00-20-3.pdf

TO 00-20-3

TECHNICAL MANUAL

MAINTENANCE PROCESSING OF REPARABLE

PROPERTY AND THE REPAIR CYCLE ASSET CONTROL

SYSTEM

(ATOS)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. HQ AFMC PA Case Number 8117. Submit recommended changes or problems with this technical order to HQ AFMC/A4UE, Wright-Patterson AFB, OH 45433-5001.

Published under authority of the Secretary of the Air Force

1 NOVEMBER 2008 CHANGE 1 - 1 JANUARY 2009

BASIC AND ALL CHANGES HAVE BEEN

MERGED TO MAKE THIS A COMPLETE

PUBLICATION.

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 DESTROY SUPERSEDED PAGES.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 shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . 1 November 2008 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . 1 January 2009

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 38, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - ii 1-1 1-2 - 1-7 1-8 Blank 2-1 - 2-4 3-1 - 3-9 3-10 Blank 4-1 - 4-2 5-1 - 5-2 6-1 - 6-7 6-8 Blank

*Zero in this column indicates an original page

A Change 1 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

1 REPAIR CYCLE ASSET MANAGE- 3.5 Documenting Maintenance Turn- MENT SYSTEM..................................................1-1 around (TRN) Transactions...................3-2

3.6 Processing Reparable for Units

1.1 Purpose........................................................1-1 Supported by a Main Operat-

1.2 Scope...........................................................1-1 ing Base .................................................3-2

1.3 Definition of Terms....................................1-1 3.7 Use of Memo Due-Outs .............................3-2

1.4 General Concept of Repair.........................1-3 3.8 Supply Points..............................................3-2

1.5 Repair Cycle Processing of XB 3.9 Processing Supply Assets Requir-

Coded Items ...........................................1-3 ing Functional Check.............................3-3

1.6 Source, Maintenance and Recov- 3.10 Due-Out Cancellations ...............................3-3 erability (SMR) Code Con- 3.11 Processing Assets for Bench flicts........................................................1-3 Check .....................................................3-3

1.7 Depot Overhaul and On Condi- 3.12 Maintenance Preparation for tion Repair of Reparable As- Turn-in of Assets to Logistic sets..........................................................1-3 Readiness Squadron (LRS)....................3-4

1.8 Uniform Criteria for Estimating 3.13 Asset Turn-in to LRS.................................3-5 Repair Costs for Use in Mak-

4 INSPECTION OF REPAIR CYCLE AS-ing Repair Decisions..............................1-4 SETS.....................................................................4-11.9 Reusable Containers ...................................1-6

2 THE REPAIR CYCLE ASSET MAN- 4.1 Authorized Inspectors and their AGEMENT...........................................................2-1 Responsibilities ......................................4-1

4.2 Base Inspection Stamps..............................4-1

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

5 MAINTENANCE PROCESSING OF2.2 Physical Layout ..........................................2-1 WARRANTY ITEMS..........................................5-12.3 Scheduling...................................................2-1

2.4 Scheduling Excess Position Items .............2-1

5.1 Special Handling of Warranty2.5 Scheduling Components Requir-

Items.......................................................5-1ing Multiple Shop Processing ...............2-1

5.2 Engine Warranties ......................................5-12.6 Repair Cycle Asset Control .......................2-1

2.7 Verification Procedures ..............................2-3 6 BASE REPAIR CAPABILITY, SELF2.8 Pickup and Delivery of Repara-

SUFFICIENCY AND AUTHORIZEDble Items.................................................2-4

REPAIR CAPABILITY.......................................6-1

3 MAINTENANCE PROCESSING OF RE-

6.1 Purpose........................................................6-1PAIR CYCLE ASSETS.......................................3-1

6.2 General........................................................6-1

6.3 Measuring Base Repair Capabili-3.1 Purpose........................................................3-1 ty and Base Self Sufficiency.................6-13.2 Processing Classified Assets ......................3-1

6.4 Base Repair Guidelines ..............................6-13.3 Processing Items Awaiting Parts ...............3-1

6.5 Request for Increasing Base Re-3.4 Processing Maintenance Turn-pair Authorization ..................................6-3around (TRN) Transactions...................3-1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

4-1 Sample Enlarged Illustration of Base 5-1 Flowchart of Warranty Decision Pro- Level Inspection Stamp ............................. 4-2 cess ............................................................. 5-2 i

LIST OF TABLES

Number Title Page Number Title Page

1-1 When to Use NRTS Codes............................... 1-6 6-1 How to Process Requests to Increase 2-1 DIFM Status Codes........................................... 2-2 Base Level Repair Authority ....................... 6-3 3-1 How to Use Condition Tags/Labels ................. 3-6 6-2 Acronyms .......................................................... 6-4 3-2 Required Entries For Condition Tags/La- 6-3 When to Use Not Repairable This Sta-bels................................................................ 3-8 tion (NRTS) Codes....................................... 6-6 ii

CHAPTER 1

REPAIR CYCLE ASSET MANAGEMENT SYSTEM

1.1 PURPOSE.

This Technical Order (TO) establishes policy and provides procedures for managing repair cycle assets. Inherent in the management of repair cycle assets is the responsibility to seek ways to maximize equipment repair capability at all levels of maintenance. This TO implements the policy established in AFMAN 23-110, Volume 2, Part 2, USAF Supply Manual, and AFI 21-101, Aerospace Equipment Maintenance Management. Procedures are also included to integrate maintenance and supply data. Each demand upon supply for a serviceable item receives a document number which maintenance records on the AFTO Form 350, Reparable Item Processing Tag. This merging of data provides the means to:

1.1.1 Identify the repair cycle assets.

1.1.2 Determine, establish, and adjust stock levels.

1.1.3 Compute world-wide spares requirements for reparable items.

1.2 SCOPE.

The provisions of this TO apply to all maintenance activities within the Air Force. TO 00-20-2, Maintenance Data Documentation and TO 00-20-14, Air Force Metrology and Calibration Program, contain procedures for Precision Measurement, Equipment Laboratory (PMEL) managed Test, Measurement, and Diagnostic Equipment (TMDE). Major commands will ensure off-base units or dispersed operating locations provide repair cycle data to the supporting LRS unit.

