicious code, software bugs or unauthorized use. (T-1)

1.7.2.1.2.6. All users will complete Maintenance Cyber Discipline Training annually in Advanced Distributed Learning Service (ADLS) or equivalent training method. (T-1)

1.7.2.1.3. MDS Lead Commands in coordination with the applicable PM will develop MDS and Support Equipment (SE) cyber threat mitigation methods and

AFI21-101 16 JANUARY 2020 17

procedures for Organizational and Intermediate level maintenance activities. The methods and procedures must detect malicious code, report cyber incidence and issues, and remediate the incidence and issue affecting the MDS or SE. Note:

Mitigation plan should be developed per DoDI 8500.01; TO 33-1-38, DoD 8570.01M, Information Assurance Workforce Improvement Program; Military Standard (MIL-STD)-38784A, General Style and Format Requirements For Technical Manuals; 17- series AFIs.

1.7.2.1.3.1. The cyber threat mitigation methods must include MDS and SE specific training requirements. (T-1) Note: Training requirements could include training aids, for example, computer-based training on how the flightline maintainer should scan support equipment for malicious software.

1.7.2.1.3.2. Lead Commands must ensure current MDS and SE specific malicious code definitions are available to ensure positive cyber threat mitigation management support is available. (T-1)

1.7.2.1.3.2.1. MAJCOM and ANG will report system-specific cyber incidents to the applicable MDS Lead Command.

1.7.2.1.3.2.2. MAJCOM and ANG will follow airframe Security

Classification Guides, TOs, and applicable technical manuals when providing “cross tell” to inform their subordinate units about system-specific cyber incidents, threats, and issues.

1.7.3. eTools.

1.7.3.1. eTools are portable electronic devices (such as laptop computer, handheld device) that operate in a disconnected mode and, are certified to inter-operate on AF networks. eTools are mission critical; the primary purpose is for viewing electronic technical publications and in some cases are used to exchange maintenance data with approved MIS at the point of maintenance. eTools are procured IAW AFMAN 17-1203, Information Technology (IT) Asset Management (ITAM). Note: eTools do not include electronic devices and test equipment issued and configuration managed by a system PM (aircraft test and support equipment).

1.7.3.2. MAJCOM/ANG A4s, will develop and implement standardized guidance on the management, use, storage, configuration, content update, security and cyber hygiene processes necessary to support the approved use of all assigned eTools consistent and IAW the weapon system MDS specific technical orders and threat specific Air Force and DoD cyber publications.

1.7.3.3. The MAJCOM/ANG A4 guidance will include any assigned command-wide cyber threat awareness and mitigation strategies with reference to supporting publications, technical orders, and MAJCOM eTool OPR contact information in their supplement or addendum to this AFI.

1.8. Environmental Compliance. It is the responsibility of all maintenance personnel to comply with all written guidance to ensure compliance with hazardous material, hazardous waste management and air emissions record keeping as required for environmental compliance IAW AFI 90-821, Hazard Communication (HAZCOM) Program, installation Environment, Safety, 18 AFI21-101 16 JANUARY 2020 and Occupational Health Management System/Environment Management System (ESOHMS/EMS) policy/guidance and applicable environmental requirements and guidance. (T- 1)

1.9. Publications. Units may tailor procedures to the unique aspects of their own maintenance operation and publish directives, instructions, supplements, addendums, and, for functional areas, Operating Instructions (OI) IAW AFI 33-360.

1.9.1. Develop, control, and maintain functional and emergency action checklists. At a minimum, each checklist is titled, dated and coordinated with the wing safety office.

Functional checklists are not to be used in place of or to circumvent technical data for operation, servicing, inspection or maintenance of aircraft, aircraft systems, munitions, and all other equipment supporting aircraft and munitions maintenance.

1.9.2. Methods and Procedures Technical Orders (MPTOs): Due to the close relationship between MPTOs and this AFI, all changes and revisions to the MPTOs cited in Attachment 1, References of this AFI will be routed from Air Force Material Command (AFMC) to AF/A4LM for content review for conflicts and policy gaps identification and mitigation prior to submission for publication.

1.10. Maintenance Training. Maintenance training provides initial, recurring and advanced proficiency, qualification, or certification skills needed by a technician to perform duties in their primary Air Force Specialty Code (AFSC), Civilian Job Series, or equivalent. Maintenance training includes combat and sortie generation skills not normally integrated into peacetime operations (such as, munitions handling, and external fuel tank build-up, hot refueling).

Maintenance training carries an equal priority with the operational training mission. For maintenance training policy and guidance, refer to AFI 36-2650, Maintenance Training and MAJCOM supplements.

