AFI21-101.pdf

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

AIR FORCE INSTRUCTION 21-101

29 JUNE 2006

Maintenance

AIRCRAFT AND EQUIPMENT

MAINTENANCE MANAGEMENT

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

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

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: HQ USAF/A4MM Certified by: HQ USAF/A4M (Brig Gen P. David Gillett)

Supersedes AFI 21-101, 1 June 2004 Pages: 463

This instruction implements AFPD 21-1, Air and Space Maintenance. It is the basic Air Force directive for aircraft and equipment maintenance management. It provides the minimum essential guidance and procedures for safely and effectively maintaining, servicing, and repairing aircraft and support equipment.

It acknowledges the foundational contributions made to Agile Combat Support (ACS) capabilities of Generating the Mission, and Supporting and Sustaining the Mission, Forces, and Infrastructure. It applies to all major commands (MAJCOMs), including the Air Force Reserve Command (AFRC) and the Air National Guard (ANG), along with their subordinates. The Air National Guard is a MAJCOM for the pur-pose of this instruction. Organizational structures may differ in the Air Reserve Component (ARC). In these instances, responsibilities will be assigned to the appropriate functional area. Waiver authority for this instruction is HQ USAF/A4M. For questions on interpreting this instruction, first contact your MAJ- COM maintenance policy activity. MAJCOMs supplementing this instruction must coordinate their sup-plements with HQ USAF/A4M and will follow guidance in Air Force Instruction (AFI) 33-360, Publication Management Program. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with the AFMAN 37-123 (will become AFMAN 33-363), Management of Records and disposed of in accordance with the Air Force Records Disposition Schedule located at https://afrims.amc.af.mil/. Maintain and dispose of records created as a result of prescribed processes in accordance with Air Force Records Disposition Schedule located at https:// afrims.amc.af.mil/.

SUMMARY OF CHANGES

This publication has been substantially revised and must be reviewed in its entirety. This revision clarifies policy and corrects errors in the June 2004 edition. This version also specifically includes certain organi-zations within AFMC that were excluded in previous versions. Specific sections within chapters will be marked as applicable to the Combat Wing Organization (CWO), which denotes the typical wing and group structures that fly and maintain aircraft. Other sections will apply only to AFMC Air Logistics Cen-ters (ALC) and the Aircraft Maintenance and Regeneration Center (AMARC) and will be identified as http://www.e-publishing.af.mil https://afrims.amc.af.mil/ https://afrims.amc.af.mil/ https://afrims.amc.af.mil/

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“ALC/AMARC.” This term includes Oklahoma City ALC, Ogden ALC, Warner-Robins ALC, and AMARC. Sections specific to ALC/AMARC are contained in Chapter 1, Chapter 2, Chapter 8, Chap-ter 9, Chapter 10, Chapter 14, and Chapter 17 of this instruction. If in doubt as to which section applies, MAJCOMs will obtain determination/waiver from HQ USAF/A4M. Chapters in this revision have been consolidated and renumbered, where appropriate, to enhance readability. The Maintenance Operations Center guidance has been incorporated into the new Chapter 6, Maintenance Operations Squadron. Chapter 7, Documenting Maintenance, and Chapter 12, Keep Enlisted Experience Program (KEEP) and an Aircraft Grounding policy for material defects have been incorporated into the new Chap-ter 14, Additional Maintenance Requirements and Programs. New chapters on Centralized Intermediate Repair Facility (Chapter 16) and Logistics Contract Management (Chapter 17) have been added to address policy gaps and emerging maintenance concepts. At the squadron level, the terms Maintenance Operations Officer and NCOIC have been replaced by Operations Officer and Maintenance Superinten-dent, respectively. The term System Program Manager is used to represent AFMC activities responsible for program management/sustainment functions. KEEP milestones have been revised to reduce program administration while maintaining program intent. Safety has been moved to Chapter 2 to highlight the importance of this program and mindset while performing the inherently dangerous maintenance mission.

Chapter 1— MANAGEMENT PHILOSOPHY AND POLICY 15

1.1. Introduction

1.2. Organization

1.3. Aircraft and Equipment Readiness

1.4. Maintenance Concept

1.5. Reliability and Maintainability (R&M)

1.6. Maintenance Discipline

1.7. Use of Technical Orders (TO) and TO Supplements

1.8. Publications

1.9. Waiver Request

1.10. Operating Instructions (OI)

1.11. Support Agreements (SA)

1.12. Performance-Based Activities

1.13. Modification Management

1.14. Maintenance Information Systems (MIS)

1.15. Maintenance Management Metrics

1.16. Communications

1.17. Duty Shifts and Rest Periods

1.18. Maintenance Training

1.19. Maintenance Repair Priorities

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Table 1.1. Maintenance Repair Priority Designators

1.20. AF Munitions Policy

1.21. Unit Committed Munitions List (UCML), Test/Training Munitions List (TTML). . 35

1.22. Associate Unit Program

1.23. Individual Mobilization Augmentees (IMA)

1.24. Civilian Visitors

1.25. Lean

1.26. Maintenance Discipline

1.27. Use of Technical Orders (TO) and Supplements

1.28. Publications

1.29. Waiver Request

1.30. Operating Instructions (OI)

1.31. Support Agreements (SA)

1.32. Performance-Based Activities

1.33. Maintenance Information Systems (MIS)

1.34. Maintenance Management Metrics. Metrics provide a measurement of performance and capability

1.35. Communications

1.36. Maintenance Training

1.37. Individual Mobilization Augmentees (IMA)

1.38. Civilian Visitors

1.39. Lean

Chapter 2— SAFETY 44

2.1. General Safety Guidance

2.2. AFOSH Guidance

2.3. Hazards

2.4. Hazard Abatement Program

2.5. Safety Equipment

2.6. AF Mishap Prevention Program

2.7. Safety Inspections

2.8. Flightline Safety

2.9. Flightline Driving

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2.10. Work Center Safety Guidance

