AFI 21-101 12 April 2010.pdf

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

AIR FORCE INSTRUCTION 21-101

12 APRIL 2010

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/A4LM

Supersedes: AFI21-101, 1 June 2006

Certified by: HQ USAF/A4L

(Maj Gen Robert H. McMahon)

Pages: 380

This instruction implements AFPD 21-1, Air and Space Maintenance and supersedes AFI 21-

101, (1 Jun 2006), AFI 21-107 (19 Jul 1994), and 21-112 (7 Sep 2001). 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) and the Air

National Guard (ANG), along with their subordinates. Lead Commands will supplement this document to identify any required deviations (applicability, variance, and/or differences in organizational placement of responsibilities/processes) for Non-Standard Organizations (NSO).

Identify each deviation on the supplement with ―(DEV)‖ directly preceding the paragraph number. These supplements must be submitted to AF/A4L for approval, however supplements not including deviations do not require AF/A4L approval. Note: for this purpose ALCs are considered NSO's). Additionally, supplements must be made IAWAFI 33-360, Publication

Management Program. Any maintenance units, Unmanned Aerial Vehicle (UAV) operations support units, or operational test units who perform maintenance on aircraft, aircraft support systems, or communication interfaces such as Remote Split Operations LRU's carrying aircraft control signals not maintained by base Communications Squadrons or DISA, must comply with the requirements identified within this instruction. Non-traditional aircraft maintenance Air

Force Specialty Codes (AFSC) such as 3D1XX, Cyber Systems career field or equivalent contractors must comply with requirements identified within this instruction or meet its intent as part of the statement of work and system of oversight. In the event of a conflict with other guidance, this instruction will take precedence over all except Technical Orders (TO)s. Waiver authority for this instruction is HQ USAF/A4L. For questions on interpreting this instruction, http://www.e-publishing.af.mil/

2 AFI21-101 12 APRIL 2010

first contact your Lead Command maintenance policy activity. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with AFMAN

33-363, Management of Records and disposed of IAW Air Force Records Disposition Schedule

(RDS) located at https://www.my.af.mil/gcss-af61a/afrims/afrims/rims.cfm

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 2006 edition. This version incorporates requirements of PAD 07-13 and subsumes AFIs 21-107 and 21-112. It has been revised in an effort to be more directive in nature providing the user a clear picture of responsibilities. The duplication of many requirements listed in both the Combat Wing Organization (CWO) sections and Air Logistics Centers (ALC)/Aircraft Maintenance and Regeneration Center (AMARC) sections of the 2006 version have been removed in order to reduce confusion and increase standardization. Chapter 8 still contains a section applicable just to ALCs but is in addition to the rest of the chapter. This revision is a complete rewrite.

