00-35D-54.pdf

TO 00-35D-54

TECHNICAL MANUAL

USAF DEFICIENCY REPORTING, INVESTIGATION, AND

RESOLUTION

(ATOS)

THIS PUBLICATION SUPERSEDES TO 00-35D-54, DATED 1 APRIL 2001 AND ALL SUBSEQUENT CHANGES.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. PA Case Number AFMC 04-334. Submit recommended changes or problems with this Technical Order to 448 MSUG/GBMUH, Bldg 3001/1AC4106C, Tinker AFB OK 73145-3041.

Published under authority of the Secretary of the Air Force

1 JULY 2004 CHANGE 1 - 15 MARCH 2006

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands.

Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . . . .1 July 2004 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . 15 March 2006

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 130, CONSISTING OF THE FOLLOWING:

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A Change 1 USAF

TABLE OF CONTENTS

Chapter Page

1 REPORTING CRITERIA, SYSTEM DESCRIPTION, AND PROGRAM RESPONSIBILITIES..............................1-1

1.1 Authority ............................................................................................................................................................1-1

1.2 Scope and Intent ................................................................................................................................................1-1

1.3 Applicability ......................................................................................................................................................1-1

1.4 Methodology ......................................................................................................................................................1-2

1.5 Deficiency Reporting Criteria ...........................................................................................................................1-2

1.6 Deficiency Categorization and Prioritization....................................................................................................1-4

1.7 Key DRIS Responsibilities................................................................................................................................1-7

1.8 DRIS Database ................................................................................................................................................1-10

1.9 Performance Metrics and Compliance Checklists..........................................................................................1-10

1.10 Cross Component Reporting ...........................................................................................................................1-10

1.11 Government Industry Data Exchange Program (GIDEP) ..............................................................................1-11

1.12 Materiel Safety Program Manager (MSPM) ..................................................................................................1-11

1.13 The Air Force Working Capital Fund (AFWCF) ..........................................................................................1-11

1.14 Waiver of DRIS Database Requirements .......................................................................................................1-11

1.15 Recommending Improvements........................................................................................................................1-12

1.16 DRIS Advisory Council ..................................................................................................................................1-12

2 DEFICIENCY REPORTING DURING TEST AND EVALUATION .........................................................................2-1

2.1 Purpose...............................................................................................................................................................2-1

2.2 Scope..................................................................................................................................................................2-1

2.3 Deficiency Reporting and Investigating System (DRIS) Database .................................................................2-1

2.4 Criteria, Category and Priority..........................................................................................................................2-1

2.5 Watch Item (WIT) Process ...............................................................................................................................2-2

2.6 Originator Responsibilities ................................................................................................................................2-2

2.7 Originating Point Responsibilities ....................................................................................................................2-3

2.8 T&E Deficiency Review Board (DRB)............................................................................................................2-4

3 DEFICIENCY IDENTIFICATION AND REPORTING ...............................................................................................3-1

3.1 Purpose...............................................................................................................................................................3-1

3.2 Scope and Applicability ....................................................................................................................................3-1

3.3 Criteria, Category and Priority..........................................................................................................................3-1

3.4 Originator Responsibilities ................................................................................................................................3-1

3.5 Originating Point Responsibilities ....................................................................................................................3-3

3.6 Disputing DR Resolution Actions ....................................................................................................................3-6

3.7 Process Satisfaction Feedback ..........................................................................................................................3-7

4 DEFICIENCY REPORT PROCESSING, INVESTIGATION AND RESOLUTION ..................................................4-1

4.1 Purpose...............................................................................................................................................................4-1

4.2 Scope and Applicability ....................................................................................................................................4-1

4.3 DRIS Management ............................................................................................................................................4-1

4.4 DR Receipt, Assignment and Acknowledgement ............................................................................................4-3

4.5 Air Force Repair Enhancement Program (AFREP) and Lateral Support Deficiencies ..................................4-7

4.6 Warranty Manager Responsibilities ..................................................................................................................4-7