2.11. Confined Spaces

2.12. Munitions Safety Guidance

2.13. Lockout and Tagout Concept

2.14. Warning Tags

2.15. Danger Tags

2.16. Contracted Operations

2.17. Safety “Knock It Off.”

2.18. Environmental, Safety and Occupational Health Management System (ESOHMS) or Environmental Management System (EMS)

2.19. Environmental and Health Working Groups (E&HWG)

Chapter 3— GENERAL RESPONSIBILITIES FOR COMMANDERS AND KEY LEADERS 49

3.1. General

3.2. Wing Commander (WG/CC) Responsibilities

3.3. Wing Vice Commander (WG/CV) Responsibilities

3.4. Maintenance Group Commander (MXG/CC) Responsibilities

3.5. Maintenance Group Deputy Commander (MXG/CD) Responsibilities

3.6. MXG Superintendent (SUPT) Responsibilities

3.7. Squadron Commander (SQ/CC) Responsibilities

3.8. Operations Officer/Maintenance Superintendent (MX SUPT) Responsibilities

3.9. Flight Commander/Flight Chief or AMU OIC/Superintendent (SUPT)

3.10. Section NCOIC

3.11. Production Superintendent (Pro Super)

Chapter 4— AIRCRAFT/HELICOPTER MAINTENANCE SQUADRON (AMXS/HMXS) 70

4.1. General

4.2. Squadron Commander Responsibilities

4.3. Operations Officer/Maintenance Superintendent (MX SUPT) Responsibilities

4.4. AMU

4.5. AMU OIC/SUPT Responsibilities

4.6. Production Superintendent

4.7. Flightline Expediter

4.8. Aircrew and Maintenance Debrief Section

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Table 4.1. Landing Status Codes

Table 4.2. System Capability Codes

Table 4.3. Deviation Cause Codes

4.9. Aircraft Section

4.10. Specialist Section

4.11. Weapons Section

4.12. Weapons Section (MH-53J/M and HH-60 Units)

4.13. UAV Weapons Section (MQ-1/9 Units)

4.14. Plans, Scheduling and Documentation Section (AMU PS&D)

4.15. Support Section

4.16. AMU Supply Support

Chapter 5— MAINTENANCE SQUADRON (MXS) 98

5.1. General

5.2. Squadron Commander Responsibilities

5.3. Operations Officer/MX SUPT Responsibilities

5.4. Production Superintendent

5.5. Specialist Support

5.6. Accessories Flight

5.7. Aerospace Ground Equipment (AGE) Flight

5.8. Armament Flight

5.9. Avionics Flight

5.10. Fabrication Flight

5.11. Maintenance Flight

5.12. Munitions Flight

5.13. Propulsion Flight

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

Chapter 6— MAINTENANCE OPERATIONS SQUADRON (MOS) 142

6.1. General

6.2. Squadron Commander Responsibilities

6.3. Maintenance Operations Flight (MOF)

6.4. Maintenance Training Flight (MTF)

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6.5. Programs and Resources Flight

6.6. Quality Assurance

Chapter 7— MAINTENANCE PLANS, SCHEDULING AND DOCUMENTATION (PS&D) 167

7.1. General

7.2. Maintenance Operations Flight (MOF) PS&D Section

7.3. AMU PS&D Section

7.4. Flying and Maintenance Planning Cycle

7.5. First Look Requirements

7.6. Annual Maintenance Planning Cycle

7.7. Quarterly Planning

7.8. Monthly Planning

7.9. Weekly Scheduling

7.10. Aircraft Document Reviews

7.11. Pre-Dock Meetings

7.12. Post-Dock Meetings

7.13. Aircraft Configuration Management

7.14. Major Maintenance Work Processing

7.15. TCTO Management

7.16. TCIs

7.17. Aircraft Generation Planning

7.18. Transfer Inspections

Chapter 8— QUALITY ASSURANCE (QA) 190

8.1. General

8.2. QA Responsibilities

8.3. Quality Assurance OIC/Superintendent (QA OIC/SUPT) Responsibilities

8.4. Quality Assurance Chief Inspector Responsibilities

8.5. Quality Assurance Inspector Responsibilities

8.6. Quality Assurance Training

8.7. Quality Assurance Augmentation

8.8. Rotation of Quality Assurance Personnel

8.9. Activity Inspection Program

8.10. Maintenance Standardization and Evaluation Program (MSEP)

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8.11. Establishing Acceptable Quality Levels (AQL/Standards)

8.12. MAJCOM-approved QA database

8.13. Monthly Summary (Quarterly for ANG)

8.14. MSEP Meetings

8.15. QA Product Improvement Programs

8.16. Configuration Management (CM) and Modification

8.17. Technical Order Distribution Office (TODO)

8.18. One-Time Inspections (OTI)

8.19. Functional Check Flights (FCFs)

8.20. Operational Check Flights (OCFs)

8.21. Inflight Operational Checks

8.22. High Speed Taxi Checks

8.23. Weight and Balance (W&B) Program

8.24. Chafing Program

8.25. Quality Assurance Evaluator (QAE)/ Quality Assurance Representative (QAR)

8.26. MSEP and Contract Maintenance

8.27. QA Responsibilities

8.28. MXW Quality Assurance Chief Responsibilities

8.29. MXG QA Chief Responsibilities. MXG QA Chief shall:

8.30. First Level Supervisor QAS Responsibilities

8.31. QAS Responsibilities

8.32. QA Training

8.33. QA Augmentation

8.34. Activity Inspections

8.35. MSEP

8.36. Establishing Acceptable Quality Levels (AQL/Standards)

8.37. MAJCOM-approved QA database

8.38. Monthly Summary

8.39. MSEP Meetings

Chapter 9— IMPOUNDMENT PROCEDURES 226

9.1. Aircraft and Equipment Impoundment

9.2. Specific Guidance

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9.3. Impoundment Terms:

9.4. Reasons for Impoundment of Aircraft or Equipment

9.5. Impoundment Official Responsibilities

9.6. Impoundment Process and Procedures

9.7. Rules of Impoundment Specifically for Explosive-Related Mishaps

9.8. MXG/CC or equivelant will appoint Impoundment Authorities and Impoundment Release Authorities

9.9. Impoundment Terms:

9.10. Reasons for Impoundment of Aircraft or Equipment

9.11. Impoundment Official Responsibilities

9.12. Impoundment Process and Procedures

Chapter 10— TOOL AND EQUIPMENT MANAGEMENT 233

10.1. Tool and Equipment Management

10.2. Guidelines for Program Management

10.3. General Program Guidelines

10.4. Tool Accountability

10.5. Marking and Tool Identification

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

10.7. Tool Room Operations and Security

10.8. Lost Item/Tool Procedures

10.9. Guidelines for Program Management

10.10. General Program Guidelines

10.11. Marking and Tool Identification

Table 10.1. ALC/AMARC ID number marking Codes

10.12. Tool Accountability, Control, and Inventory

10.13. Locally Manufactured or Developed Tools and Equipment

10.14. Tool Room Operations and Security

10.15. Lost Item/Tool Procedures

Chapter 11— MAINTENANCE SUPPLY SUPPORT 247

11.1. General

11.2. Maintenance Supply Liasion (MSL) Section

11.3. Decentralized supply support

AFI21-101 29 JUNE 2006 9

11.4. Ordering Parts

11.5. Processing MICAPs

11.6. Readiness Spares Package (RSP) Review

11.7. Bench Stock

11.8. Consumable Readiness Spares Package (CRSP)

11.9. Shop Stock

11.10. Operating Stock

11.11. Work Order Residue

11.12. Adjusted Stock Levels

11.13. Shelf life Items

11.14. Equipment Items

11.15. Special Purpose Recoverable Authorized Maintenance (SPRAM)

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

11.17. Time Compliance Technical Order (TCTO) Kit Procedures

11.18. Supply Points

11.19. Local Manufacture

11.20. Production Scheduling

11.21. Control of AWP Assets and Cross-CANN

11.22. Repair Cycle Assets

11.23. DIFM

11.24. Tail Number Bins (TNB)

11.25. CANN actions. See section 14.8 for CANN procedures and responsibilities

11.26. Bench Check and Repair Policy

11.27. Maintenance Turn-Around (TRN) Record Update Processing

11.28. Maintenance Turn-In to Supply

11.29. Buildup Items

11.30. Supply Reports and Listings

11.31. Deficiency Report (DR) Exhibits

11.32. Work Center Supply Management

11.33. Maintenance Repair/Supply Delivery Priorities

11.34. Intermediate Repair Enhancement Program (IREP)

11.35. Destruction of TOP SECRET Material

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11.36. Certifying Items Associated With Explosives:

Chapter 12— WING WEAPONS MANAGER AND WEAPONS STANDARDIZATION 260

12.1. Wing Weapons Manager (WWM)

12.2. Weapons Standardization

12.3. Loading Standardization Crew (LSC)

12.4. Academic Instructor

12.5. Lead Crews

12.6. Training Facilities/Aircraft

12.7. Academic Training

12.8. Practical Training

12.9. Load Crew Composition

12.10. Task Assignment List (TAL)

12.11. Weapons Load Training Basic Terms

12.12. Load Crew Certification/Decertification

12.13. Load Configurations

12.14. MPRL

12.15. Load Crew Semi-Annual Evaluations

12.16. Documenting Load Crew Training

12.17. Transient Aircraft Responsibilities

12.18. Dual Loading Operations (DLO)

12.19. Weapons Task Qualification

12.20. Munitions Load Time Standards

Table 12.1. Fighter Aircraft Munitions Family Group and Load Training Time Standards (in minutes). 280

Table 12.2. Bomber Aircraft Munitions Family Group and Load Training Time Standards (in minutes). 281

Table 12.3. Unmanned Aerial Vehicle Munitions Family Group and Load Training Time Standards (in minutes). 282

Chapter 13— MOBILITY AIRCRAFT DEFENSIVE SYSTEMS LOADING POLICY 284

13.1. Units required to install/remove chaff/flare on mobility aircraft

13.2. The WTQM and the Weapons Task Qualification Crew (WTQC)

13.3. Training Requirements

AFI21-101 29 JUNE 2006 11

13.4. Disqualifying Chaff/Flare Load Personnel

13.5. Transient Aircraft

13.6. Identification of Chaff/Flare-Loaded Aircraft

13.7. AF IMT 2434 Requirements

13.8. AMC requires documenting DS software version data and aircraft inspections

13.9. Chaff/Flare Build-up

Chapter 14— ADDITIONAL MAINTENANCE REQUIREMENTS AND PROGRAMS 289

Section 14A—CWO ONLY 289

14.1. Aircraft Battle Damage Repair (ABDR)

14.2. Aircraft and Equipment Decontamination

14.3. Aircraft Grounding (Materiel Defect)

14.4. Aircraft Inlet/Intake/Exhaust Certification

14.5. Aircraft Rapid/Hot Defueling (Tanker Aircraft)

14.6. Aircraft Structural Integrity Program (ASIP)

14.7. Reserved

14.8. Cannibalization Program

14.9. Combat Sortie Generation

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

14.11. Dropped Object Prevention (DOP) Program

14.12. F100 Eddy Current Inspection

14.13. End-of-Runway (EOR) Inspection

14.14. Engine Blade Blending Training and Certification Program

14.15. Engine Run Training and Certification Program

14.16. Flash Blindness Protective Device

14.17. Engine Flexible Borescope Inspection Training and Certification Program

14.18. Flying Crew Chiefs (FCC)

14.19. Foreign Object Damage (FOD) Prevention Program

14.20. Forms Documentation

14.21. Ground Instructional Trainer Aircraft (GITA)

14.22. Hangar Queen Aircraft

14.23. Hot Refueling Procedures

14.24. IFF Mode IV Program

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14.25. Retention Management of Active Duty Enlisted Maintenance Personnel (N/A to the ARC)