1.11. Modification Management. A modification proposal is a recommendation to change the operation, use, or appearance of AF equipment. Modifications (temporary, permanent, or safety) to AF aircraft or equipment are expressly prohibited without PM approval. Note: PM is used in this publication as defined in AFPD 63-1, Integrated Life Cycle Management. Refer to AFI 63- 101/20-101, for modification management procedures.

1.11.1. Modifications to Munitions. All proposed modifications to aircraft-carried munitions include AFI 63-101/20-101 and SEEK EAGLE certification IAW AFI 63-101/20-101and Air Force Pamphlet (AFPAM) 63-129, Air System Development Process and Procedures. All modifications to AF nuclear munitions or their associated support and training equipment are nuclear certified IAW AFI 91-103, Air Force Nuclear Safety Design Certification Program and AFI 63-125, Nuclear Certification Program. All modifications to AF conventional munitions or their associated support and training equipment are certified IAW AFI 91-205, Non-Nuclear Munitions Safety Board.

1.12. Maintenance Information Systems (MIS). MIS refers to automated maintenance information systems that support and enable maintenance business processes. MIS is used to document maintenance actions and track fleet health. The information entered into the MIS is accomplished IAW TO 00-20-2 and matches the content of the aircraft forms. MIS data entries do not have to be accomplished by the same individual who documented the aircraft forms, but employee numbers, man numbers, and User IDs of individuals accomplishing the actual work

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are entered into the MIS. Red Ball maintenance is documented IAW Chapter 11 of this instruction. Data integrity is the responsibility of every member of the unit. All personnel are responsible for ensuring accuracy and completeness.

1.12.1. Units use the approved MIS for their assigned weapon system.

1.12.2. Serial numbers will be documented in the MIS for all serially-controlled and tracked assemblies that are identified by an asterisk in the Work Unit Code (WUC) or Logistics Control Number (LCN) manual IAW TO 00-20-2.

1.13. General Safety Guidance. Maintenance personnel are exposed to a large variety of hazardous situations, machinery, equipment, and chemicals. Most hazardous situations can be avoided by following approved procedures, asking for assistance when needed, and using all required personal protective equipment (PPE).

1.13.1. Safety “Knock It Off” and Risk Management. Due to the inherent danger to life, limb, and property associated with maintenance operations, personnel are empowered to terminate an operation or situation which they perceive is unsafe or too dangerous. When supervisors or crew leaders become task-focused, junior personnel are often better able to assess the danger; however, deferring to the experience and judgment of the supervisor or crew leader, they may choose to remain silent, missing an opportunity to break the mishap sequence chain. Maintenance commanders and supervisors are responsible for fostering a culture in their units so that a simple, but recognizable “audible” from anyone can prevent a potential mishap. Note: See AFI 90-802, Risk Management, and AFPAM 90-803, Risk Management (RM) Guidelines and Tools for additional information.

1.13.2. Visitors. Unit Commanders shall not permit visitors to operate any AF equipment unless they are qualified to operate such equipment and are doing so in the performance of their assigned official duties. (T-1) Visitors will not be allowed in the flightline area if munitions operations are present IAW AFMAN 91-201, Explosive Safety Standards. (T-1)

1.14. Duty Shifts and Rest Periods. MXG/CC or equivalent will establish minimum requirements that ensure units (home station or deployed) maintain an equitable distribution of supervision (Officer and Senior Non-Commissioned Officer (SNCO)) across all on-duty shifts in their supplement to this AFI. (T-2)

1.14.1. During normal operations, maintenance personnel are scheduled for duty based on a 40-hour work week. Maintenance personnel duty hours are aligned to provide optimal mission support.

1.14.2. Personnel will not be scheduled for more than 12 hours of continuous duty time. (T-

1) Duty time begins when personnel report for duty and ends when their supervisor releases them. Time spent in exercise or contingency deployment processing lines and in-transit counts toward the total duty day. Exception: MXG/CCs are the final approval authority for duty time extensions exceeding the 12-hour limit up to a maximum of 16 hours. Note:

Aircraft or detachment commanders assume this responsibility in Temporary Duty (TDY)/travel status.

1.14.3. Commanders and supervisors will provide a rest period after each shift. (T-1) A rest period is a block of time that gives a person the opportunity for 8 hours of uninterrupted

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sleep in a 24-hour period. Note: This rest period also applies during exercises or inspections.

1.14.4. Personnel will not handle, load or perform maintenance on nuclear weapons, conventional munitions, or egress explosives beyond a 12-hour continuous duty period. (T-1) This requirement may not be waived for exercises or inspections; however, the 12-hour continuous duty period may be exceeded for shift turnover or administrative actions only and will be avoided to the maximum extent possible. The MXG/CC or equivalent may waive this requirement during advance defense readiness conditions, actual emergencies as defined in DoD Directive 3150.02, Department of Defense Nuclear Weapons Surety Program, or to resolve an unexpected event (such as disabled vehicle, Weapons Storage and Security System fault, hoist failure).