Chapter 1—MANAGEMENT PHILOSOPHY AND POLICY 14

1.1. Introduction

1.2. Organization

1.3. Aircraft and Equipment Readiness

1.4. Maintenance Concept

1.5. Maintenance Discipline

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

1.7. Publications

1.8. Waiver Request

1.9. Operating Instructions (OI)

1.10. Performance-Based Activities

1.11. Modification Management

1.12. Maintenance Information Systems (MIS)

1.13. Communications

1.14. Duty Shifts and Rest Periods

1.15. Maintenance Training

1.16. Maintenance Resource Management (MRM)

1.17. Maintenance Repair Priorities

Table 1.1. Maintenance Repair Priority Designators

1.18. AF Munitions Policy

https://www.my.af.mil/gcss-af61a/afrims/afrims/rims.cfm

AFI21-101 12 APRIL 2010 3

1.19. Unit Committed Munitions List (UCML), Test/Training Munitions List (TTML). 23

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

1.21. Civilian Visitors

Chapter 2—SAFETY 26

2.1. General Safety Guidance

2.2. Air Force Occupational and Health (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

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 29

3.1. General

3.2. Wing Commander (WG/CC) Responsibilities

3.3. Wing Vice Commander (WG/CV) Responsibilities

3.4. Maintenance Group Commander Responsibilities

3.5. Deputy MXG/CC will:

3.6. MXG Superintendent Responsibilities

3.7. Squadron Commander (SQ/CC) Responsibilities

4 AFI21-101 12 APRIL 2010

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

Responsibilities

3.9. Flight Commander/Flight Chief or AMU Officer in Charge (OIC)/Superintendent: 39

3.10. Section NCOIC/Chief

3.11. Production Superintendent (Pro Super)

Chapter 4—AIRCRAFT/HELICOPTER MAINTENANCE SQUADRON (AMXS/HMXS) 46

4.1. General

4.2. MX Operations Officer (MOO)/Maintenance Superintendent (MX SUPT)

Responsibilities

4.3. AMU

4.4. AMU OIC/SUPERINTENDENT Responsibilities

4.5. Production Superintendent

4.6. Flightline Expediter

4.7. Aircrew and Maintenance Debrief Section

Table 4.1. Landing Status Codes

Table 4.2. System Capability Codes

Table 4.3. Deviation Cause Codes

4.8. Aircraft Section

4.9. Specialist Section

4.10. Weapons Section (excluding systems listed in para 4

4.11. Weapons Section (Helicopter/CV-22/UAS Units)

4.12. Support Section

4.13. AMU Supply Support Element

Chapter 5—MAINTENANCE SQUADRON (MXS) 72

5.1. General

5.2. MX Operations Officer(MOO)/MX SUPT Responsibilities

5.3. Production Superintendent

5.4. Specialist Support

5.5. Accessories Flight

5.6. Aerospace Ground Equipment (AGE) Flight

5.7. Armament Flight

5.8. Avionics Flight

Figure 5.1. Example Index Numbers

AFI21-101 12 APRIL 2010 5

5.9. Fabrication Flight

5.10. Maintenance Flight

5.11. Munitions Flight

5.12. Propulsion Flight

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

Chapter 6—MAINTENANCE OPERATIONS SQUADRON 113

6.1. General

6.2. Maintenance Operations Flight (MOF)

6.3. Maintenance Training Flight (MTF)

6.4. Programs and Resources Flight

Chapter 7—MAINTENANCE PLANS, SCHEDULING AND DOCUMENTATION (PS&D) 130

7.1. General

7.2. Manage the following programs for assigned aircraft and equipment using the following guidelines:

7.3. Operations and Maintenance Planning Cycle

7.4. First Look Requirements

7.5. Annual Maintenance Planning Cycle

7.6. Quarterly Maintenance and Operations Planning

7.7. Monthly Maintenance and Operations Planning

7.8. Weekly Scheduling

7.9. AMU/AMXS

7.10. Wing Aerospace Vehicle Distribution Officer (AVDO)

7.11. The PS&D section NCOIC is the wing 2R1XX functional manager

7.12. Responsibilities of Contingency/Expeditionary (Cont/Exp) units (i

Chapter 8—QUALITY ASSURANCE (QA) 153

8.1. General. 153

Section 8A—All Units 153

8.2. Responsibilities

8.3. Quality Assurance OIC/Superintendent (QA OIC/SUP) (MXG QA Chief in ALC)

Responsibilities

8.4. Chief Inspector (First Level Supervisor QAS for ALC) Responsibilities

8.5. Quality Assurance Inspector/Quality Assurance Specialists (QAS) Responsibilities. 156

8.6. Quality Assurance Training

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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)

8.11. Lead Command-approved QA database

8.12. QA Product Improvement Programs (PIP)

8.13. Configuration Management (CM) and Modification Management

8.14. Technical Order Distribution Office (TODO)

8.15. One-Time Inspections (OTI) program

8.16. Functional Check Flights (FCFs) to include Operational Check Flights (OCFs). . 170

8.17. Inflight Operational Checks

8.18. High Speed Taxi Checks

8.19. Weight and Balance (W&B) Program

8.20. Chafing Awareness Program

8.21. Quality Assurance Evaluator (QAE)/ Quality Assurance Representative (QAR). 174

Section 8B—ALC in addition to section 8A the following guidance applies: 174

8.22. QA Responsibilities

8.23. MXW Quality Assurance Chief Responsibilities

8.24. MXG QA Chief Responsibilities

8.25. Training Requirements

Chapter 9—IMPOUNDMENT PROCEDURES 177

9.1. Aircraft and Equipment Impoundment

9.2. Specific Guidance

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

Chapter 10—TOOL AND EQUIPMENT MANAGEMENT 182

10.1. Tool and Equipment Management

10.2. Guidelines for Program Management

10.3. General Program Guidelines

AFI21-101 12 APRIL 2010 7

10.4. Tool Accountability

10.5. Tool and Equipment Marking and Identification

Table 10.1. ALC/AMARG ID number marking Codes

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

10.7. Tool Room Operations and Security

10.8. Lost Item/Tool Procedures

Chapter 11—MAINTENANCE SUPPLY SUPPORT 194

11.1. General

11.2. Maintenance Supply Liaison (MSL) Section

11.3. Decentralized supply support

11.4. Ordering Parts

11.5. Processing

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

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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

11.36. Certifying Items Associated With Explosives:

Chapter 12—WING WEAPONS MANAGER AND WEAPONS STANDARDIZATION 206

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

Figure 12.1. Weapons Expeditor 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. Minimum Proficiency Requirement Loading

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

AFI21-101 12 APRIL 2010 9

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

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

Table 12.3. Unmanned Aerial Vehicle Munitions Family Group and Load Training Time Standards