14.26. Land Mobile Radio (LMR) Management

14.27. Lead Technician

14.28. MRT Procedures

14.29. Protective Aircraft Shelter (PAS) Environment

14.30. Radar Warning Receiver (RWR)/Radar Threat Warning (RTHW) Testing

14.31. Ramp Inspection Program

14.32. Red Ball Maintenance

14.33. Scanning Electron Microscope/Energy Dispersive X-Ray (Sem/Edx) Master Chip Detector Analysis Program (MCDP)

14.34. Self-Inspection Program

14.35. Senior Leaders’ Maintenance Course (SLMC)

14.36. SCR

Table 14.1. Mandatory Special Certification Roster (SCR) and Prerequisites

14.37. WRM External Nestable Fuel Tank Build-Up (NFTBU)

14.38. 406 MHz Emergency Locator Transmitter (ELT) Systems

Section 14B—ALC/AMARC Only 357

14.39. Dropped Object Prevention (DOP) Program

14.40. End-of-Runway (EOR) Inspection

14.41. Foreign Object Damage (FOD)

14.42. Forms Documentation

14.43. Retention Management of Active Duty Enlisted Maintenance Personnel

14.44. Land Mobile Radio (LMR) Management

14.45. Senior Leaders’ Maintenance Course (SLMC)

14.46. Product Improvement Programs

14.47. Technical Order Distribution Office (TODO)

14.48. Functional Check Flights (FCFs)

14.49. High Speed Taxi Checks

14.50. Weight and Balance (W&B) Program

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Chapter 15— AIR AND SPACE EXPEDITIONARY FORCES (AEF)

MAINTENANCE POLICY 374

15.1. AEF Effectiveness

15.2. AEF Processes

15.3. Readying the Force

15.4. Preparing the Battle Space

15.5. Positioning the Force

15.6. Employing the Force

15.7. Sustaining the Force

15.8. Recovering the Force

15.9. Centralized Intermediate Repair Facilities (CIRF)

15.10. Governing directives

Chapter 16— CENTRALIZED INTERMEDIATE REPAIR FACILITIES (CIRFS) 389

16.1. Introduction

16.2. Organization

16.3. Command Authority

16.4. CIRF

16.5. Rotable Pools

16.6. Retained Tasks

16.7. Documentation

16.8. Metrics

16.9. Liaison with LRS

16.10. Repair Funding

16.11. ACS Planning

Chapter 17— LOGISTICS PROGRAM MANAGEMENT FOR PERFORMANCE-BASED

ACTIVITIES 393

17.1. Introduction

17.2. Pre-Contract Award and Pre-Planning for Management Plan Requirements

17.3. Post-Contract Award And MEO/HPO Implementation Procedures

17.4. Forms Prescribed

Attachment 1— GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 408

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Attachment 2— SUPPLY REPORTS AND LISTINGS 451

Attachment 3— AIRCRAFT COMMANDER FEEDBACK ON FCC 453

Attachment 4— QUARTERLY FCC REPORT FORMAT 454

Attachment 5— ANNUAL FCC REPORT 455

Attachment 6— FCC SDAP REQUEST 456

Attachment 7— MAINTENANCE RECOVERY TEAM (MRT) TASKING CHECKLIST. 457

Attachment 8— MAINTENANCE RECOVERY TEAM (MRT)

CHIEF RESPONSIBILITIES 459

Attachment 9— MAINTENANCE RECOVERY TEAM (MRT)

CHIEF TASKING CHECKLIST 461

Attachment 10— WAIVER/CHANGE REQUEST FORMAT 463

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Chapter 1

MANAGEMENT PHILOSOPHY AND POLICY

1.1. Introduction. This instruction prescribes basic aircraft and equipment maintenance policy and pro-cedures used throughout the USAF, and provides senior leadership and management direction for the accomplishment of the mission. Local managers are expected to effectively use the resources assigned to ensure successful mission accomplishment. Maintenance resources (personnel, materiel, equipment, and information) make up the essential capabilities required to generate mission elements, and support and sustain mission systems, components, and equipment in both peacetime and wartime environments. Man-agers may use additional maintenance management procedures not specifically prohibited by this instruc-tion, technical order (TO) or other applicable maintenance instruction. Innovation is encouraged;

however, any conflict with this guidance is prohibited without MAJCOM review and HQ USAF/A4M waiver/variance approval. This instruction supports the Air Force (AF) Core Values and its application to maintenance professionals: Integrity - do the job right the first time; Service - mission accomplishment over personal gain; Excellence - put forth the best possible effort all the time. HQ USAF/A4M oversees maintenance at all levels, from the maintainers on the flightline and in the support shops through the depot technicians/engineers in AFMC. The MAJCOM maintenance function sets management policy for all maintainers within their MAJCOM. MAJCOMs determine applicability for non-standard maintenance organizations (e.g., AFIA, AFRL, AEDC, AMOG)

1.2. Organization. AF wings will organize according to AFI 38-101, AF Organization, or as authorized by HQ USAF/A1M. Contractor and civil service maintenance functions are not required to organize in accordance with (IAW) AFI 38-101, but will implement the organization as outlined in their proposal as accepted by the government. Maintenance capabilities and their inherent resources are organized in right-sized capability segments, or unit type codes (UTCs), to perform maintenance on mission elements, components, and equipment in deployed conditions.