NOTE

When considered a better method, and computer capability exists, major commands may direct the use of automated data systems in lieu of the requirements outlined in this TO. This does not negate the required entries on Forms forwarded with equipment/components.

1.3 DEFINITION OF TERMS.

1.3.1 Aircraft Parts Store. An LRS function located near flight line maintenance and functions as a demand processing unit, customer service, and aircraft parts warehouse for maintenance activities.

1.3.2 AWP Validation Listing (D19). Daily listing of AWP repair part due-outs, corresponding due-ins, and status. In addition, it provides financial data to allow maintenance managers to consider the impact of repairing parts versus repairing the end item.

1.3.3 Daily Document Register (DO4). A daily register which provides LRS customers a comprehensive review of all customer transactions and fund expenditures. It also identifies transactions that may require further analysis or action. This report is in document number sequence and reflects supply action resulting from customer inputs for the previous day. It is for use at the shop level and provides the shop a ready reference for reconciling supply actions to customer requirements.

1.3.4 Demand Code. A one digit code used on issue requests to indicate how to accumulate demand information for stock leveling and DIFM control (e.g., recurring-R; initial issue-I; nonrecurring-N; etc.).

1.3.5 Due-Out. An obligation assumed and recorded by any supply echelon to issue at a subsequent date; commonly referred to as a backorder.

1.3.5.1 Firm Due-Out. A due-out for which supply requisitioning action has taken place to satisfy the requirement.

1.3.5.2 Memo Due-Out. A due-out for which no supply requisitioning action has taken place to satisfy the requirement.

1.3.6 Due-Out Cancellation. Deletion of a previously established due-out (either memo or firm).

Change 1 1-1

1.3.7 Expendability, Recoverability, Reparability, Cost Designator (ERRCD). Used to categorize Air Force inventory into various management groupings. The groupings determine the type of management used throughout the logistics cycle, designates the process to be used in computing requirements and are used in the correction and reporting of asset and usage data.

1.3.7.1 XB3. Base-level non-recoverable items normally managed with the stock fund program.

1.3.7.2 XF3. Expendable field recoverable items normally managed within the stock fund program.

1.3.7.3 XD2. Expendable depot recoverable items managed under the recoverable assembly management process system.

1.3.7.4 NF3/4. Field recoverable equipment managed within the Air Force Equipment Management System (AFEMS).

1.3.8 Issue Request. A requirement placed on the supply system by maintenance for a spare, repair part, or bit and piece, etc.

1.3.9 Logistics Readiness Squadron (LRS). Integrates the functions of Supply, Transportation, and Logistics Plans into one squadron.

1.3.10 Maintenance Control (MC). The main functions are to support the units operational mission and to serve as the management function which monitors, coordinates, and controls the use of manpower and material in support of the maintenance production. It is the focal point for the assembly collation and assessment of significant logistics information and requirements.

1.3.11 Maintenance Priority Code (MPC). Assigned programmatically for each item record for repair cycle items (XD, XF) to indicate the priority of sequence of repair based on stockage position of the asset. MPC codes include: 3, Air Force Materiel Command (AFMC) critical item; 4, item required for forecasted base requirements; 7, item excess to base requirements; L, computed supply critical items with less than 10 days on-hand stock and due-out balance; and T, computed supply critical items with less than 10 days on-hand stock and no due-out balance.

1.3.12 Maintenance Turnaround (TRN). The means to record demand data in the supply system for either repairs in place or removal, repair, reinstallation of a recoverable item without ordering a replacement item.

1.3.13 Production Scheduler (PS). For the purpose of this technical order (TO), the term production scheduler applies to any individual or function that schedules repair cycle assets into the performing work center for repair.

1.3.14 Regionalized Supply Squadron (RSS). The RSS is a centralized operations support activity, subordinate to the MAJCOM, and responsible for core supply and traffic management processes in a regionalized context. Core supply functions include Mission Capable (MICAP) and AWP management, Stock Control, Equipment Management, and Funds Management.

1.3.15 Repair Cycle Assets. Any recoverable item with an ERRCD code of XD or XF.

1.3.16 Repair Cycle Asset Management List (D23). Provides a current inventory of DIFM assets for use by maintenance and supply to assure positive control and to reconcile supply and maintenance records. The summary data provides supply and maintenance managers statistics to measure the effectiveness of the DIFM program.

1.3.17 Flight Service Center (FSC). The main function of the FSC is to maintain accurate computer records of location and status for all unserviceable assets in maintenance and is the central turn-in point for reparable assets.

1.3.18 Requisition. A request or demand for supplies levied on wholesale distribution agencies.

1.3.19 Retested OK (RTOK). Items returned from the base to the repair facility as NRTS which are retested and found to be operable and not defective.