(in minutes)

Chapter 13—MOBILITY AIRCRAFT DEFENSIVE SYSTEMS LOADING POLICY 231

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

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:

13.9. Chaff/Flare Build-up

Chapter 14—ADDITIONAL MAINTENANCE REQUIREMENTS AND PROGRAMS 236

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

14.6. Aircraft Structural Integrity Program (ASIP)

14.7. Hydraulic Fluid Purification (HFP):

14.8. Cannibalization Program

14.9. Combat Sortie Generation

14.10. Crash Damaged or Disabled Aircraft Recovery (CDDAR) Program

14.11. Dropped Object Prevention (DOP) Program

14.12. F100-PW-100/220/220E 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

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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. Land Mobile Radio (LMR) Management

14.25. Lead Technician

14.26. MRT Procedures

14.27. Protective Aircraft Shelter (PAS) Environment

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

14.29. Ramp Inspection Program

14.30. Red Ball Maintenance

14.31. Scanning Electron Microscope/Energy Dispersive X-Ray (SEM/EDX) Master Chip

Detector Analysis Program (MCDP)

14.32. Self-Inspection Program

14.33. Senior Leaders’ Maintenance Course (SLMC)

14.34. Special Certification Roster (SCR)

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

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

14.36. 406 MHz Emergency Locator Transmitter (ELT) Systems

14.37. Lead Commands will establish an IFF Mode IV Program

Chapter 15—MAINTAINING COMMERCIAL DERIVATIVE AIRCRAFT 307

15.1. Background Information and Objective

15.2. AF/A4L Responsibilities:

15.3. HQ Air Force Materiel Command (HQ AFMC/EN)Responsibilities:

15.4. Lead Command Responsibilities:

15.5. Field Units Responsibilities:

15.6. Certification Requirements

15.7. Inspection Requirements

15.8. Deviations From Inspection Requirements

15.9. Component Overhaul and Time Change Intervals

AFI21-101 12 APRIL 2010 11

15.10. Airframe Overhaul

15.11. Aircraft and Component Modifications

15.12. Time Compliance Technical Orders

Chapter 16—AIRCREW EGRESS SYSTEMS MAINTENANCE 309

16.1. Egress Maintenance:

16.2. Facilities:

16.3. Safety Requirements

16.4. Classification Training:

16.5. Initial Certification of Egress Personnel:

16.6. Initial Certification of Non-Egress Personnel:

16.7. Decertification:

16.8. Recertification:

16.9. Using Newly Assigned Uncertified Egress Personnel:

16.10. Egress/Cockpit Familiarization Training:

16.11. Units with Unique, Experimental, or Test Aircraft

16.12. Egress Systems Inspections and Documentation:

16.13. Aircraft Static Display

16.14. Technical Assistance

16.15. Training Aircraft

16.16. Conferences:

Chapter 17—CENTRALIZED REPAIR FACILITIES (CRFS) 315

17.1. Introduction

17.2. Organization

17.3. Command Authority

17.4. CRF Common Operating Picture (COP)

17.5. Rotable Pools

17.6. Wing-Retained Tasks

17.7. Documentation

17.8. Metrics

17.9. Liaison with Logistics Readiness Squadron (LRS)

17.10. Agile Combat Support (ACS) Planning

Chapter 18—CONTRACT SURVEILLANCE 320

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18.1. Government Contract Quality Assurance

18.2. Management of Government Property

18.3. Contract Administration

18.4. Contracting Officer

18.5. FC/FD Role

18.6. Chief QAE

18.7. QAE

18.8. QAE/FC/FD training requirements

18.9. PP

Figure 18.1. Key Elements

18.10. Surveillance Scheduling

18.11. Inspections

18.12. Functional Check Flight (FCF) Pilot Responsibilities

18.13. Documenting/correcting contractor performance

18.14. End of month surveillance summary

18.15. Contractor non-conformance

18.16. Past Performance Reporting

18.17. Acceptance of services will be accomplished utilizing DD Form 250 or the Wide Area

Work Flow system (WAWF)