1.14.5. In alert force or standby duty situations where facilities are available for resting, established norms may be exceeded. Adjust rest periods to allow for 8 hours of uninterrupted sleep.

1.14.6. Commanders and supervisors will ensure individuals are afforded adequate duty rest periods and breaks to prevent fatigue or thermal injury. (T-1) Stop anyone if fatigue may jeopardize safety. In all cases, aircraft commanders or supervisors ensure aircraft maintenance personnel are not required to perform duty when they have reached the point of physical or mental fatigue rendering them incapable of performing their assigned duties safely and reliably.

1.14.7. MAJCOM Commanders will assume the risk for any Flying Crew Chief (FCC) deviations from normal duty shifts, rest periods, and exceedance of the 16-hour maximum duty day. MAJCOM Commanders will publish risk-mitigation procedures in order to meet critical mission requirements.

1.15. Communications. Commanders shall develop communication plans according to AF mission requirements. (T-2) See Chapter 11 for detailed communication requirements.

1.15.1. Effective maintenance accomplishment requires the ability to efficiently and effectively communicate across all facets of the maintenance operation. Communication technology (government issued Portable Electronic Devices (PED), Portable Maintenance Aid (PMA), radios, cell phones, computers, wireless internet) must be available to expedite personnel, equipment, material, and maintenance data throughout the maintenance complex.

(T-2)

1.15.2. MAJCOMs will publish guidance for the use and control of personal communications devices (personal cell phones, tablets and computers) on the flightline, in munitions areas, hangars, and other industrial work areas as required to mitigate cyber risk and ensure compliance with cyber and communication AFI requirements relevant to their operational environments.

1.15.3. Unit Commanders will enforce procedures that prohibit the introduction of government or personal cellular, personal communications system, Radio Frequency (RF), Infrared (IR) wireless devices, and other devices such as cell phones and tablets, and devices that have photographic or audio recording capabilities into areas (for example, rooms, offices) where classified information is stored, processed, or discussed IAW AFMAN 17- 1301, Computer Security (COMPUSEC). (T-1) Coordinate waiver requests with the

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applicable Approving Official (AO), and ensure adherence to Certified TEMPEST Technical Authority (CTTA) requirements IAW Department of Defense Directive (DoDD) 8100.02, Use of Commercial Wireless Devices, Services, and Technologies in the DoD Global Information Grid (GIG) written approval by the AF CTTA IAW AFI 16-1404, Air Force Information Security Program, NIST SP 800-53A Revision 4, Assessing Security and Privacy Controls in Federal Information Systems and Organizations: Building Effective Security Assessment Plans, and the Enterprise Authorizing Official (AO) IAW AFI 31-101, Integrated Defense (ID) and AFMAN 17-1301. (T-1)

1.16. Maintenance Repair Priorities. Maintenance repair priorities are listed in Table 1.2 This does not prohibit the Production Superintendent (Pro Super), in coordination with the Maintenance Operations Center (MOC), from changing the maintenance repair priority when warranted. During tasked Operational Plan (OPLAN) or operational exercise, the pre-planned maintenance flow determines the job sequence. The maintenance repair priority and the Logistics Readiness Squadron (LRS) delivery priorities (listed in Air Force Handbook (AFH 23-123V, Materiel Management Reference Information) are normally identical. Raising or lowering maintenance repair priorities does not necessarily require a corresponding change in the LRS delivery priority. However, the Pro Super may authorize the use of a less responsive LRS delivery priority.

Table 1.2. Maintenance Repair Priority Designators.

PRIORITY APPLICATION

1 Aircraft on alert status, war plan or national emergency missions, including related Aerospace Ground Equipment (AGE), munitions and Munitions Support Equipment.

2 Primary mission aircraft, related AGE, munitions, and munitions support equipment, for the first 8 work hours after landing or start of recovery or within 6 work hours of a scheduled launch, alert or test flight and during simulated generation or Operational Readiness Exercises (ORE). Air evacuation, rescue, weather (WX) mission aircraft, related AGE, munitions, and munitions support equipment.

All transient support, and FAA aircraft. Flight or missile crew training simulator, other training equipment or related AGE required repair, which is impacting the mission by preventing or delaying student training.

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Primary mission aircraft, engines, air launched missiles and related AGE, munitions and munitions equipment, and equipment undergoing scheduled or unscheduled maintenance, if not performed or repaired will prevent or delay mission accomplishment. Transient air vehicles not otherwise listed.