4.7 Deficiency Report Investigations, Exhibit Disposition, and Analysis.............................................................4-8

4.8 MIP Review Boards (MIPRB)........................................................................................................................4-11

4.9 Resolution of Disagreements ..........................................................................................................................4-12

4.10 DR Status, Resolution and Closing ................................................................................................................4-13

4.11 Credit Reversal Procedures .............................................................................................................................4-22

Change 1 i

5 TECHNICAL COORDINATION PROGRAM (TCP) AND INTERNATIONAL ENGINE MANAGE-

MENT PROGRAM (IEMP) PARTICIPANTS DEFICIENCY REPORTING AND INVESTIGATING

PROCEDURES ...........................................................................................................................................................5-1

5.1 Purpose...............................................................................................................................................................5-1

5.2 Scope and Applicability ....................................................................................................................................5-1

5.3 Security Classification.......................................................................................................................................5-2

5.4 Deficiency Reporting Criteria ...........................................................................................................................5-2

5.5 Deficiency Category and Priority .....................................................................................................................5-4

5.6 Key Responsibilities ..........................................................................................................................................5-6

5.7 Submitting Organization Tasks.........................................................................................................................5-6

5.8 Deficiency Report Processing, Investigation And Resolution .......................................................................5-15

5.9 DR/MIP Response/Resolution Performance...................................................................................................5-18

6 EXHIBIT HANDLING AND PROCESSING................................................................................................................6-1

6.1 Purpose...............................................................................................................................................................6-1

6.2 Applicability ......................................................................................................................................................6-1

6.3 Establishing the Exhibit Processing System.....................................................................................................6-1

6.4 Exhibit Control, Marking, and Handling..........................................................................................................6-1

6.5 Originator Exhibit Processing ...........................................................................................................................6-2

6.6 Originating Point Exhibit Processing................................................................................................................6-6

6.7 Exhibit Holding and Shipping Activity Processing - Base Level ...................................................................6-6

6.8 Action Point Exhibit Responsibilities...............................................................................................................6-8

6.9 ALC Receiving and Storage Activity Exhibit Processing .............................................................................6-10

6.10 Support Point Exhibit Processing ...................................................................................................................6-11

7 DELETED........................................................................................................................................................................7-1

8 AIR FORCE BAD ACTOR PROGRAM .......................................................................................................................8-1

8.1 Background ........................................................................................................................................................8-1

8.2 Selection Procedures..........................................................................................................................................8-1

8.3 Identification Procedures...................................................................................................................................8-1

8.4 Depot Maintenance Data Documentation Systems ..........................................................................................8-2

8.5 Accountability and/or Supply Procedures ........................................................................................................8-2

8.6 Screening Point..................................................................................................................................................8-2

8.7 Engineering Analysis Activity to Maintenance................................................................................................8-2

8.8 Engineering Failure Analysis Procedures.........................................................................................................8-2

8.9 Engineering Analysis Guidelines ......................................................................................................................8-3

9 ACCEPTANCE INSPECTION DEFICIENCY REPORT SUBMISSION, PROCESSING AND RESOLU-

TION............................................................................................................................................................................9-1

9.1 Purpose...............................................................................................................................................................9-1

9.2 Scope and Applicability ....................................................................................................................................9-1

9.3 Performing Acceptance Inspections..................................................................................................................9-1

9.4 Reporting Acceptance Inspection Results ........................................................................................................9-2

9.5 Resolving Acceptance Inspection Discrepancies..............................................................................................9-5

9.6 Final Resolution and AI Report Closing ..........................................................................................................9-6

A METRICS AND COMPLIANCE CHECKLISTS.........................................................................................................A-1

B MATERIEL CONDITION CODE Q............................................................................................................................. B-1

C ABBREVIATIONS AND DEFINITIONS .................................................................................................................... C-1