18.18. Award fee administration

18.19. Transition administration (FAR Part 49)

18.20. Prescribed Forms

18.21. Adopted Forms

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 333

Attachment 2—SUPPLY REPORTS AND LISTINGS 367

Attachment 3—AIRCRAFT COMMANDER FEEDBACK ON FCC 369

Attachment 4—QUARTERLY FCC REPORT FORMAT 370

Attachment 5—ANNUAL FCC REPORT 371

Attachment 6—FCC SDAP REQUEST 372

Attachment 7—MAINTENANCE RECOVERY TEAM (MRT) TASKING CHECKLIST. 373

Attachment 8—MAINTENANCE RECOVERY TEAM (MRT) CHIEF RESPONSIBILITIES 375

Attachment 9—MAINTENANCE RECOVERY TEAM (MRT) CHIEF TASKING CHECKLIST 377

AFI21-101 12 APRIL 2010 13

Attachment 10—WAIVER/CHANGE REQUEST FORMAT 378

Attachment 11—DROPPED OBJECT PROGRAM (DOP) REPORTING FORMAT 379

Attachment 12—FOREIGN OBJECT DAMAGE (FOD) REPORT 380

14 AFI21-101 12 APRIL 2010

Chapter 1

MANAGEMENT PHILOSOPHY AND POLICY

1.1. Introduction. This instruction prescribes basic aircraft and equipment maintenance policy and procedures used throughout the USAF. Any deviations from this guidance are prohibited without Lead Command review and HQ USAF/A4L waiver/variance approval. For the purpose of this instruction and development of maintenance policy, Lead Commands are Air Combat

Command, Air Mobility Command, Air Force Special Operations Command, Air Education and

Training Command, Air National Guard, Air Force Reserve Command, Air Force Space

Command, Air Force Global Strike Command and Air Force Materiel Command. As it pertains to weapon system specific issues or requirements, AFPD 10-9 takes precedence. For the purpose of this policy, the term AFMC Single Manager (SM) includes System Program Directors (SPD), Product Group Managers (PGM) and Supply Chain Managers (SCM),

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.

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. 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 components 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 units must implement and manage the tasks specified in the scheduled program for their assigned aircraft and associated support equipment (SE).

Preventive maintenance concepts are described in TO 00-20-1, Aerospace Equipment

Maintenance Inspection, Documentation, Policies, and Procedures.

1.3.2. Mission Generation maintenance activities must have the capability to launch and recover aircraft and sustain the preventive maintenance program. Generally, this means most units must possess a complement of equipment and supplies to perform on-equipment and off-equipment maintenance.

1.3.2.1. Off-Equipment Maintenance—Maintenance tasks that cannot be effectively accomplished on or at the weapon system or end-item of equipment, but require the removal of the component to a shop or facility for repair.

AFI21-101 12 APRIL 2010 15

1.3.2.2. On-Equipment Maintenance—Maintenance tasks that can be effectively performed on or at the weapon system or end-item of equipment.

1.4. Maintenance Concept. Maintenance is organized into two mutually supporting networks, Mission Generation Network (MGN) and Repair Network (RN), The MGN is optimized for mission generation at the wing level and contains the minimum capabilities required to launch, recover, configure, inspect and repair aircraft. The RN supports the MGN by providing serviceable components/equipment and conducting inspection, repair, and modification of aircraft and equipment.

1.4.1. Requests For Assistance (RFA). If a maintenance activity requires assistance for evaluation and/or repair beyond unit capability, the request must be made IAW AFI 21-103, Equipment Inventory, Status And Utilization Reporting, TO 00-25-107, Maintenance

Assistance, and TO 00-20-14, AF Metrology and Calibration Program, or automated process as approved by the mission design series (MDS) specific system manager (e.g., C-130

AIRCATS, F-16 TAR). All requests for assistance must be coordinated through the Quality

Assurance (QA) office and Maintenance Operations Squadron (MOS) Plans, Scheduling and

Documentation (PS&D).

1.5. Maintenance Discipline. It is the responsibility of all maintenance personnel to comply with all written guidance to ensure required repairs, inspections, and documentation are completed in a safe, timely, and effective manner. Supervisors are responsible for enforcing and establishing a climate that promotes maintenance discipline.

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

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

1.5.1.2. Should - Indicates a preferred method of accomplishment.

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

1.6. Use of Technical Orders (TO) and TO Supplements. Use of the prescribed technical data to maintain aircraft and equipment is mandatory.

1.6.1. Units/Supervisors will:

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

1.6.1.2. Establish and manage TOs and supplements IAW TO 00-5-1, AF Technical

Order System

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

1.6.1.4. Ensure all authorized technical data variances are kept with aircraft/equipment historical records until no longer applicable.

1.6.2. All personnel will:

1.6.2.1. Recommend improvements or corrections for TO deficiencies IAW TO 00-5-1.

The AFTO IMT 22 prescribed in TO 00-5-1 may be submitted as an attachment to an e-

16 AFI21-101 12 APRIL 2010

mail to report problems of a TO. Official TO updates are the only valid authority for correcting a technical deficiency and implementing change.

1.6.2.2. Continually assess the currency, adequacy, availability, and condition of their

TOs and supplements.

1.6.2.3. Ensure waivers to, deviations from, or additional technical data procedures are issued using approved official communication methods (e.g., signed letter, organizational

E-mail, AMHS message or authorized automated TO 00-25-107 technical assistance request system, or applicable guidance from ALC). Ensure all authorized technical data variances are kept with aircraft/equipment historical records until no longer applicable.