Administrative aircraft within 8 hours of scheduled flight or on alert status with standby crews.

Time change requirements for nuclear weapons.

Repair cycle assets to satisfy a Mission Impaired Capability Awaiting Parts (MICAP) condition. Spares not available in supply.

Critical end items and spares not available in supply.

Routine maintenance of aircrew or missile-training simulator, or other training devices or related AGE or sites and aircraft or equipment used for maintenance training.

Avionics shop electronic AGE and automated test stations.

Routine or extensive repair of primary air mission and related AGE and repair cycle assets.

Administrative aircraft undergoing scheduled or unscheduled maintenance.

Routine maintenance of AGE, not otherwise listed above.

War Reserve Materiel (WRM) items due maintenance or inspection.

Inspection, maintenance, and Time Compliance Technical Order (TCTO) compliance of Mission Support Kit or Mobility Readiness Spares Package (MRSP) materiel.

Extensive repair of aircrew or missile training simulators, other training devices, or related AGE.

Inspection, maintenance, and TCTO compliance of munitions and munitions equipment, excluding spares excess to base requirements not listed above.

Scheduled calibration and unscheduled repairs on Precision Measurement Equipment (PME) not listed above.

Scheduled maintenance to include periodic inspections, routine TCTO, Master Configuration Lists (MCL) Grounding, and Time Change Items (TCIs).

Primary mission Comprehensive Engine Management System (CEMS) or equipment including associated AGE undergoing extensive repair or modification.

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5 Non-tactical or non-primary-mission aircraft undergoing extensive repair.

Fabrication and repair of aeronautical items not carrying a higher priority.

Bench stock requirements.

Extensive repair of aircrew training devices.

Time change requirements not listed above.

Routine repair of AGE and repair cycle assets.

Alternate and other CEMS or equipment, including associated AGE undergoing extensive repair or modification.

Clearing routine delayed discrepancies on training equipment or AGE, and routine maintenance which will not impair or affect mission accomplishment.

Equipment requirements.

6 Fabrication and repair of non-aeronautical items.

Repair cycle asset shortages required to fill a peacetime operating stock authorization

7 Spares/repair cycle assets excess to base requirements.

1.17. Associate Unit Program/Total Force Integration (TFI) The USAF employs the Associate Unit/TFI program in some locations where RegAF and Air Reserve Component (ARC) units are collocated and share aircraft, equipment, facilities, and other resources IAW AFI 90- 1001, Planning Total Force Associations (TFAS), and MAJCOM supplements. For the purpose of this instruction, in an Active Association, the ANG or AFR owns the aircraft, and RegAF personnel will follow ANG or AFR maintenance policy. (T-1) In an ARC association, AFR owns the aircraft, and ANG personnel will follow AFR guidance, or vice versa. (T-1) In a classic association, RegAF owns the aircraft, and ANG or AFR personnel will follow RegAF maintenance policy. (T-1) Type of association is determined by the Program of Record for the associated unit.

1.18. Performance-Based Activities. MAJCOMs may publish the basic responsibilities for managing performance-based activities.

1.18.1. If published MAJCOMs will:

1.18.1.1. Designate focal points for organizational, functional, and technical questions pertaining to each performance-based activity program.

1.18.1.2. Specify measurement areas and performance levels required for aircraft, systems, and equipment operated or maintained by performance-based activities.

1.18.1.3. Specify the forms, methods of documentation, and frequency of reporting used to assess performance-based activities and ensures these requirements are included in the Quality Assurance Surveillance Plan (QASP).

1.18.1.4. Ensure units with assigned Contracting Officer Representative personnel meet requirements in AFI 63-138, Acquisition of Services.

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1.18.1.5. Ensure aircraft depot maintenance contracts, Statements of Work (SOW), and Performance Work Statements (PWS) are coordinated with the applicable MAJCOM Functional, to include Munitions.

1.18.2. Unit Commanders will:

1.18.2.1. Designate a focal point for all functional, technical, and contracting officer representative matters pertaining to performance-based activities. (T-1)

1.18.2.2. In coordination with the contracting officer and the Program Manager of Functional Services Manager, provide specific guidance to the performance-based activity to ensure proper maintenance discipline and flight worthiness of aircraft and subsystems. (T-2)

1.18.2.3. Develop and publish contingency procedures for support of continuing operations in the event of disruption, termination, or default of contracts. (T-1)

1.19. Changes to Technical Orders. Official TO updates are the only valid authority for maintaining TO accuracy and currency. To maintain this currency, the AF has instituted an enterprise electronic TO Recommended Change (RC) process.

1.1…