1.3.20 Spare. A spare is an assembly, subassembly, or shop replaceable unit (SRU) in the repair cycle for which LRS issued or backordered a like item.

1.3.21 Standard Assets Tracking System (SATS). SATS was developed to improve the process of tracking assets through base level supply channels and to reduce the amount of paper produced and stored in LRS. SATS puts the control and responsibility of the property in the hands of the person who has the property. Barcode labels, identification numbers, and passwords are used throughout the system to track and move assets through the supply process.

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1.3.22 (Supply) Transaction Identification Code (TRIC). A three-digit code identifying an internal transaction with the (SBSS) (e.g., issue-ISU; turn in-TIN; etc.).

1.4 GENERAL CONCEPT OF REPAIR.

The basic concept is to perform repairs at the lowest level of maintenance, to the fullest extent possible, consistent with good management and quality assurance. Troubleshooting and repair shall be extended to the lowest possible component or part.

Repair is not limited to procedures found in equipment technical directives. Unless specifically prohibited, procedures in general maintenance TOs and common sense maintenance actions should also be used to aggressively pursue maximum local repair. Defective components will be either replaced with a like item; repaired in place; or removed, repaired and installed.

Care must be taken to ensure XB items are not disposed of simply because they are classified as nonrecoverable. These XB items must be considered for repair when it is cost effective or warranted by mission requirements IAW AFI 21-123, Air Force Repair Enhancement Program (AFREP).

1.5 REPAIR CYCLE PROCESSING OF XB CODED ITEMS.

1.5.1 ERRCD codes do not dictate maintenance policy. They are primarily for use by LRS to decide how to manage parts in the supply system. TO 00-25-195, Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems, and Equipments governs maintenance policy which authorizes repair of XB items when the Source, Maintenance, and Recoverability (SMR) code includes maintenance repair level (MRL) code B. Unusual situations may also make it necessary to repair parts even though the SMR code indicates the part is not repairable.

1.5.2 Specific equipment TOs do not prescribe repair actions for individual XB items; however, general purpose TOs and common sense maintenance actions can be used to repair these items. If the repair of an XB item is prudent, but it does require parts, tools, test equipment, technical data, or skills having sole application to the item or its repair, the item’s SMR and ERRC designators may qualify for change.

NOTE

The design of some XB items requires routine periodic maintenance, such as adjustment and lubrication. A TO should designate when and how to accomplish this kind of “designed for” maintenance. This type of work, which is effectively custodial care, is not repair.

1.5.3 Process and control XB items through the normal maintenance functions using the same procedures as for controlling XD and XF items; however, accumulation of repair cycle data and DIFM procedures do not apply. Order parts required to repair XB items with TEX code E using the SRD and serial number of the aircraft/end item. Units may develop local procedures for monitoring and controlling parts ordered against XB items. Control numbers, such as AFTO FORM 350 tag numbers, may be used in the MARK FOR field for this purpose in lieu of an aircraft serial number. Turn in XB items in accordance with AFMAN 23-110, Volume 2, Part 13.

1.6 SOURCE, MAINTENANCE AND RECOVERABILITY (SMR) CODE CONFLICTS.

The SMR code reflects both maintenance and supply management techniques and dictates the ERRCD. Repair guidance, including specific restrictions, is provided in the applicable system or equipment -6 TO. For equipment that does not have a - 6 TO, repair restrictions may be provided in other equipment TOs, such as the -2, -3, or -6 WC. The SMR code, ERRCD, and repair restrictions in the equipment TO should be compatible. If an incompatibility exists, action must be taken to correct the codes or to add, delete, or correct the repair restrictions. SMR codes are corrected in accordance with TO 00-25-195. ERRCD are corrected in accordance with AFMAN 23-110, Volume 2, Part 2, Chapter 27. Repair restrictions are added, deleted, or corrected in the equipment TO by submitting an Air Force Technical Order (AFTO) Form 22 in accordance with TO 00-5-1, AF Technical Order System. In cases where the SMR code or repair restrictions are not consistent with existing repair capability, take action in accordance with Section VI of this TO.

1.7 DEPOT OVERHAUL AND ON CONDITION REPAIR OF REPARABLE ASSETS.

Reparable assets received in depot facilities (including contractors) will be inspected and functionally tested as necessary.

Condition and applicability of overhaul or on-condition repair methods are determined based on guidelines stated below in the applicable equipment repair manual.

1.7.1 Overhaul Criteria. Selected equipment items, by reason of their design characteristics, function, or application are predetermined to require a complete overhaul whenever returned to the depot in a reparable status. Other items may be

1-3 committed to a complete overhaul on a judgment basis during receiving inspection and functional test or by direction of the IM as stated in work specifications. Items generally requiring complete overhaul include:

1.7.1.1 Time Change Items (TCI) whose allowable operating time has expired. TCIs returned due to premature failure which the IM determines a complete overhaul is the more cost effective method based on remaining time of the item shall be evaluated on a case-by-case basis.

1.7.1.2 Items involved in a weapon system accident.

1.7.1.3 Items which have evidence of contamination.

1.7.1.4 Items of which the condition cannot be determined.

NOTE

Avionic items, for which complete overhaul is not practical, are handled as on-condition repair as outlined below.

