306_FTG_OI_21-107.pdf

BY ORDER OF THE COMMANDER 306 FTG OPERATING INSTRUCTION 21-107

306 FLYING TRAINING GROUP (FTG)

9 May 2012

Air and Space Maintenance

Quality Assurance Surveillance Plan

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: This publication is available digitally in the 306 FTG Stan/Eval

SharePoint® Publication Library located at: https://eim.usafa.edu/unit/306ftg/ftgv/frst/ default.aspx

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: 306 FTG/FTGQ Certified by: 306 FTG/CD

(Lt Col Esper)

Supersedes: 306 FTG OI 21-107, 24 May 2011 Pages: 35

This publication implements Air Force Policy Directive (AFPD) 21-1, Air and Space

Maintenance. This Quality Assurance Surveillance Plan (QASP) has been developed to implement the contract surveillance requirements of Air Force Instruction (AFI) 21-101, Aircraft and Equipment Maintenance Management, Air Education and Training Command (AETC)

Supplement, Chapter 18, and Air Force Federal Acquisition Regulation Supplement (AFFARS)

Mandatory Procedure 5301.602-2(d) for the United States Air Force Academy (USAFA)

Contractor Logistics Support Contract. Its purpose is to provide the Contracting Officer

Representative (COR) an effective and systematic surveillance method for fairly evaluating the contractor's performance throughout the life of the contract. COR personnel will ensure contract compliance through the guidance contained in this Operating Instruction (OI) and the terms of the contract.

This OI provides a planned process for surveilling the contractors’ actual performance against the contractual requirements to determine conformity with the technical requirements of the contract. The OI prescribes a combination of surveillance methods, which assures the government of the contractor's performance. It is based on the premise that the contractor, not the government, is responsible for management and quality control actions to meet the terms of the contract. COR are to be objective, fair, and consistent in evaluating contractor performance against the requirements of the contract. COR are required to sample, but are not expected to identify, all discrepancies that may exist which should be identified by contractor quality control

(QC) personnel. Send comments and suggested improvements to this publication on AF Form

847, Recommendation for Change of Publication, through channels, to 306 FTG/FTGV, 9206

Airfield Drive, USAFA, CO 80840. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with (IAW) Air Force Manual

AFMAN 33-363, Management of Records, and disposed of IAW the Air Force Records

Disposition Schedule (RDS), located at https://www.my.af.mil/afrims/afrims/afrims/rims.cfm.

SUMMARY OF CHANGES

This operating instruction was previously published as 306 FTG OI 21-107, Performance Plan dated 24 May 2011. This includes terminology changes throughout; training requirements

(paragraph 2.1.) and training documentation requirements (paragraph 2.2.); ratings (paragraph https://eim.usafa.edu/unit/306ftg/ftgv/frst/%20default.aspx https://eim.usafa.edu/unit/306ftg/ftgv/frst/%20default.aspx

2 306 FTG OI 21-107, 9 May 2012

3.1.4.); monthly summary (paragraph 3.1.5.); quality control follow-up inspections (paragraph

4.1.3.); in-process inspections (paragraph 4.1.4.); waiving an observation guide (paragraph

5.1.4.); other surveillance methods (Chapter 6); Hourly/Annual and Equalized Maintenance for

Maximum Availability Inspections (paragraph A4.1.1.); Basic Post Flight/Pre-Flight (paragraph

A4.1.2.); Unscheduled Maintenance Inspections (paragraph 4.1.5.); Area Foreign Object

Inspections (paragraph A4.1.10.); Special Inspections (paragraph A4.2.); Technical/Special

Inspection frequency (Attachment 5); Technical Inspections Acceptable Quality Levels

(Attachment 6); Observation Guide Inspections (Attachment 7); update 306 FTG Form 1.