1.6.3. Lead Command will ensure any new or modified configurations or maintenance conditions are coordinated with, and approved by, the designated Weapons System Lead

Command IAW AFPD 10-9 and the System Program Manager (SPM) responsible for the operational safety, suitability, and effectiveness (OSS&E) of the systems and end-items prior to implementation.

1.7. Publications. Lead Commands 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 specific procedures will enhance operations. Units shall adhere to the following procedures:

1.7.1. Do not publish unit instructions or Operating Instructions (OI) to change or supplement TOs. Units must use procedures in TO 00-5-1 to update TOs.

1.7.2. Coordinate directives with all appropriate unit agencies.

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

1.7.4. Conflicts between procedural technical publications and weapon system specific technical publications will be resolved in favor of the weapon system specific technical publication.

1.7.5. Conflicts between Air National Guard/AF Reserve and AF publications are resolved

IAW AFI 33-360.

1.7.6. Develop, control, and maintain technical data checklists IAW Chapter 8 of this instruction, TO 00-5-1, and Lead Command instructions.

1.7.7. 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 area(s) during actions such as aircraft crash, mass loads, severe weather warning or evacuation, self-inspections, activity inspections, etc. Functional checklists shall not be used in place of or to circumvent technical data for operation, servicing, inspection or maintenance of aircraft, aircraft systems and all other equipment supporting aircraft and munitions maintenance. QA will ensure functional checklists are reviewed every two years for currency and document this review.

AFI21-101 12 APRIL 2010 17

1.8. Waiver Request. MAJCOMs are not permitted to deviate from this instruction without receiving written approval from HQ USAF/A4L. Units must submit waiver requests through the

Lead Command. Waivers should only be submitted when urgent or immediate action is required.

These circumstances are usually mission impacting and cannot be submitted as part of the normal AFI change process. See Attachment 10 for template.

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

TOs. Publish MX 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: OG, MXG, MSG, etc. The MXG QA will be the 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.

1.9.1. QA will review all OIs every 2 years for accuracy, intent and necessity and document this review. (ALC the MXW Management Operations Office will perform this function)

1.9.2. 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.

1.10. Performance-Based Activities. This section identifies the basic responsibilities for managing performance-based activities (e.g., contract maintenance, Most Efficient Organization

(MEO), or High Performance Organization (HPO) except DoD High Performing Organization

Pilot program under section 337 of the NDAA 2004 (Public Law 108-136) which will follow

DoDI 4100). 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.

1.10.1. Lead Command/MAJCOM Responsibilities:

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

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

1.10.1.3. Specify the forms, methods of documentation, and frequency of reporting used to assess performance-based activities and ensures these requirements are included in the

Performance Management Assessment Program (PMAP).

1.10.1.4. Approve base-level requests that would permit a single Federal Aviation

Administration (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 aircraft off-station.

1.10.1.5. Identify the qualifications, training requirements, and responsibilities for QAE personnel assigned to surveil performance-based activities.

1.10.1.6. Ensure units with assigned QAE personnel meet requirements of AFI 63-124 along with other applicable guidance.

18 AFI21-101 12 APRIL 2010

1.10.1.7. Ensure aircraft depot maintenance contracts, Statements of Work (SOW), and

Performance Work Statement (PWS) are coordinated with the MAJCOM Munitions

Functional to ensure munitions accountability and disposition requirements are adhered to.

1.10.2. Unit Responsibilities:

1.10.2.1. Designate a focal point for all functional, technical, and QAE matters pertaining to performance-based activities.

1.10.2.2. Designate a MXG focal point (e.g., Environmental Coordinator) for all

Environmental, Safety, and Occupational Health requirements, compliance, and, as appropriate, worker protection issues affecting performance-based activities. The

Environmental Coordinator will perform duties as outlined in AFPD 90-8, Environment, Safety, and Occupational Health/AFI 32-7080, Pollution Prevention Program and AFI

32-7086, Hazardous Materials Management.

1.10.2.3. 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 worthiness of aircraft and subsystems.

1.10.2.4. Develop and publish contingency procedures for support of continuing operations in the event of disruption, termination, or default of contract. This includes the provision of contingency procedures for the accomplishment of critical mission operations in the aftermath of natural or man-made events such as natural disasters, major accidents, and terrorist attacks involving chemical, biological, or radiological materials.

1.11. Modification Management. A modification proposal is a recommendation to change the operation, use, or appearance of AF equipment. Modifications (temporary, permanent, or safety) to AF aircraft or equipment are expressly prohibited without SPM approval. Refer to AFI 63-

1101, Modification Program Management, for modification management procedures.