1.3. Aircraft and Equipment Readiness. Aircraft and equipment readiness is the maintenance mission.

The maintenance function ensures assigned aircraft and equipment are safe, serviceable, and properly configured to meet mission needs. Maintenance actions include, but are not limited to, inspection, repair, overhaul, modification, preservation, refurbishment, troubleshooting, testing, and analyzing condition and performance. All levels of supervision must place emphasis on safety, quality, and timeliness in the performance of maintenance. The concept of quality maintenance must be fostered by each supervisor and technician to ensure the integrity and skill of each maintainer is not degraded. Shortcuts or incomplete maintenance actions are prohibited. To the greatest extent possible, maintenance is accomplished on a preplanned scheduled basis. Planning provides the most effective and efficient use of people, facilities, and equipment, reduces unscheduled maintenance, and allows for progressive actions toward maintaining and returning aircraft and equipment to safe operating condition. Conducting a bench check of compo-nents and proper control of repair cycle assets throughout the maintenance cycle are also critical elements of the equipment maintenance program.

1.3.1. Preventive Maintenance. AF aircraft require regular maintenance and repair to ensure their optimum availability for mission tasking. Each aircraft is designed with a maintenance concept tai-lored to its operational mission. Built into that concept are specific inspection and servicing require-ments, which form the basis of a preventive maintenance program. All AF units must implement and manage the tasks specified in the scheduled program for their assigned aircraft and associated support

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equipment (SE). By following that program, aircraft systems and components will operate with greater reliability over time to ensure maximum aircraft availability. A conscientious and disciplined approach to preventive maintenance will be the method used to meet that goal safely and effectively.

Preventive maintenance concepts are described in TO 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures.

1.3.1.1. Preventive Versus Corrective. The purpose of the entire maintenance process is to sustain a capability to support the flying and training missions. To accomplish this objective, the primary focus of the effort should be on preventive, rather than corrective, maintenance. Preventive (or scheduled) maintenance ensures equipment is ready and available at the time of need. On the other hand, corrective (or unscheduled) maintenance is generated during the process of using equip-ment.

1.3.2. On-Equipment and Off-Equipment. There are two basic types of maintenance performed:

on-equipment and off-equipment. On-equipment is work performed on an aircraft or piece of SE.

Off-equipment work is typically performed in a repair shop on components removed during on-equip-ment maintenance. Either type of work can be scheduled or unscheduled. Components removed from equipment for in-shop repair are considered to be in the repair cycle. Like preventive maintenance, effective repair cycle management is critical to sustaining maintenance capability. Repair cycle man-agers must strive to eliminate bottlenecks by ensuring adequate parts, equipment, and trained person-nel are available to minimize repair cycle time.

1.3.3. Base-level aircraft maintenance activities must have the capability to launch and recover air-craft and sustain the preventive maintenance program. Generally, this means most units must possess a full complement of equipment and supplies to perform on-equipment and off-equipment mainte-nance. Aircraft repair sources may include: (a) in-house (organic) from operational or support com-mands, (b) other military services, and (c) commercial organizations under contract.

1.3.4. Maintenance cross-tells will be initiated when a condition or trend is discovered regarding (but not limited to) a weapon system or common components that should be shared with other users or potential users. This information should be transmitted using DMS or e-mail to ensure widest dissem-ination and ensure it is brought to the attention of unit commanders in order to prevent or mitigate mishaps, injury, or damage to AF personnel, equipment, or property. Typically cross-tells will provide relevant background information and history and can include such information as National Stock Numbers (NSN), part numbers, specific location of problems areas, etc. Cross-tell information will be provided to applicable MAJCOM functional managers, lead command weapon system management offices, deployed maintenance activities, and System Program Manager offices as appropriate to ensure dissemination to all affected agencies.

1.4. Maintenance Concept. The AF requires varying degrees of maintenance capability at different locations. Maintenance capability depends upon mission requirements, force protection, economics of repair, transportation limitations, component reliability, workload agreements, facility requirements, fre-quency of tasks, and special training required. This capability is described (in order of increasing capabil-ity) as either organizational, intermediate, or depot.

1.4.1. Organizational - First level of maintenance performed on-equipment (directly on aircraft or support equipment) at flightline level. This level generally includes repair, inspection, testing, servic-ing and/or calibration.

AFI21-101 29 JUNE 2006 17

1.4.2. Intermediate - Second level of maintenance performed off-equipment (on removed component parts or equipment) at backshop level. Primarily testing and repair or replacement of component parts.

This level also includes Centralized Intermediate Repair Facilities (CIRFs).

1.4.3. Depot - Third level of maintenance performed on- or off-equipment at a major repair facility.

Highest level of maintenance for more complex repairs.

1.4.3.1. Requests for Depot Level Assistance. If base-level maintenance requires depot level assistance for evaluation and/or repair beyond unit capability, the request must be made IAW AFI 21-103, TO 00-25-107, Maintenance Assistance, and TO 00-20-14, AF Metrology and Calibra-tion Program, or automated process as approved by the mission design series (MDS) specific sys-tem manager (e.g., C-130 AIRCATS, F-16 TAR). All requests for depot level assistance must be coordinated through the Maintenance Group (MXG) Quality Assurance (QA) office and MOS/

MOF PS&D.

1.4.4. Two-level maintenance (2LM) - maintenance approach using two of the three levels of mainte-nance to support weapons systems. The 2LM approach modifies or eliminates the intermediate (off-equipment) function where possible, consolidating that repair function at the depot level. Refer to AFI 21-129, Two Level Maintenance and Regional Repair of AF Weapon Systems and Equipment, for detailed procedures.

1.4.5. Three-level maintenance (3LM) - maintenance approach employs all three levels of mainte-nance. This level typically includes legacy systems (e.g., F-15, B-52, T-38).

1.4.6. Standard maintenance units and operational test units that possess non-traditional aircraft main-tenance Air Force Specialty Codes (AFSC) such as 2EXXX, Communications/Electronics Systems career field, who perform maintenance on aircraft or aircraft support systems must comply with the requirements identified within this instruction. In the event of a conflict with other guidance, this instruction will take precedence.

Section 1A—CWO ONLY

1.5. Reliability and Maintainability (R&M). At the core of AF R&M efforts are technical working groups (e.g., PIWG, MDS maintainers conferences, Component Improvement Program). Units will for-ward inputs IAW AFI 21-118, Improving Aerospace Equipment Reliability and Maintainability. Assess-ing unit R&M concerns is twofold. First, review all reported R&M deficiencies and determine those caused by unit factors and local conditions versus those beyond the unit's control. Second, review avail-able maintenance and supply trends and high work hour consuming repairs. Maintenance Analysis and the Logistics Readiness Squadron (LRS) provide the majority of this information.