C.1 Abbreviations.................................................................................................................................................... C-1 ii Change 1

C.2 Definitions......................................................................................................................................................... C-7

D DELETED.......................................................................................................................................................................D-1

E DELETED....................................................................................................................................................................... E-1

F DELETED........................................................................................................................................................................F-1

G DELETED.......................................................................................................................................................................G-1

H DELETED.......................................................................................................................................................................H-1

I DELETED........................................................................................................................................................................ I-1

J DELETED........................................................................................................................................................................ J-1

K DELETED.......................................................................................................................................................................K-1

L DELETED....................................................................................................................................................................... L-1

M DELETED...................................................................................................................................................................... M-1

N DELETED.......................................................................................................................................................................N-1

O DELETED.......................................................................................................................................................................O-1

P DELETED........................................................................................................................................................................P-1

Q DELETED.......................................................................................................................................................................Q-1

R DELETED....................................................................................................................................................................... R-1

S DELETED........................................................................................................................................................................S-1

LIST OF ILLUSTRATIONS

Number Title Page

2-1 T&E DR Process ......................................................................................................................................................2-5 5-1 DD Form 2332, Product Quality Deficiency Report Exhibit (Front) ...................................................................5-22 5-2 DD Form 2332, Product Quality Deficiency Report Exhibit (Back) ...................................................................5-22 5-3 DD Form 1575, Suspended Tag - Material ...........................................................................................................5-23 6-1 DD Form 2332, Product Quality Deficiency Report Exhibit (Front) new version................................................6-5 6-2 DD Form 2332, Product Quality Deficiency Report Exhibit (Back) .....................................................................6-5

Change 1 iii

6-3 DD Form 1575, Suspended Tag - Materiel ...........................................................................................................6-13 8-1 Identification of Bad Actors Through Data Analysis (Flow 1) ..............................................................................8-4 8-2 Tracking of Bad Actors (Flow 2) ............................................................................................................................8-5 8-3 Unit-level Identification of Bad Actors (Flow 3)....................................................................................................8-6 8-4 Depot Identification of Bad Actors (Flow 4) ..........................................................................................................8-7 8-5 Resolution of Bad Actors (Flow 5)..........................................................................................................................8-8

LIST OF TABLES

Number Title Page

1-1 Attributes That May Affect Operational Safety, Suitability, and Effectiveness ....................................................1-3 1-2 DR Category and Priority Determination ................................................................................................................1-6 1-3 Conditions Not To Be Reported ..............................................................................................................................1-9 1-4 Key DR Reporting, Investigation, Resolution, and Oversight Responsibilities ...................................................1-13 4-1 DR Validation Actions .............................................................................................................................................4-4 4-2 DR Status Codes.....................................................................................................................................................4-13 4-3 Deficiency Responsibility Code .............................................................................................................................4-16 4-4 Severity of Defect...................................................................................................................................................4-16 4-5 Broad Cause of Defect Codes................................................................................................................................4-17 4-6 Detailed Cause Codes.............................................................................................................................................4-17 4-7 Action Taken Code.................................................................................................................................................4-19 4-8 Material Disposition ...............................................................................................................................................4-19 4-9 Result of Investigation Codes ................................................................................................................................4-20 4-10 Credit/Replacement Statement ...............................................................................................................................4-22 5-1 List of Attributes.......................................................................................................................................................5-3 5-2 DR Submittal Criteria...............................................................................................................................................5-3 5-3 Conditions Not to be Reported ................................................................................................................................5-4 5-4 DR Category and Submission Timelines.................................................................................................................5-5 5-5 How to Complete a TCP/IEMP Participant Deficiency Report .............................................................................5-8 5-5 How to Complete a TCP/IEMP Participant Deficiency Report - Continued.......................................................5-11 5-6 HQ AFSAC Supply Discrepancy Report (SDR) Office Addresses .....................................................................5-15 5-7 Deficiency Report Action Point Addresses for TCP Participants Only ...............................................................5-18 5-8 Deficiency Report Action Point Addresses for IEMP Participants Only.............................................................5-20 5-9 Countries Supported by TCP/IEMP.......................................................................................................................5-20 5-10 How to Complete a DD Form 2332 ......................................................................................................................5-21 5-11 Required Entries for DD FORM 1575 Condition Tags........................................................................................5-23 6-1 How to Complete a DD Form 2332 ........................................................................................................................6-4 6-2 Required Entries For DD FORM 1575 Condition Tags .......................................................................................6-13 9-1 Discrepancy Classification Guide ............................................................................................................................9-3 A-1 DR Response/Resolution Timelines........................................................................................................................A-2 iv Change 1