1.11.1. In addition to requirements set forth in AFI 63-101, temporary modifications extending beyond a 12 month period will not be maintained by government employees unless verified red-line technical data is available.

1.11.2. 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 Design Certification Program. All modifications to AF conventional munitions or their associated support/training equipment shall be certified IAW AFI 91-205, Non-Nuclear Munitions Safety Board.

1.12. Maintenance Information Systems (MIS). MIS refers to automated maintenance information systems that support and enable maintenance business processes. MIS will be used to document maintenance actions and determine fleet health. The information entered into the

MIS must match the content of aircraft forms. MIS data entries do not have to be accomplished by the same individual who documented the aircraft forms, but employee number/man number/USERID of person accomplishing the actual work must be input into the MIS. Red Ball maintenance will be documented IAW chapter 14 of this instruction.

AFI21-101 12 APRIL 2010 19

1.12.1. Units must use approved MIS portfolio which may be viewed by accessing the

Enterprise Information Technology Database Repository located on the AF Portal. If a unit desires to use a system other than the authorized standard MIS the unit must submit a request to their Lead Command 3-digit Maintenance Management Division (i.e., A4M or A4Q).

Lead Command 3-digit functional managers shall coordinate on all requests and forward through the Lead Command A4 to HQ USAF/A4L for final consideration/approval. Upon receipt of A4L approval request for MIS systems procurement must be done through the

AF/A4RB process.

1.13. Communications. Effective maintenance requires efficient communication. Radios must be available to expedite personnel, equipment, material, and maintenance data throughout the maintenance complex. Unit commanders shall develop communication plans according to mission requirements.

1.13.1. Lead Commands will develop guidance on the use and proper control of personal electronic and communication devices (i.e. cell phones, pagers, portable music/video players, electronic games) on the flightline, in munitions areas, hangars, and/or other industrial work areas.

1.14. Duty Shifts and Rest Periods. During normal operations, maintenance personnel will be scheduled for duty based on a goal of a 40-hour work week. Maintenance personnel will have their duty hours aligned to provide the best mission support. Consider climatic conditions when determining work schedules; local work/rest schedules for extreme temperatures are recommended by the Medical Group commander.

1.14.1. Supervision at all levels will be equitably distributed to cover all duty periods.

1.14.2. The following guidance establishes maximum duty periods and minimum rest periods for all personnel assigned to a maintenance activity. MXG/CCs may waive the following provisions during emergencies and advanced readiness conditions. Duty periods for crew chiefs and maintenance technicians traveling in their units’ aircraft are normally controlled by the aircraft commander.

1.14.3. Duty time begins when personnel report for duty (this includes aircraft showtime) and ends when their supervisor releases them. A rest period is a block of time that gives a person the opportunity for at least 8 hours of uninterrupted sleep in a 24-hour period. (Note:

This rest period may not be waived for exercises or inspections.)

1.14.4. Do not schedule personnel for more than 12 hours of continuous duty time. Provide a rest period after each shift. Time spent in exercise/contingency deployment processing lines and in-transit counts toward the total duty day, and may impact time available to perform maintenance at the destination.(This includes Flying Crew Chiefs (FCC), Mission Essential

Personnel (MEP), Maintenance Recovery Teams (MRT), and normal deployment travel).

MXG/CCs are final approval authority for exceeding 12-hour limit up to a maximum of 16 hours. AC/Detachment CC assumes this responsibility in deployed/travel status.

1.14.5. Personnel will not handle, load or perform maintenance on nuclear weapons, conventional munitions and/or egress explosives beyond a 12-hour continuous duty period.

This requirement may not be waived for exercises or inspections; however, the 12-hour continuous duty period may be exceeded for shift turnover/administrative actions only and will be avoided to the maximum extent possible. The Group Commander or equivalent may

20 AFI21-101 12 APRIL 2010

waive this requirement during advance defense readiness conditions, actual emergencies as defined in DoD Directive 3150.2, DoD Nuclear Weapons System Safety Standards, or to resolve an unexpected event (e.g.; disabled vehicle, WS3 fault, hoist failure, etc…).

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

1.14.7. Ensure individuals are afforded adequate rest periods and breaks. Consider climatic conditions when determining work schedules. Stop anyone if fatigue may jeopardize safety.

In all cases, aircraft commanders/supervisors ensure aircraft maintenance personnel are not required to perform duty when they have reached the point of physical or mental fatigue rendering them incapable of performing their assigned duties safely and reliably.

1.15. Maintenance Training. Maintenance training provides initial, recurring and advanced proficiency, qualification, or certification skills needed by a technician to perform duties in their primary AF Specialty Code (AFSC)/Civilian Job Series. Provide training in combat and sortie generation skills not normally integrated into peacetime operations (e.g., munitions and external fuel tank build-up, hot refueling). When balancing resources, (e.g., aircraft, support equipment, facilities, tools, funding, personnel), maintenance training carries an equal priority with the operational training mission. For maintenance training policy and guidance, refer to AFI 36-

2232, Maintenance Training and Lead Command directives.