1.7.2 On-condition maintenance will be accomplished for those items whose circumstances are not outlined above. The extent of overhaul when not specified, is that amount of work required to return the equipment to technical order specification and meet all operational and design requirements. Use that part of the repair manual which contains the detailed requirements and procedures for on-condition repair to include total unit inspection, test and verification processes within existing capability to assure complete serviceability of the required item.

NOTE

Whenever it is found that the overhaul/repair manual for an item does not contain adequate instructions, a deficiency report (AFTO Form 22) will be submitted to the responsible item manager.

1.7.3 AFMC validates the condition of reparable property being returned for repair.

1.7.3.1 When the RTOK rate on an item reaches 10 percent, the IM will advise the base and using command, and work with them to resolve the problems.

1.7.3.2 Reparable items being returned for repair must have a properly completed AFTO FORM 350 attached so that the repair facility can determine the base from which the item came.

1.7.3.3 When the IM advises a base that the RTOK rate on their item is 10 percent or more, the base must attempt to discover why the high RTOK rate exists. The IM must work closely with the base on this investigation since many factors outside of the base’s management responsibility can affect the rate, e.g., technical data, support equipment, software.

1.7.3.4 Items with a reported RTOK rate of 10 percent or less are still candidates for improvement and should be sampled on a biannual basis to ensure that the RTOK rate has not increased. Although priority management action should be addressed to 10 percent or above, any item with a RTOK rate of 10 percent or below should be studied and its management improved as resources permit.

1.8 UNIFORM CRITERIA FOR ESTIMATING REPAIR COSTS FOR USE IN MAKING REPAIR DECISIONS.

This section establishes standard criteria and principles for use by all Air Force activities in estimating the cost of repair to equipment as a factor in making repair decisions. Other factors which bear on the repair decision include the availability of a replacement item or suitable substitute, future anticipated needs for the item, the mission impact of not repairing the item, anticipated permanence of the repair (i.e., shall it be back in the shop again next week), and availability of resources to accomplish the repair (qualified personnel, tools, equipment, etc.). Maintenance managers must consider these factors in making repair decisions with the goal of providing optimum mission support at the lowest cost.

1.8.1 Base level personnel will not condemn ERRCD XD items with a unit cost of $1000, or more, unless beyond total repair (e.g., crushed, burned, battle damaged). Return XD coded items to a depot repair facility for the repair determination when they are beyond base repair capability. (XD items in excess of $1000 unit cost may be condemned with prior Item Manager and/or Equipment Specialist approval. This waiver can be made for the specific NSN on a one time basis; or may be granted for continuing approval for the NSN restricted to one or more designated bases; or continuing approval Air Force wide).

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1.8.2 Operating locations may condemn XF coded items, and XD coded items having a unit cost of less than $1000, if supported by an economic repair determination.

1.8.3 Repair/condemnation criteria for equipment items, ERRC NF is contained in AFMAN 23-110, Volume 2, Part 13, TO 00-25-211 and other applicable directives.

1.8.4 Economical repair of Air Force property is 75 percent of the current stock list price unless otherwise specified in TOs or other published directives. If you know or suspect that the stock list price is 3 years old or older take cost escalations into account before applying the 75 percent unit cost criteria. Current replacement cost data may be requested from the IM. Base cost estimates on accomplishment of the required maintenance at the nearest government or commercial facility which has the repair capability and performs similar maintenance. Use the cost elements discussed in paragraphs (1) through (8) in estimating repair costs.

1.8.4.1 Direct labor is the military or civilian labor which you can identify specifically to the repair job. Use the job-standard or job-average man-hours required for the repair action. If a job-standard or job-average is not available, estimate the repair hours based on experience, then apply the military or civilian labor rate to the man-hours required for repair. Labor rates for military personnel will be weighted-average military wage rate for the involved work center. Base the labor rate for civilian personnel on the rate for the applicable job skill and level in the local geographic area of the repairing activity.

Therefore, contact the comptroller of the unit concerned for the average hourly rate scale. When determining costs of civilian labor on the basis of annual salaries, compute these costs by adding a factor of 9.0 percent to the gross pay as shown in current pay tables. When determining costs of civilian labor on the basis of direct hours applied, increase the gross pay reflected in current civilian pay scales by a factor of 29.0 percent for annual/sick leave and fringe benefits. Extract the pay rate scales for military personnel from AFI 65-503, US Air Force Cost and Planning Factors.

1.8.4.2 Direct material costs are the cost of all materials identified with and applied directly to the item or equipment that requires repair. This includes government furnished materials consumed by a contractor in performing all or part of the maintenance job; consumable items obtained from supply stocks costed at the stock list price; items locally procured costed at the latest invoice or quoted price and including any transportation charges; fabricated items priced at expected cost including labor cost as described in paragraph 1.8.4.1.; and indirect expenses described in paragraph 1.8.4.3. When the repair involves use of components and assemblies on an exchange basis, cost such components and assemblies at the exchange price; i.e., stock list price less credit for the return of the reparable components. The exchange price may be established as a percent of the stock list price provided it reflects the estimated cost to repair the components or assemblies. If the repair cost is not known, cost estimate exchange items (issue of a serviceable for a reparable) at 35 percent of the stock list price.

1.8.4.3 Indirect expenses may be included in the estimated cost of repair for an item or piece of equipment. Since it is impossible to identify specific indirect expenses for each item, determine this cost element by applying an indirect expense rate to the estimated direct cost expenditures. The indirect costs included in the indirect expense rate represent a portion of the production expenses incurred within or identifiable to the work center or organization performing the repair work; a portion of the general and administrative expenses incurred in management or supervision; and the costs of maintaining the repair facility. A factor of 33 percent of direct expenses may be used to cover indirect expenses if they are not known. The estimated total cost of repair will then be the direct expense estimate multiplied by 1.33.