CHAPTER 1

REPORTING CRITERIA, SYSTEM DESCRIPTION, AND PROGRAM

RESPONSIBILITIES

1.1 AUTHORITY.

1.1.1 This Technical Order (TO) implements AFPD 63-5, Quality Assurance and AFI 63-501, Air Force Acquisition Quality Program requirements for deficiency reporting. The processes of this TO also ensure compliance with federal acquisition requirements in accordance with Title 41, Code of Federal Regulations, Subpart 101-26-8, Discrepancies or Deficiencies in GSA or DOD Shipments, Material, or Billings and supports AFI 21-115, Product Quality Deficiency Report Program.

1.2 SCOPE AND INTENT.

1.2.1 Deficiency reporting, investigating, and resolution processes promote the ability to identify and correct deficiencies before they impact mission capability. Successful implementation drives resolution decisions, tempered by total ownership cost, to correct, mitigate, and/or accept risk of, conditions impacting operational safety, suitability and effectiveness (OSS&E). Success is based upon two premises: 1) the user/operator/maintainer report deficiencies on their assigned systems;

and, 2) the program manager establishing a proactive process to analyze data and act accordingly to implement solutions.

Specific objectives include:

1.2.1.1 Identify and resolve Test & Evaluation, Product Quality, and Materiel deficiencies throughout a product or system lifecycle.

1.2.1.2 Commence deficiency reporting and resolution as early as possible during systems acquisition and throughout the government test and evaluation so systems improve faster with the least cost.

1.2.1.3 Integrate deficiency analysis and resolution processes within quality, systems engineering, and overall lifecycle management plans to identify root cause and prevent or mitigate recurrence.

1.2.1.4 Obtain cost credit and/or contractual remedy for procurement related quality deficiencies resulting from poor workmanship, nonconformance to applicable specifications, drawings, standards, processes or other technical requirements.

1.2.1.5 Provide historical collection of deficiency data to share knowledge to authorized activities responsible for design, development, safety, purchasing, production, supply, maintenance, contract administration, and other functions.

1.2.2 The processes of this TO supports AFI 63-1201, Assurance of Operational Safety, Suitability, and Effectiveness providing standardized methods, supporting databases, tools, and procedures to identify, investigate, and resolve deficiencies.

During Test and Evaluation, deficiency reporting identifies deficiencies or proposed enhancements at a point in development where changes may be made at a significantly reduced cost. Throughout operational deployment and sustainment, this TO provides a method to formally communicate user/operator identified deficiencies or proposed enhancements to managing activities for analysis and resolution.

1.2.3 The data captured by deficiency reporting may also be used as a source of information (with analysis), to reflect the past performance history of either a contractor or organic entity. In addition, organizations such as the Air Force Office of Special Investigation and the Defense Criminal Investigation Service may use this data to support or conduct investigations.

1.3 APPLICABILITY.

1.3.1 USAF Deficiency Reporting and Resolution processes apply to all USAF and contractor members and organizations who operate or sustain USAF owned or managed military or weapon systems (Aeronautical, Air Armament, Space, and Command and Control and Information Systems), their sub and support systems; as well as vehicles, clothing, and textiles.