1.15.1. Cross-Utilization Training (CUT). CUT provides the unit internal flexibility by training individuals to perform tasks that are outside their primary AFSC. CUT is not a long-term fix or management solution for an AFSC shortfall. Ensure the training records of individuals receiving CUT are appropriately documented. Address questions regarding CUT to the applicable MAJCOM AFSC Functional Manager.

1.15.2. For emerging weapon systems, extensive CUT may be necessary until proper workforce AFSC balancing and assignment is achieved. MAJCOM Functional managers will closely monitor the effects of CUT for adverse trends. Note: Prohibitions in this guidance do not apply to UAS (Predator/Global Hawk) weapon systems or other weapon systems where the AF approved maintenance philosophy dictates the merger of AFSCs.

1.15.3. Weapons Load Training (WLT). Weapons standardization provides initial and recurring weapons load training and certification.

1.16. Maintenance Resource Management (MRM). MRM is a course designed to immerse all personnel into the culture and knowledge of human factors philosophy focusing on the importance, requirements, and implementation of MRM principles into daily maintenance activities. Error reduction efforts through human factors will be used to improve processes, reduce maintenance errors, decrease maintenance induced damage, and decrease on-the-job-injuries. This will be done by integrating the technical skills of maintenance personnel with interpersonal skills and basic human factors knowledge along with operational risk management in order to improve communication, effectiveness, and safety in maintenance operations.

1.16.1. To facilitate our common MRM culture, the Air Force’s Core MRM course will consist of a one-time, 4-hour block of instruction taught by a certified MRM facilitator using the mandatory course material currently documented at the MRM CoP, https://afkm.wpafb.af.mil/ASPs/CoP/EntryCoP.asp?Filter=OO-LG-AN-83. To meet the needs of our total force, MAJCOMS have the option of supplementing the course, in both https://afkm.wpafb.af.mil/ASPs/CoP/EntryCoP.asp?Filter=OO-LG-AN-83

AFI21-101 12 APRIL 2010 21

frequency and duration, to meet unique unit and mission requirements. MAJCOMs can further delegate individual MXG/CCs the authority to supplement their MRM courses to address local, base-level requirements.

1.16.2. MRM training is required at all stateside and overseas long-tour locations and will be taught to all military personnel serving in maintenance organizations. MAJCOMs will determine the applicability and requirement for MRM training for contractors, government civilians, and AF military personnel possessing a maintenance AFSC but performing duties in a non-maintenance role. Because of the challenges posed by wholesale manpower rotations, MRM training is not required at short-tour locations; however, these units will advocate MRM to the maximum extent possible in order to strengthen the cultural changes

MRM requires to succeed.

1.16.3. The AF/A4L appointed OPR will:

1.16.3.1. Conduct annual course reviews to ensure currency of MRM course content.

1.16.3.2. Coordinate course updates with HQ AFSC (AF Safety Center)/SEFO and

AFSC/SEFL for subject matter expertise, to include those areas such as human factors, fatigue, etc, and for current safety statistics.

1.16.3.3. Ensure current course content is available on the MRM CoP.

1.16.4. MAJCOM A4s will:

1.16.4.1. Assign an MRM OPR and identify the OPR POC to AF/A4LM.

1.16.5. MXG/CC

1.16.5.1. Encourage training participation and attendance by other base agencies.

1.16.5.2. When practical, ensure classes are populated with a mixture of AFSs, skill levels and ranks from across the MXG to maximize benefits of course discussions.

1.16.5.3. Ensure course completion is tracked in the applicable MIS.

1.17. Maintenance Repair Priorities. Maintenance repair priorities are listed in Table 1.1.

This does not prohibit the Production Superintendent, in coordination with the Maintenance

Operations Center (MOC), from changing the maintenance repair priority when warranted.

Raising or lowering maintenance repair priorities does not necessarily require a corresponding change in the Logistics Readiness Squadron (LRS) delivery priority. During Operational Plan

(OPLAN) 8010 or operational exercise, the preplanned maintenance flow determines job sequence. The maintenance repair priority and LRS delivery priorities are normally identical.

However, the Production Superintendent may authorize the use of a less responsive LRS delivery priority.

Table 1.1. Maintenance Repair Priority Designators.

PRIORITY APPLICATION

1 Aircraft on alert status, war plan or national emergency missions, including related Aero space Ground Equipment (AGE), munitions and munitions support equipment (MSE).