1.8.4.4 Other direct charges include the cost of contractual services required incident to or identifiable with the performance of all or a portion of the specific maintenance job. If a contractor is to perform a significant portion of the maintenance job, include the total contract price or the estimated total contract price for the repair. When the item or equipment cannot be repaired on site and preparing the item for shipment will incur costs, include these costs in the estimated repair costs. For reparable material located overseas where there is no theater repair capability, include the cost of freight to the continental United States repair facility as an element of cost. Exclude the cost of freight in all other cases. Include any other charges required to accomplish the required maintenance and directly identifiable to the material although not specifically mentioned herein.

1.8.4.5 When there is a modification or Time Compliance Technical Order (TCTO) concurrent with the repair, exclude the cost of the modification or TCTO compliance from the estimated repair cost.

1.8.4.6 Do not include items such as tires, antifreeze, and fuel which are incident to normal operation of equipment in the cost of repair. However, include these items if they are replaced as a result of an accident.

1.8.4.7 Do not include the cost to overhaul or replace accessory items such as sirens, tool kits, or two-way radios, used to adapt the equipment for special usage, in the estimated repair cost.

1.8.4.8 A sample computation follows:

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DATA REQUIRED:

Item: Circuit board

ERRCD: XF3

Stock list price: $842.00

75 percent of stock list price: $631.50

Job standard: 33 hours

Civilian pay for work center: $12.00/hour

Benefits: 29.0 percent of $3.48/hour

Total wage rate: $15.48/hour

Direct labor cost: $15.48/hour x 33 hours = $510.84

Direct material total: $38.60

Indirect expense: 33 percent

COMPUTATION:

$510.84 direct labor

38.60 material

$549.44 total material and labor x 1.33 indirect expense rate

$730.76 total repair cost

DECISION: Item is XF3, condemnable at base level. The estimated total repair cost exceeds 75 percent of the current stock list price; therefore, the item may be condemned at base level if other repair decision factors support the condemnation decision.

1.9 REUSABLE CONTAINERS.

Do not destroy or discard reusable containers. The maintenance activity will make maximum use of reusable containers.

Reusable containers shall normally be kept with the asset during in-shop repair. However, if the containers cannot be stored with the item due to size and shape, store the containers in an area mutually agreed upon by maintenance and supply. Use the AF Form 451, Request for Packaging Service, to request local fabrication of new containers in the event the original containers are lost, damaged, or destroyed.

Table 1-1. When to Use NRTS Codes

A B then assign action

RULE If an asset is a DIFM item and repair cannot be completed due to taken code

NOTE

Every effort must be made to repair XF items prior to making a NRTS decision.

1 Bench checked-NRTS (not reparable this station). Repair not authorized. Shop is 1 not authorized to accomplish the repair. This code shall be used only when the repair required to return an item to serviceable status is specifically prohibited by current technical directives. This code shall not be used due to lack of authority for equipment, tools, facilities, skills, parts or technical data.

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Table 1-1. When to Use NRTS Codes - Continued

A B then assign action

RULE If an asset is a DIFM item and repair cannot be completed due to taken code 2 Bench checked-NRTS-lack of equipment, tools or facilities. Repair not prohibited 2 but cannot be accomplished because authorized equipment, tools or facilities are not available.

3 Bench checked-NRTS-lack of technical skills. Repair cannot be accomplished 3 due to lack of technically qualified people.

4 See Chapter 3, paragraph 3.3.4. 4

5 Bench checked-NRTS-shop backlog. Repair cannot be accomplished due to ex- 5 cessive shop backlog.

NOTE

Only use NRTS code 5 after MAJCOM or IM disapproval of a formal request to defer maintenance.

6 Bench checked-NRTS-lack of technical data. Repair cannot be accomplished due 6 to lack of maintenance manuals, drawings, etc., which describe detailed repair procedures and requirements.

7 Bench checked-NRTS-lack of equipment, tools, facilities, skills, parts or techni- 7 cal data. Repair authorized but cannot be accomplished due to lack of authoriza-tion to obtain or possess required equipment, tools, facilities, skills, parts or technical data.

8 Bench checked-return to depots. Return to depots by direction of (SPM) or (IM). 8 Use only when items that are authorized for repair at the operating location are directed to be returned to depot facilities by specific written or verbal communi-cation from the IM or SPM, or when items are to be returned to depot facilities for modification in accordance with a Time Compliance Technical Order (TCTO), or as UMR exhibits. The AFTO FORM 350, block 15, will be annotat-ed to identify ALC and name of the individual (IM/SPM) who verbally author-ized the return or other media of authorization (including phone number, if applicable).

9 Bench checked-condemned. Item cannot be repaired and is to be processed for 9 condemnation, reclamation or salvage. This code will also be used when a “con-demned” condition is discovered during field maintenance disassembly or repair.

10 Bench checked-NRTS-warranty item: repair not authorized, item under warranty. 0

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CHAPTER 2

THE REPAIR CYCLE ASSET MANAGEMENT

2.1 PURPOSE.

This chapter prescribes the physical layout of the repair cycle asset management, assigns scheduling responsibility and methodology, and establishes control procedures. It also addresses DIFM procedures, verification procedures and the shop interface with production scheduling.