For military and weapon systems, deficiency reporting and resolution processes shall be established prior to government test and evaluation, and will continue throughout the system life cycle. For the purposes of this Technical Order, these processes shall be referred to as the Deficiency Reporting and Investigating System (DRIS).

Change 1 1-1

1.3.2 Applicability includes the National Aeronautics and Space Administration (NASA), which operate systems for which the USAF has program management responsibility. Through letter of agreement, DRIS also provides NASA with the capability to perform cross-component deficiency reporting IAW with this TO and AFI 21-115, Product Quality Deficiency Report Program.

1.3.2.1 NASA will perform Originator, Originating Point, and functional manager responsibilities consistent with the requirements identified in paragraph 1.7 and Chapter 3 of this TO.

1.3.2.2 When operations are co-located at a USAF location, the tenant NASA organization will coordinate with the host organization to de-conflict and document exhibit handling support requirements.

1.3.3 The procedures of this TO apply regardless of the contracting methodology employed. Contracting clauses such as warranty special provisions or contractor logistics support shall not preclude the implementation of these procedures for a system or component.

1.3.4 These procedures apply to all agencies and contractors involved in USAF test and evaluation on Air Force managed systems, programs, and items.

1.3.5 Joint systems under test, operated and/or maintained by the USAF will use these procedures to ensure commonality of reporting and resolution. The individual program office or lead service may establish specific reporting and resolution requirements over and above the requirements of this TO as long as those requirements are seamless to USAF users.

1.3.5.1 During test and evaluation, a Joint system may use the US Navy T&E DR process governed by NAVAIR 3960.5, Naval Air Systems Command Technical Assurance Board Monitoring and Reporting of Aircraft Weapon System Development. However, this process will also include a method to capture the condition and resolution within or through

DRIS.

1.3.5.2 During sustainment, deficiencies discovered by USAF users/operators of a Joint system managed by another service component will report these deficiencies to the USAF database. Assigned Action Points will then forward the DR using the cross-component reporting requirements established in AFI 21-115, Product Quality Deficiency Report Program.

1.3.6 Countries participating in the Deficiency Reporting program use the procedures under Chapter 5 of this TO and include those involved in the Technical Coordination Program (TCP), International Engine Management Program (IEMP), Foreign Military Sales (FMS), Security Assistance (SA), and European Participating Air Forces (EPAF) governed by AFMAN 16-101, and/or Letters of Offer Acceptance (LOA), and individual FMS case provisions, Multi-National Configuration Management Plan, and IEMP Agreements.

1.3.7 This TO interacts with AFI 21-118, Improving Air and Space Equipment Reliability and Maintainability; AFI 99-103, Capabilities Based Test and Evaluation; AFOTECI 99-101, Conduct of Operational Test and Evaluation; AFMAN 23-110, USAF Supply Manual; and the Government Industry Data Exchange Program (GIDEP).

1.4 METHODOLOGY.

1.4.1 DRIS basic system capability is centrally funded and available without cost to all programs and systems. DRIS shall remain under government cognizance in order to realize the benefits derived from commonality of reporting and to remain uninhibited from outside influences.

1.4.2 DRIS systems may be tailored to the unique aspects of a program while conforming to the requirements of this TO.

The use of contractor operated and maintained deficiency data systems may also augment DRIS capability if required, but may not replace the USAF DRIS as the official deficiency repository. When used to compliment DRIS capability the contractor system will have a USAF DRIS database interface and shall provide the same management visibility as established in Chapter 4 of this TO. Tailored requirements outside of the current DRIS baseline may require additional DRIS development and sustainment funding from the requesting organization.

1.5 DEFICIENCY REPORTING CRITERIA.

1.5.1 Deficiencies that impact the operational safety, suitability, and effectiveness (OSS&E) of systems or equipment in development, test, or employment shall be reported through DRIS to the appropriate managing activity. Table 1-1 provides examples of attributes to consider when identifying deficiencies and/or recommended enhancements. Deficient conditions shall be identified according to criteria and report type and categorized according to their impact to mission and/or safety, Table 1-2, DR Category and Priority Determination.