2 Primary mission aircraft, related AGE, munitions, and munitions support equipment, for the first 8 work hours after landing or start of recovery or within 6 work hours of a sched uled launch, alert or test flight and during simulated generation/ORI.

22 AFI21-101 12 APRIL 2010

Air evacuation, rescue, weather mission aircraft, related AGE, munitions, and munitions support equipment.

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

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

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

Time change requirements for nuclear weapons.

Repair cycle assets to satisfy a Mission Capable (MICAP) condition.

Spares not available in supply.

Critical end items and spares not available in supply.

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

Avionics shop electronic AGE and automated test stations.

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

Administrative aircraft undergoing scheduled or unscheduled maintenance.

Routine maintenance of AGE, not otherwise listed above.

WRM items due maintenance or inspection.

Inspection, maintenance, and Time Compliance Technical Order (TCTO) compliance of mission support kit (MSK) or mobility readiness spares package (MRSP) materiel.

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

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

Scheduled calibration and unscheduled repairs on PME not listed above.

Scheduled maintenance to include periodic inspections, routine TCTO, MCL, and Time

Change Items (TCIs).

Primary mission CEM systems or equipment including associated AGE undergoing extensive repair or modification.

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

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

Bench stock requirements.

Extensive repair of aircrew training devices.

Time change requirements not listed above.

Routine repair of AGE and repair cycle assets.

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

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

Equipment requirements.

6 Fabrication and repair of non-aeronautical items.

AFI21-101 12 APRIL 2010 23

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

7 Spares/repair cycle assets excess to base requirements.

1.18. AF Munitions Policy. AF Munitions Policies are contained in AFI 21-200, Munitions and Missile Maintenance Management, AFI 21-201, Conventional Munitions Maintenance

Management and AF Nuclear Munitions Policy is contained in AFI 21-204, Nuclear Weapons

Maintenance Procedures. Lead Commands will develop and provide policy and guidance on managing and limiting munitions use as necessary . This will ensure munitions remain available and in reliable condition and at the same time provide a realistic training environment and support for exercise purposes.

1.18.1. Live and inert missiles (or electrical simulators) of the same type must not be loaded or flown together on an aircraft for any purpose. Live and inert (to include training or practice) bombs must not be loaded in/on the same dispenser/rack or flown on an aircraft load together. Any request to deviate from or waiver to this policy must be coordinated through the WWM, and must be submitted via official message to the MAJCOM Munitions

Division, Weapons Safety, and Operations Weapons and Tactics/Training Divisions. The

MAJCOM Munitions Division is the sole approval authority for these deviations/waivers.

Test organizations may load and fly live and inert munitions on the same aircraft for test missions only, as long as the flight profile is IAW an approved test directive that has been through a Safety Review Board process and flight clearance through the applicable System

Program Office SPO/Seek Eagle office has been properly obtained.

1.18.2. Request for waiver of, or deviation to, this policy will include as a minimum: 1).

Operational Risk Assessment report and proposed controls to mitigate or eliminate hazards to personnel, damage to aircraft and support equipment or inadvertent employment of live ordnance, and, 2). A signed copy of the Test Requirement Plan, Test Plan, or Concept

Employment Plan. Approved requests will remain valid only for the event requested and will not exceed 60 days.

1.18.3. Captive Air Training Munitions (CATM): Safety pins/streamers for arming keys/safe-arm handles on CATMs may be removed for daily training/flying operations provided positive control and accountability is maintained for these items. (Note: AIM-9M

CATM arming handles will be permanently removed). MXG/CC may authorize removal of additional components (i.e.; wings, fins, etc.) for daily training/flying operations provided

CATMs are flown in an authorized flight configuration (Seek Eagle) IAW applicable MDS -

1 flight manuals. These components are only removed for foreign or dropped object prevention. Any CATM missiles used for exercises, Load Crew Training and inspections will be configured to the maximum extent possible with all safety devices and components to mirror the parent tactical munitions.

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

(TTML). Operational units will use UCML’s, Test/Training (AETC and AFMC only (includes

ARC gained units in these commands)) will use TTML’s unless they already require a UCML

(i.e., NORAD Committed). The UCML/TTML is a list of primary munitions (PM), support munitions (SM), and limited-use munitions (LM) necessary to meet unit operational/test/training requirements and is published IAW this instruction. The list of PM cannot include more than 10 individual munitions or munitions family groups (MFG) combined per mission, design, and series (MDS) aircraft assigned. The UCML/TTML also specifies the minimum certified load

24 AFI21-101 12 APRIL 2010

crews required to meet unit requirements. MAJCOMS may supplement UCML/ TTML processing, coordination and appendix requirements.

1.19.1. As a minimum, UCML/TTML’s will be updated annually to identify all munitions tasked and/ or required to support test/training or OPLANs and Designed Operational

Capability…