2.2 PHYSICAL LAYOUT.

Route all reparable item documentation through the maintenance function responsible for processing reparable assets. The items will be scheduled through the shops for repair and turned into maintenance for reinstallation. The maintenance function responsible for this may be the applicable maintenance repair activity or other activity determined by the unit.

2.2.1 Production Scheduling (PS) is considered as a repair shop responsibility. The Maintenance Information System (MIS), if available, shall be used to process all parts through the repair shop.

2.3 SCHEDULING.

Repair shops must establish/manage production flow times, in-shop production, and track parts scheduled through the shop.

2.3.1 In-shop priorities shall be assigned based on the applicable maintenance need. Components shall be assigned the same repair priority as the end item.

2.4 SCHEDULING EXCESS POSITION ITEMS.

Items which are in an excess position (MPC 7) shall be scheduled for repair after all other priority work is accomplished.

2.5 SCHEDULING COMPONENTS REQUIRING MULTIPLE SHOP PROCESSING.

Process items needing multiple shop actions in the same manner as other scheduled work. However, the repair shop or the originating shop shall mark involved shops in block 15 of the AFTO Form 350, PART I. Each shop will use the same repair priority first assigned. Upon completion of work, shops will:

2.5.1 Notify the repair shop.

2.5.2 Annotate block 15 of the AFTO FORM 350 to reflect that shop’s action.

2.5.3 Route to the next shop. The repair shop must coordinate closely with all subsequent shops to ensure the item is repaired in a timely manner. Each subsequent shop shall process the item in the same manner.

2.6 REPAIR CYCLE ASSET CONTROL.

A repair cycle asset is a part for which LRS normally requires a one-for-one trade. Repair cycle assets are considered part of the total base asset position, whether serviceable or reparable.

2.6.1 A demand on supply for an XD or XF coded asset suspenses the asset in the DIFM control system. This will ensure a one-for-one exchange by tracking each asset through the repair cycle until returned to LRS. The quick return of the asset to LRS expedites the stock replenishment action.

2.6.2 An AFTO Form 350 is required when a repair cycle asset is removed from an end item and for items requiring bench check and/or repair. A repair cycle asset issued by LRS will be accompanied by an issue document (SATS label or DD Form 1348-1). The issue documentation, accompanied with the AFTO Form 350 provides a means for controlling reparable items, and must be returned to LRS to clear the DIFM detail.

2.6.3 Process DIFM assets through the repair cycle and return to LRS. The repair shops shall review the D23 for accuracy daily. If an item is beyond repair, prepare the appropriate NRTS documentation and return the asset expeditiously through the appropriate supply channels.

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2.6.4 The repair shop and LRS shall perform a quarterly DIFM reconciliation on a coordinated date as prescribed in AFMAN 23-110, Volume 2, Part 2, Chapter 24.

2.6.5 DIFM files shall be established using one of the following methods:

2.6.5.1 If a SATS issue label is received, the repair shop shall establish a suspense file. Ensure the supply document number, federal stock class and national stock number (NSN), on the AFTO Form 350 attached to the item agree with the document number, federal stock class and NSN on the SATS issue label.

2.6.5.2 If the DD Form 1348-1A is used in lieu of SATS, the repair shop shall retain copy 3.

2.6.6 Each AFTO Form 350 shall contain the date the item was scheduled or received into the shop in the base repair cycle data block of Part II. The repair shop shall detach Part II of the form and verify the part number entry in block II against:

2.6.6.1 The data plate.

2.6.6.2 The number stamped, stenciled, or embossed on the item.

2.6.6.3 The parts catalog.

2.6.7 Correct any error in Part II and annotate the correct part number in block 18. If the data plate is in error, advise the work center to update the data plate.

2.6.8 Repair cycle asset control is a repair shop responsibility. The repair shop shall report/update current repair cycle asset location and condition status through the MIS, if available, to maintain surveillance of items. If MIS is unavailable, contact FCS for status and location update. Table 2-1 presents the DIFM status codes used for this purpose.

Table 2-1. DIFM Status Codes

CODE DEFINITION DETERMINED BY

BLANK No location established Maintenance

AWI Awaiting installation Maintenance

AWF Awaiting testing Maintenance

AWM Awaiting maintenance Maintenance

AWP Awaiting parts with one AWP due-out detail Program Control (see note 1)

(N)(N)P AWP with two or more AWP due-out details Program Control (see note 1)

(N) = numeric

AXC Aircraft cross-country Maintenance

BFN Base funded, nonstandard MAJCOM peculiar repair cycle items LRS

CEH Scheduled work order item in BCE hold area Civil Engineer (BCE)

CMD CEM mobile detachment Maintenance

CTE Contract maintenance (equipment) Maintenance

CTR Contract maintenance Maintenance

DWO UJC AR/BR retained on system Maintenance (see note 2)

DWP Repair cycle item which is a component of another repair cycle Maintenance item that is in AWP

EWI Engine components awaiting installation Maintenance

FEM Forecasted engine maintenance Program Control (see note 3)

FSP Intransit from forward supply point LRS

FTL Flight line Maintenance

FWP Previous AWP item ready for scheduling and repair Program Control (see note 4)

INO Intransit issue (off-base only) LRS

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Table 2-1. DIFM Status Codes - Continued