1-2 Change 1

Table 1-1. Attributes That May Affect Operational Safety, Suitability, and Effectiveness

Compatibility Malfunction

Design Quality

Difficulty of operation or maintenance Reliability

Effectiveness Repairability

Environmental Safety

Expense of operation or maintenance Security

Fidelity/conformity of technical publications Suitability

Human Factors Survivability

Integration Training fidelity

Interoperability Undocumented features

Logistics supportability Utility

Maintainability Vulnerability

1.5.2 Report deficiencies on Government-owned products to include, but not limited to premature equipment failures;

products in use that do not fulfill their expected purpose, operation, or service requirement due to deficiencies in workmanship, nonconformance to applicable specifications, drawings, standards, processes or other technical requirements in design, materiel, manufacture, repair, modification, or maintenance; and known or suspected causes of Air Force Mishap/HAP incidents. Report deficiencies on systems undergoing development during the systems acquisition process that do not meet Air Force system specifications or critical performance parameters as measured during developmental test and evaluation (DT&E), or fail to meet operational requirements as measured during operational test and evaluation (OT&E).

Deficiencies shall be reported using the Deficiency Report Entry And Mail Submitter (DREAMS) submission tools, (paragraph 1.8.4), the Standard Form (SF) 368, Product Quality Deficiency Report or equivalent format. The types of USAF report designations include:

1.5.2.1 Acceptance Inspection Deficiency Report (AIDR). This report type is used to report discrepancies discovered during acceptance inspections performed on aircraft, engines, engine modules and major assemblies, support systems, and equipment. Reportable discrepancies are those that are attributed to non-conformance to applicable quality specifications during manufacture, repair, modification, or maintenance associated with the general work requirements and contract specifications of the work performed. See Chapter 9 for additional guidance.

1.5.2.2 Dropped Object Report (DOR). A report of a materiel or quality deficiency involving any aircraft part, component, surface, or other item lost during aircrew operations from engine start to engine shutdown that is confirmed or suspected to be the result of a materiel or design deficiency. The DOR will reference the associated dropped object prevention (DOP) program report number, any resulting damages and the results of any further inspections performed as a result of the dropped object.

1.5.2.3 Mishap/HAP Deficiency Reports (MHAP). These are materiel or quality deficiencies that have been identified as having High Accident Potential (HAP) or that are a known or suspected cause of an Air Force Mishap. In all cases, these reports are in support of safety reports and investigations conducted in accordance with AFI 91-204 and shall include coordination with the local safety office, include the safety investigating officer contact information, and will reference the associated HAP or mishap event number.

1.5.2.4 Materiel Deficiency Report (MDR). This report type is used to report an unacceptable condition such as a component/item failure, or recommendation for an enhancement that impacts the operational safety, suitability, and/or effectiveness of a system, subsystem or component. It may include aging system issues or trends, improvement recommendations or request for investigation to determine the root cause or condition that induced the failure. A MDR may be submitted with or without an exhibit and may include trending observations made and/or recommendations for inclusion as an agenda item in improvement working groups or forums.

1.5.2.5 Product Quality Deficiency Report (PQDR). These are reports of deficiency resulting from an initial failure, defect, or nonconforming condition discovered on a new, newly repaired, or overhauled product when that product is placed in service. PQDRs include the reporting of failures that occur on contractually prescribed warranted items within the warranty period. These may also include failures that result after the item was placed in service that are suspected as latent defects or

Change 1 1-3 quality escapes resulting from poor workmanship, nonconformance to applicable specifications, drawings, standards, processes or other technical requirements.