1.6. Maintenance Discipline. Maintenance discipline involves integrity in all aspects of the mainte-nance process. It is the responsibility of all maintenance personnel to comply with all written guidance to ensure required repairs, inspections, and documentation are completed in a safe, timely, and effective manner. Supervisors are responsible for enforcing and establishing a climate that promotes maintenance discipline. All personnel who fail to maintain maintenance discipline standards will be held accountable.

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

1.6.1.1. Shall, Must, Will - Indicate mandatory requirements. (Will is also used to express a dec-laration of purpose for a future event.)

18 AFI21-101 29 JUNE 2006

1.6.1.2. Should - Indicates a preferred method of accomplishment.

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

1.7. Use of Technical Orders (TO) and TO Supplements. Use of the prescribed technical data to maintain aircraft and equipment is mandatory IAW AFPD 21-3, Technical Orders. Responsibilities for managing TOs are described in AFI 21-303, Technical Orders and 00-5 series technical orders. The AF is modernizing the TO system using the Technical Order Concept of Operations (TO CONOPS) as a foun-dation. The TO CONOPS goal is to provide user friendly, technically accurate, and up-to-date digital technical data at the point of use that is acquired, sustained, distributed and available in digital format from a single point of access for all technical data users. TO users will access technical data using a view-ing device called an Electronic Tool (E-Tool). E-Tools (desktop and laptop computers, hand held devices, etc.) are common infrastructure allowing access to logistics information systems (to include the AF Stan-dard TO Management System (JCALS until ETIMS is fielded)) that will automatically update TOs, pro-vide automated change requests (similar to AFTO IMT 22) and integrate with other Maintenance Information Systems (MIS). AF TOs shall be available for viewing via the AF Portal either automatically or on a case-by-case basis. AF maintenance personnel will use E-Tools where available. Funding for E-Tools will be IAW the FY Annual Planning and Programming Guidance.

1.7.1. Supervisors will:

1.7.1.1. Strictly enforce adherence to and compliance with TOs and supplements.

1.7.1.2. Establish and manage TOs and supplements IAW to TO 00-5-1, AF Technical Order Sys-tem, , and AFI 21-303.

1.7.1.3. Establish procedures for shipping TOs, E-Tools, support equipment associated with E-Tools, and supplements to support mobility requirements.

1.7.2. All personnel will:

1.7.2.1. Recommend improvements or corrections for TO deficiencies IAW TO 00-5-1. Printed e-mail/faxes are not acceptable methods of updating or revising TOs. The AFTO IMT 22 pre-scribed in TO 00-5-1 may be submitted as an attachment to an e-mail to report problems of a TO;

however, replies to recommended changes are for information only. Official TO updates are the only valid authority for correcting a technical deficiency and implementing change.

1.7.2.2. Continually assess the currency, adequacy, availability, and condition of their TOs and supplements.

1.7.2.3. Ensure waivers to, deviations from, or additional technical data procedures are issued using approved official communication methods (e.g., signed letter, organizational E-mail, DMS message or authorized automated TO 00-25-107, Maintenance Assistance, technical assistance request system, or applicable guidance for ALC/AMARC). Ensure all authorized technical data variances are kept with aircraft/equipment historical records until no longer applicable.

1.7.3. MAJCOMs will ensure any new or modified configurations or maintenance conditions are coordinated with, and approved by, the System Program Manager (SPM) responsible for the opera-tional safety, suitability, and effectiveness (OSS&E) of the systems and end-items prior to implemen-tation.

AFI21-101 29 JUNE 2006 19

1.8. Publications. MAJCOMs will supplement this AFI. Units must tailor procedures to the unique aspects of their own maintenance operation and publish directives (instructions, supplements, and, for functional areas, operating instructions IAW AFI 33-360), for areas where more detailed guidance or spe-cific procedures will enhance operations. Units shall adhere to the following procedures:

1.8.1. Do not publish unit instructions or Operating Instructions (OI) to change or supplement TOs.

Units must use procedures in AFI 21-303 and TO 00-5-1 to update TOs.

1.8.2. Coordinate directives with all appropriate unit agencies.

1.8.3. Conflicts between administrative and technical publications will be resolved in favor of the technical publication.

1.8.4. Conflicts between procedural technical publications and weapon system specific technical pub-lications will be resolved in favor of the weapon system specific technical publication.

1.8.5. Conflicts between Air National Guard/AF Reserve and AF administrative publications are resolved IAW AFI 33-360.

1.8.6. Develop, control, and maintain technical data checklists IAW AFI 21-303, Chapter 8 of this instruction, TO 00-5-1, and MAJCOM instructions. Technical data checklists provide abbreviated step-by-step procedures for operation and maintenance of systems and equipment in the sequence deemed most practical, or to ascertain operational readiness of equipment and minimum serviceable condition.

1.8.7. Develop, control, and maintain functional checklists. Functional Checklists are not formatted IAW TO 00-5-1 and Chapter 8 of this instruction, but at a minimum are titled and dated. Functional checklists are required for use by functional areas(s) during actions such as aircraft crash, mass loads, severe weather warning or evacuation, self-inspections, activity inspections, etc. Functional check-lists shall not be used in place of or to circumvent technical data for operation, servicing, inspec-tion or maintenance of aircraft, aircraft systems and all other equipment supporting aircraft and munitions maintenance. MAJCOMs and/or unit supplements may provide additional guidance for management and use of checklists. QA will ensure functional checklists are reviewed annually for currency and document this review.

1.9. Waiver Request. MAJCOMs are not permitted to deviate from this instruction without receiving written approval from HQ USAF/A4M. Units must submit waiver requests through the MAJCOM. See Attachment 10 for template.