CODE DEFINITION DETERMINED BY

INR Intransit return (off-base only) LRS

INW In shop Maintenance

MTM Maintenance to maintenance Maintenance

MWI ICBM item awaiting installation Maintenance

OAM Retained on system Maintenance

RFS Warehouse refusal LRS

RPR Repair and return Maintenance

TCG Time change Maintenance

TIN Turn-in to LRS Maintenance

TNB Tail or registration Maintenance

TOC TCTO required on end item Maintenance

TWP Bits and pieces required for repair action intransit LRS

VHM Scheduled work order item in vehicle maintenance hold area Maintenance (see note 5)

Z(MM) Reserved. Assigned by MAJCOM

NOTES

1. When the first AWP due-out is set up, the code on the end-item DIFM detail will be changed to AWP under program control. When the second AWP due-out is set up, the code will be changed from AWP to 02P. Further processing increases or decreases the status code counter; that is, sequential processing will result in code assignment AWP, 02P, 03P, 04P, etc., 03P, 02P, AWP, FWP.

2. DWO should be assigned to UJC AR/BR requirements when the asset must be retained on the end item or system.

3. Status code FEM is assigned when the issue request UJC is AU, BU, or CU, and the delivery destination field is

FEM.

4. When the last AWP due-out is released or cancelled, the code on the end-item DIFM detail will be changed to FWP under program control.

5. Status code VHM can only be applied by vehicle maintenance organization.

2.7 VERIFICATION PROCEDURES.

A prompt responsive verification process is the key to success in preventing unwarranted NMC/PMC conditions, cannibalization, priority system abuses, and unnecessary fund expenditures. Verification information usually centers around the following types of data:

2.7.1 Is the item on bench stock and available?

2.7.2 Status and location of any DIFM?

2.7.3 Is the item repairable?

2.7.4 Are any assets in the tail number bins (TNB)?

2.7.5 Can the item be locally manufactured?

2.7.6 Is the next higher system assembly available?

2.7.7 Is the assembly a spare?

2.7.8 Possibility of feasible cannibalization?

2.7.9 Are there suitable substitutes?

2.7.10 Accuracy of requisition date in accordance with AFMAN 23-110?

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2.8 PICKUP AND DELIVERY OF REPARABLE ITEMS.

The Maintenance Group Commander (MXG/CC), or designated representative shall establish pickup points for repair cycle assets, in coordination with the Logistics Readiness Squadron (LRS) Commander. In addition, they shall establish times to check the pickup points to ensure pickup of assets on a timely basis. Do not allow shop production and reparable turn-ins (completed work) to accumulate at these pickup points. Ensure fragile components are transported using vehicles with appropriate protective devices. Pickup and delivery responsibilities are listed in AFI 24-301, para 1.2.8.10.3.

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CHAPTER 3

MAINTENANCE PROCESSING OF REPAIR CYCLE ASSETS

3.1 PURPOSE.

This chapter prescribes specific procedures for processing and documenting repair actions. It also covers use of memo due-outs, due-out cancellation procedures, the establishment of supply points, and asset turn-in procedures.

3.2 PROCESSING CLASSIFIED ASSETS.

Process classified reparable components in the same manner as other components. However, the initiator of the AFTO Form 350 shall indicate on the face of the AFTO Form 350 that the item is classified. Use a stamp which states, “This Item is Classified and shall be handled in accordance with AFI 31-401, Information Security Program Management.” For classified components under COMSEC control (i.e., those using the Top Secret nomenclature system), use a stamp that states, “This Item is Classified and shall be handled in accordance with AFKAG-series, Air Force Crytographic Operational General Publication” or use bold block lettering, if no stamp is available. The shop responsible for bench check/repair will ensure the security classification of the component is conspicuously visible. The preferred method of marking the classification on components is to stencil with paint or attach a plate with screws or rivets depicting the classification.

3.3 PROCESSING ITEMS AWAITING PARTS.

When a shop requires bit and piece parts, a demand shall be placed on supply through the MIS, if available.

3.3.1 After processing issue requests, LRS shall notify the repair shop of the issue status. Under the “fill or kill” option, the requester must verify for re-input and change the delivery destination code, if required.

3.3.2 Sometimes bits and pieces required to return an end item to serviceable status have an extended estimated delivery date. It may be prudent to place another demand on supply for the next higher assembly. For example, when the next higher assembly is a subassembly, the second requisition should be for this subassembly. Maintenance and LRS must monitor AWP closely to ensure positive action to return AWP assets to a serviceable condition. These actions may include: cannibalization, local purchase, supply difficulty letters, follow-ups, and substitutions.

3.3.3 In-shop serviceable assets may be cannibalized to preclude or satisfy MICAP conditions. However, the AWP monitor must update the appropriate due-outs. These actions do not require documentation unless the items are removed from complete engine modules or engines.

3.3.4 LRS and maintenance must expend special efforts to obtain parts and perform authorized maintenance to preclude returning AWP assets to the depot. Base level managers have the authority to evacuate unserviceable end articles awaiting parts (AWP), NRTS 4 after aggressive actions have been taken to secure the SRUs, components, or parts for repair. Prior to evacuation, disposition instructions need to be obtained from the end article item manager. The request for AWP end article evacuation shall include the current condition of the end article. When furnished the disposition instructions, route the reparable item to the shop for preparation for turn-in. The repair shop shall complete maintenance data collection processing in the MIS, and turn into LRS. The AWP monitor will cancel due-outs for bit and pieces not received.