1.5.2.6 Software Deficiency Report (SWDR). These include but are not limited to an error, omission, or enhancement in statements or instructions that comprise a computer program for a system or component. The deficiency may consist of syntax, logic, or other discrepancies that cause the program to fail or inadequately perform the intended functions. SWDRs include, but are not limited to, deficiencies on Mission Information Systems (MIS), Automated Information Systems (AIS), Operational Flight Programs (OFP), and other supporting software.

1.5.2.7 Test and Evaluation Deficiencies (T&E DR). These are reports of deficiency identified during test and evaluation.

These include, but are not limited to those deficiencies that are the result of incompatibility or failures as measured against required capabilities, applicable specifications, procedures, or test equipment and recommendations for enhancements to improve OSS&E. T&E DRs will be designated as such in field I4000 and may use a further DR classification as SWDR, PQDR, MDR, etc., in field I550.

1.6 DEFICIENCY CATEGORIZATION AND PRIORITIZATION.

1.6.1 The deficiency category and associated risk priority is used to capture the severity of the condition by relative importance and the urgency of response. The submitting organization will be diligent in the categorization of deficiencies, particularly when describing support equipment, subsystems, reliability, and maintainability deficiencies. Each deficiency must be considered for its overall OSS&E impact.

1.6.2 Category I deficiencies are those which may cause death, severe injury, or severe occupational illness; may cause loss or major damage to a weapon system; critically restricts the combat readiness capabilities of the using organization; or result in a production line stoppage.

NOTE

The SAF/AQX preferred term of Program Manager is used in place of the Single Manager throughout this TO and is intended to also represent the responsibilities of the System Program Director, and if delegated by the PM, the Supply Chain Manager.

1.6.2.1 Category I deficiencies require the immediate attention and response of the system Program Manager and Chief/Lead Engineer to mitigate risk and/or limit/resolve mission impact, therefore strict application of Category I criteria is essential. If a Category I condition is noted or suspect, assess safety, mission, or operational impact and include a detailed statement outlining the safety, mission, or operational impact to the system or end item.

1.6.2.2 Suspected Category I deficiencies shall be validated as such by the appropriate authority level within the reporting organization (Chief of Maintenance, Safety Office, or other authority within the reporting organization). If any doubt exists concerning the category of a report between Category I and Category II, it will be coordinated with the wing safety office and/or other authority to aid in assessment of the deficiencies impact.

1.6.2.3 Report Category I deficiencies immediately to applicable organizations (MAJCOM, Program Manager, safety offices) within 24 hours by telephone, facsimile, email or other expedited methods, as required. Due to the critical nature of Category I DRs, the use of telecommunications facilities are authorized during MINIMIZE (MINIMIZE is the reduction of record and voice telecommunications traffic in an emergency).

1.6.3 Category II deficiencies are those that impede or constrain successful mission accomplishment (system impacts OSS&E but does not meet the safety or mission impact criteria of a Category I deficiency). Category II deficiencies may also include recommended enhancements that improves or complements successful mission accomplishment but is not absolutely required. If incorporated, the recommendation will enhance a system’s operational safety, suitability and/or effectiveness (OSS&E). An enhancement report should not be designated as such solely due to an “out-of-scope” condition as described in contractual requirements.

NOTE

Program Managers will not close deficiencies as an enhancement solely because it is “out of scope” to contractual requirements. Enhancement deficiencies will be assessed as a potential requirement and prioritized based upon their impact to OSS&E.

1-4 Change 1

1.6.4 Table 1-2 will assist the Originating activity in determining the report category and impact are consistent and provides the recommended priority. All Category I reports and all Category I & II T&E reports require the selection of a recommended priority. Priority selection is optional for all other Category II reports.

1.6.5 As a general rule, Priority 1A - 1C are considered Emergency conditions; Priority 1D - 2B are considered Urgent conditions; and Priority 2C - 2E are considered Routine conditions.

1.6.6 The PM will consider the priority as a statement of the tester and/or operator impact. The PM analyzes the priority in view of existing program factors and budget constraints and should prioritize resolution actions accordingly.