1.10. Operating Instructions (OI). OIs are not published to change AF instructions, policy or TOs.

Group instructions pertaining to maintenance are published as OIs IAW AFI 33-360. When crossing group lines, OIs must be coordinated and approved by the affected commanders and published as wing instructions. Wing instructions will be published when expanded guidance encompasses other group responsibilities, for example: Operations Group (OG), MXG, Mission Support Group (MSG), etc. QA will be the Office of Primary Responsibility (OPR) for maintenance policy guidance and consolidation.

IAW AFI 33-360, units may supplement this instruction in lieu of creating individual OIs as mandated in this instruction.

1.10.1. QA will review all OIs annually for accuracy, intent and necessity and document this review.

20 AFI21-101 29 JUNE 2006

1.10.2. The appropriate Safety activity will review OIs affecting munitions operations or safety;

including all locally developed checklists, instructions, supplements, plans, or operating procedures relating to nuclear surety IAW AFI 91-101, AF Nuclear Weapons Surety Program.

1.11. Support Agreements (SA). Maintenance organizations may be tasked to support functions not related to the primary unit mission. Intra-service, inter-service, inter-command, and international support agreements outline the degree of support provided and the responsibilities of the supported function. The agreements must be developed and reviewed in terms of possible impact on the primary unit mission and all other existing agreements and fully coordinated with the LRS plans function.

1.12. Performance-Based Activities. This section identifies the basic responsibilities for managing per-formance-based activities (e.g., contract maintenance, Most Efficient Organization (MEO), or High Per-formance Organization (HPO)). Additional guidance may be found in AFI 63-124, Performance-Based Services Acquisition (PBSA) and AFI 38-203, Commercial Activities Program. NOTE: By definition, a contractor, MEO, or HPO will be referred to as a service provider.

1.12.1. Contractors have historically provided significant support to the U.S. Armed Forces. Contrac-tor support can augment existing capabilities, provide expanded sources of supplies and services, bridge gaps in the deployed force structure, leverage assets, and reduce dependence on U.S.-based maintenance. The war fighter’s link to the contractor is through the contracting officer or the contract-ing officer’s representative (e.g., quality assurance representative (QAR), contracting officer’s techni-cal represetative (COTR), quality assurance evaluator (QAE)). For MEO and HPO, contact the unit commander. NOTE: for the purposes of this instruction QAE is synonymous with QAR, COTR, and

COR.

1.12.2. Developing Performance-Based Requirements Documents. Performance-based requirements documents (e.g., Statement of Objectives, Statement of Work, Performance Work Statements) focus on desired outcomes and performance standards that communicate what the contractor is asked to pro-vide. Requirements documents provide desired outcomes, performance standards, milestones (if appropriate), and metrics which not only measure the contractor's performance but reflect the manage-ment imperatives and initiatives that drive the AF (e.g., Mission Capable Rate) and other key effi-ciency and effectiveness metrics. Requirements documents do not provide "how to" details that dictate the contractor's organization, management, personnel development, or approach to completing work. The only exceptions are safety, environmental management, and security when the contractor operates on a military installation. Additionally, the contractor is required to follow applicable TOs when performing maintenance. Unlike MEO and HPO, contractor operations and personnel are not supervised by government personnel. Any changes to the scope of the work shall be reflected in an official change to the requirements document, which is provided to the contracting officer for modifi-cation of the contract.

1.12.3. HQ USAF/A4M Responsibilities:

1.12.3.1. Establish and approve policies and procedures for direction and management of the per-formance-based activity.

1.12.3.2. AF maintenance focal point for all inter-service and interagency matters pertaining to the performance-based activity.

AFI21-101 29 JUNE 2006 21

1.12.3.3. Ensures requirements for measurement, documentation, and reporting of the perfor-mance-based activity exist.

1.12.3.4. Ensures policies and procedures contain provisions for continuation of required opera-tion and services in the event of disruption, termination, or default of the performance-based activ-ity.

1.12.4. MAJCOM Responsibilities:

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

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

1.12.4.3. Specifies the forms, methods of documentation, and frequency of reporting used to assess performance-based activities and ensures these requirements are included in the Perfor-mance Management Assessment Program (PMAP).

1.12.4.4. Approves base-level requests that would permit a single Federal Aviation Administra-tion (FAA) certified Airframe/Powerplant (A/P) contractor technician maintaining contracted logistics support (CLS) aircraft to repair and sign off their own Red X’s when sent to recover air-craft off-station.

1.12.4.5. Identifies the qualifications, training requirements and responsibilities for QAE person-nel assigned to surveil performance-based activities.

1.12.4.6. Develops and publishes contingency procedures for support of continuing operations in the event of disruption, termination, or default of contract.

1.12.4.7. Ensures units with assigned QAE personnel meet requirements of AFI 63-124 and Chapter 17 of this publication, along with other applicable guidance.

1.12.5. Unit Responsibilities:

1.12.5.1. Designates a focal point for all functional, technical, and QAE matters pertaining to per-formance-based activities. Ensures the organizational relationship, physical location, and lines of communication between the Functional Director/Commander, QAE personnel, contracting officer, and the performance-based activity, promote efficiency and continuity of operations. If maintenance requires depot level assistance for evaluation and/or repair beyond unit capability, the request shall be made IAW TO 00-25-107.

1.12.5.2. Designates a focal point (e.g., Environmental Coordinator) as the MXG (or equivalent) for all Environmental, Safety, and Occupational Health requirements, compliance, and, as appro-priate, worker protection issues for affecting performance-based activities. The Environmental Coordinator focal point will lead the installation Candidate Process analysis program as identified in AFPD 90-8, Environment, Safety, and Occupational Health/AFI 32-7080/7086 and assist installation tenants and other organizations as required.

1.12.6. In coordination with the contracting officer and the MXG/CC (or equivalent), provide specific guidance to the performance-based activity to ensure proper maintenance discipline and flight worthi-ness of aircraft and subsystems.