3.4 PROCESSING MAINTENANCE TURNAROUND (TRN) TRANSACTIONS.

The basic maintenance concept and parts ordering policy for repair cycle assets is to remove and replace the defective component with a serviceable asset issued from LRS. The unserviceable asset is then processed for bench check and repair through the repair shop. However, under certain conditions it may be prudent to remove, bench check, repair and reinstall an item without a demand on supply. In these cases process a maintenance turnaround transaction (TRN).

3.4.1 Some of the reasons for processing a TRN are:

3.4.1.1 The component may be “married” or integrated to another component where replacement (in the case of an issue from LRS) would necessitate replacement of the other component.

3.4.1.2 The defective component may require a minor repair while a new issue may need elaborate bench checking. Time constraints may dictate the repair.

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3.4.1.3 The component may be trimmed and fitted to the end item in which case repair will usually be easier than replacement.

3.4.1.4 It may be easier to repair the defect on the equipment, in which case a demand on supply would be impossible.

3.4.2 Repair and return processing procedures are the same as normal reparable processing. If repaired, the repair shop shall process the TRN through the MIS or forward to LRS for processing. If repair cannot be accomplished, the repair shop shall process and control the removed items using normal DIFM procedures.

3.4.3 Processing a TRN provides the same demand data as an issue and turn in of a serviceable asset. Only maintenance action taken codes A, F, G, K, L, or Z qualify for TRN transactions. Failure to process TRNs affects stock levels and results in incomplete reports on which AFMC bases buy, repair, and distribution decisions.

3.5 DOCUMENTING MAINTENANCE TURNAROUND (TRN) TRANSACTIONS.

3.5.1 If the MIS is unavailable, forward all AFTO Forms 350, Part II, which require TRN processing to the LRS TRN monitor by the most expedient method available. Ensure the AFTO Forms 350 contain valid part number, NSN, maintenance action taken code, the SRD of the weapon system or equipment from which the item was removed and number of repair days.

3.5.2 Maintain a record of turnarounds processed using AF Form 2521, TURNAROUND TRANSACTION LOG or a copy of the Daily Document Register (DO4).

3.5.3 Verify the TRN processed using the DO4. The repair shop and LRS shall determine the corrective action if the TRN processed incorrectly.

3.6 PROCESSING REPARABLE FOR UNITS SUPPORTED BY A MAIN OPERATING BASE.

Use the following procedures in conjunction with the procedures authorized in AFMAN 23-110, Volume 2, Part 2 for units operating at locations where little or no repair capability exist, when deployed to a forward operating location (FOL) supported by a forward supply location (FSL), or enroute support activity. The repair shop at the FSL schedules the accomplishment of off-equipment maintenance.

3.6.1 When the FOL cannot perform the repair action, they shall forward the component with an attached AFTO Form 350 to the forward support location. The AFTO Form 350 shall be annotated with action taken code D, bench check/repair, when transferred to another base. This identifies items the forward maintenance activity cannot code NRTS, or repair.

3.6.2 Upon receipt of a transferred item from the FOL, the FSL shall schedule the item into the shop for repair.

3.6.3 Air Mobility Command’s (AMC) Forward Supply System (FSS) uses the same procedures. In addition, the FSL shall overstamp the front of the AFTO Form 350 with “FSS” in red ink prior to transferring the item to the primary supply point for repair.

3.6.3.1 LRS shall be responsible for delivery of unserviceable FSS items to the appropriate production scheduler/shop.

3.6.3.2 Upon receipt of completed reparable FSS engines at the primary supply point for maintenance or inspection, the engine manager shall immediately notify the documentation section of the requirement to load an ID number for the engine.

3.7 USE OF MEMO DUE-OUTS.

The supply system provides a technique to maintain visibility of an asset processed through maintenance when the request for an assembly or subassembly results in a “kill.” This visibility is accomplished by creating a memo due-out. To create the memo due-out, maintenance must verify the requirement and request re-input with a transaction exception (TEX) code 7.

3.8 SUPPLY POINTS.

The MXG/CC, or designated representative, in coordination with the LRS Commander, may establish supply points within the maintenance complex. Supply point stocks may include any item of supply, except equipment items. Expendable items (ERRCD XB3) must be approved by Materiel Management Flight Officer. The MXG/CC, or designated representative, must provide adequate facilities to accommodate the supply points.

3.8.1 The supply point concept allows pre-positioning selected assets in designated maintenance shops. Generally this procedure is reserved for items requiring buildup or bench check prior to issue. LRS is responsible for transferring the assets

3-2 to the shop and processing the necessary documentation. The supply point monitor shall advise LRS each time the item is removed from the supply point and notify LRS. LRS shall process a paper work turn-in to clear the DIFM and update the repair cycle data. NRTS and condemnation actions require normal DIFM turn-in procedures.

3.8.2 The supply point monitor shall assist LRS in accomplishing the semi-annual supply point reconciliation and the annual inventory.

3.9 PROCESSING SUPPLY ASSETS REQUIRING FUNCTIONAL CHECK.

Repair shops must identify those items requiring functional check or calibration, prior to issue. The repair shop shall prepare a consolidated list of repair parts and forward it to LRS. As a minimum, this list shall identify the parts by NSN, repair shop delivery destination code, and frequency of functional check. Criteria to be used in selecting items for inclusion in the functional check program include: the length of time required for a prior to use bench check, the failure history of the item, the need to “marry” components, and other considerations as determined by the unit.