1.6.7 Conditions that do not meet the criteria of a Category I or Category II report should be investigated by the identifying organization to determine if other reporting avenues are available. These may include, but are not limited to product and component improvement working group action items, as well as transportation and supply discrepancy reporting. Refer to Table 1-3, Conditions Not To Be Reported, for deficiencies which are excluded from the provisions of this TO.

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Table 1-2. DR Category and Priority Determination

Annotate the DR Category (I or II) and the corresponding alpha-numeric priority. Submit a Category I DR and assign the corresponding priority when a condition:

CAT I Priority Impact

1A If uncorrected, may cause death, severe injury, or severe occupational illness and no workaround is known; or, 1B If uncorrected, may cause major loss or damage to equipment or a system and no workaround is know; or, 1C Prevents the accomplishment of an essential capability or critically restricts OSS&E, to include required interaction with other mission critical platforms or systems; and no acceptable workaround is known.

1D Adversely affects an essential capability or negatively impacts operational safety, suitability, or effectiveness and no acceptable workarounds are known.

1E Adversely affects technical, cost or schedule risks to the project or to life cycle support of the system, or, results in a production line stoppage and no acceptable workaround is known.

When the condition does not meet the safety or mission impact criteria of a Category I report, submit a Category II DR with the corresponding priority when the condition:

CAT II Priority Impact

2A Adversely affects an essential capability or negatively impacts operational safety, suitability, or effectiveness and adequate performance is achieved through signifi-cant compensation or acceptable workaround.

2B Adversely affects technical, cost, or schedule risks to the project or to life cycle support of the system, but an acceptable workaround is known.

2C Does not affect an essential capability but may result in user/operator inconve-nience or annoyance. Adequate performance is achieved through minimal compen-sation.

2D Results in inconvenience or annoyance for development or maintenance personnel, but does not prevent the accomplishment of the task. Adequate performance is achieved through minimal compensation.

2E Any other effect, i.e., enhancements having little or no impact to OSS&E under current requirements.

NOTES:

1. Careful consideration should be given in assigning the category and corresponding priority recommendation to accurately define the deficiencies impact.

2. Priority 1A - 1C are considered Emergency Conditions; Priority 1D - 2B are considered Urgent Conditions; and Priority 2C - 2E are considered Routine conditions.

3. Priority selection, DREAMS field I63, is mandatory for Category I reports and all T&E reports.

4. Prior to Test, the test team and program office, the PM, and Test team shall define key phrases relative to their program such as:

5. Category I reports shall be coordinated with the appropriate organizational authority prior to submission.

6. Originators/Originating Points should consider factors such as cost, schedule and performance risks; availability of spares; difficulty of operation or maintenance, repair, or replacement; system redundancy; associated trends; secondary failures or damages; and environmental impacts among other possible factors.

7. Workarounds refer to approved/authorized alternate procedures which could include, but are not limited to: manual processes, order of task accomplishment, more restrictive or intensive procedures, and the use of back-up or redundant systems or processes, etc.

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1.7 KEY DRIS RESPONSIBILITIES.

1.7.1 The following provide a summary of primary DRIS positions and their key responsibilities. These responsibilities are not all inclusive; specific tasks and performance responsibilities are in Table 1-4, DR Submission and Processing Responsibility Chart and the corresponding chapters of this TO.

1.7.2 ORIGINATOR. The Originator may be any individual who identifies conditions that limit or restrict an item or system from fulfilling its intended purpose. The Originator discovers the deficiency, identifies its impact, and initiates reporting and exhibit processes as established within their organization or Group.

1.7.3 ORIGINATING POINT. The Originating Point is a function typically located within the organization’s quality, safety, or resource management office and has overall DR program management responsibility for the submitting organization or Group. Responsibilities include promoting the DR program to ensure knowledge of criteria and processes;

interacting with Originators to ensure the DR is valid, accurate, and complete; validating the deficiency category; ensuring applicable exhibits are available, secured, and…