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1.13. Modification Management. A modification proposal is a recommendation to change the opera-tion, use, or appearance of AF equipment. Modifications (temporary, permanent, or safety) to AF aircraft or equipment are expressly prohibited without MAJCOM approval. Units will forward modification pro-posals on an AF IMT 1067, Modification Proposal, or approved Research, Development, Test & Evalu-ation (RDT&E) process form, IAW AFI 63-1101, Modification Management, AFI 10-601, Capabilities Based Requirements Development, and MAJCOM directives to the MAJCOM focal point, SPM, and HQ USAF/A4M for approval.

1.13.1. In addition to requirements set forth in AFI 63-1101, an additional requirement is levied by HQ USAF/A4M. Temporary modifications extending beyond a 12 month period requires annual HQ USAF/A4M approval. Extensions must be coordinated through the SPM and lead MAJCOM to HQ USAF/A4M approximately 30 days prior to the anniversary date. For all temporary and permanent modifications, the system and end item Operational Safety, Suitability, & Effectiveness (OSS&E) shall be preserved IAW AFPD 63-12, Assurance of OSS&E, and AFI 63-1201, Assurance of OSS&E.

OSS&E is integral to the modification management process and as such shall be preserved throughout modification planning and execution to ensure operational safety, design integrity and suitability for all modified systems and end items. The weapon system SPM is responsible for maintaining system engineering integrity; the lead command is responsible for fleet-wide interoperability and commonal-ity of that system. Therefore, all proposed permanent and temporary modifications must be approved by both the SPM and lead command and reviewed by the lead command Configuration Review Board (CRB) prior to being implemented. (The lead command is the command that serves as operator’s interface with the SPM for a weapon system as defined by AFPD 10-9, Lead Operating Command Weapon Systems Management).

1.13.2. Modifications to FAA certified aircraft. Modifications to AF aircraft having FAA certification shall not cause the aircraft to lose its FAA certification. All modifications to such aircraft shall comply with AFPD 62-4, Civil Airworthiness Standards for Passenger Carrying Commercial Derivative Transport Aircraft and AFPD 62-5, Standards of Airworthiness for Commercial Derivative Hybrid Aircraft. Such modifications are required to keep the weapon system or aircraft in compliance with FAA standards and to maintain FAA certification.

1.13.3. Modifications to Munitions. All proposed modifications to aircraft-carried munitions shall include SEEK EAGLE certification (per AFI 63-104, The SEEK EAGLE Program). All modifications to AF nuclear munitions or their associated support/training equipment shall be nuclear certified IAW AFI 91-103, AF Nuclear Safety Certification Program. All modifications to AF non-nuclear muni-tions or their associated support/training equipment shall be certified IAW AFI 91-205, Non-Nuclear Munitions Safety Board.

1.14. Maintenance Information Systems (MIS). MIS refers to automated maintenance information systems included in the maintenance portfolio and the AF Knowledge Services (AFKS). MIS includes systems and applications that support and enable maintenance business processes. MIS will be used to document maintenance actions and determine fleet health. MIS and aircraft forms will be documented by the individual completing the task (for Red Ball maintenance, follow locally developed documentation procedures). MIS provides maintenance supervisors with products to evaluate organizational effective-ness and to aid in decision-making. Therefore, deploying units must ensure that all appropriate hardware (e.g., computers and servers) are available at the deployed locations to establish and sustain connectivity.

Refer to Chapter 6 of this instruction. As the maintenance portfolio owner, AF/A4M has central authority for policy and guidance covering all MIS IAW applicable AF 33-series publications. AF/A4M must have

AFI21-101 29 JUNE 2006 23

control over the proliferation of unit- or MAJCOM-unique MIS. If a unit desires to use a system other than the authorized standard MIS, whether commercial off-the-shelf (COTS), government off-the-shelf (GOTS) or locally generated, the unit must submit a request for permission to their MAJCOM 3-digit Maintenance Management Division (i.e., A4M or A4Q). MAJCOM 3-digit functional managers shall coordinate on all requests and forward through the MAJCOM A4 to HQ USAF/A4M for final consider-ation/approval. User may view the approved MIS portfolio by accessing the Enterprise Information Tech-nology Database Respository located on the AF Portal.

1.14.1. MIS Data. Data contained, entered, and retrieved in MIS is "Sensitive/For Official Use Only (FOUO).” Safeguards have been put in place to ensure control of this “Sensitive/FOUO” data with access through “military only” systems. Use is limited to authorized personnel who have been granted access through a controlled process. Each MIS has additional protection with unique, individually granted, need-to-know USERID/Password assurances. It is vital, especially during contingency oper-ations, to capture maintenance data at every location to provide in-depth current/after action analysis of AF, MAJCOM, and unit efforts for deployments and contingencies.

1.15. Maintenance Management Metrics. Metrics provide a measurement of performance and capabil-ity. Leaders, supervisors and technicians must have accurate and reliable information to make decisions.

Primary concerns of maintenance managers are how well the unit is meeting mission requirements, how to improve equipment performance, identifying emerging support problems, and projecting future trends.

Maintenance management metrics—sometimes called quality performance measures or indicators—are a crucial form of information used by maintenance leaders to improve the performance of maintenance organizations, equipment and people when compared with established goals and standards. Metrics often take the form of an “MC Rate Graph” or a “Status of Personnel Training Slide,” presenting a gauge of an organization’s effectiveness and efficiency. Properly used, metrics are roadmaps that help determine where you’ve been, where you’re going, and how (or if) you’re going to get there.

1.15.1. The overarching objective of AF maintenance is to maintain aircraft and equipment in a safe, serviceable and ready condition to meet mission needs. Maintenance management metrics serve this overarching objective and shall be established or maintained by Headquarters AF, Major Commands, Wings and/or Squadrons to evaluate/improve equipment condition, personnel skills and long-term fleet health. Metrics shall be used at all levels of command to drive improved performance and adhere to well-established guidelines.