(Attachment 8)

Chapter 1– Responsibilities

1.1. Functional Commander Responsibilities

1.2. Chief COR Responsibilities

1.3. COR Responsibilities

Chapter 2– Contracting Officer Representative Training

2.1. COR Training

2.2. COR Appointment Letter

Chapter 3 – Quality Assurance Surveillance

3.1. Surveillance Areas

3.1.1. Surveillance Schedules

3.1.2. Hours of Surveillance

3.1.3. Documentation

3.1.4. Ratings

3.1.5. Monthly Summary

Chapter 4 – Technical Inspections General Information

4.1. Technical Inspections

4.1.1. Additional Inspections

4.1.2. Red X Discrepancies

4.1.3. Quality Control Follow Up Inspections

4.1.4. In-Process Inspections

4.1.5. After-The-Fact Inspections

4.1.6. Technical Inspection Ratings

4.1.7. Technical Inspection Baselines

4.1.8. Special Inspections

Chapter 5 - Observation Guides General Information

5.1. Observation Guides

5.1.1. Minimum Requirements

5.1.2. Annual Review

306 FTG OI 21-107, 9 May2012 3

5.1.3. Follow-up Inspection

5.1.4. Waiving an Observation Guide

5.1.5. Observation Guide Ratings

Chapter 6 - As Observed Inspection General Information

6.1. As Observed Inspection

Chapter 7 -Surveillance Documentation

7.1. 306 FTG Form 1, COR Inspection/Evaluation Report

7.2. 306 FTG Form 2, Customer Complaint Records

7.3. Corrective Action Request

7.4. COR Database

7.5. Safety Violations

7.6. Past Performance Reporting

7.7. Acceptance of Services

Chapter 8 – Contractor Proposals

8.1. COR Role

Chapter 9 – Government-Furnished Property Surveillance

9.1. COR Surveillance

9.1.1. Joint Inventory

9.1.2. Contractor Receipt

9.1.3. Adjustments to Master List

Chapter 10 – Verification and Contractor Modification Process

10.1. Contractor Request Review

10.1.1. Cost Comparison

10.1.2. Contract Modifications

10.1.3. Verifying Invoices

Chapter 11 – Contractor Reports

11.1. Contractor Report Inspections

Attachment 1 – Glossary of References and Supporting Documentation

Attachment 2 – Symbols

Attachment 3 – Additional Discrepancies

Attachment 4 – Technical/Special Inspections

Attachment 5 – Technical/Special Inspection Frequency

Attachment 6 – Technical Inspections Acceptable Quality Levels (TIAQL)

Attachment 7 – Observation Guide Inspections

4 306 FTG OI 21-107, 9 May 2012

Attachment 8 – 306 FTG Form 1, Contract Monitoring and Surveillance Report

Attachment 9 – 306 FTG Form 2, Customer Complaint Record

306 FTG OI 21-107, 9 May2012 5

Chapter 1

Responsibilities

1.1. Functional Commander Responsibilities. The 306 FTG Commander (CC) is the

Functional Commander (FC) of the USAFA Contractor Logistics Support (CLS) Contract. The

Functional Commander responsibilities are detailed in AFI 21-101 and AETC Supplement, Chapter 18.

1.2. Chief COR Responsibilities. Chief COR responsibilities are detailed in AFI 21-101 and

AETC Supplement, Chapter 18 and AFFARS MP5301.602-2(d). The Chief COR will ensure surveillance of contract performance and report noncompliance or abnormalities to the FC and the Contracting Officer (CO). Review the contractors QC plan and operating instructions and make recommendation to the CO for approval.

1.3. COR Responsibilities. COR is the "eyes and ears" of the FC and CO relative to the actual application of the contract; however, they are not a quality control function. COR will not direct work or the re-accomplishment of work, change the contract, or formally interpret the contract.

The CO resolves these types of issues. COR responsibilities are detailed in AFI 21-101 and

AETC Supplement, Chapter 18.

6 306 FTG OI 21-107, 9 May 2012

Chapter 2

Contracting Officer Representative Training

2.1. COR Training. Newly assigned QAE must complete Contracting Officer contract specific training IAW AFFARS MP5301.602-2(d) before performing unsupervised surveillance duties on new or existing contracts. COR will attend the AETC Quality Assurance Evaluator Course and the Chief COR will attend the Chief COR course within 90 days of COR assignment. COR will accomplish the AETC developed refresher course annually and the AETC Quality Assurance

Evaluator Course every three years and the Chief COR will re-accomplish the Chief COR course every three years. Air Force (AF)/AETC directives and Original Equipment Manufacturers

(OEM) maintenance manuals will be used to complete on-the-job training (OJT) in areas where the individual COR requires additional training. OJT will be conducted by qualified COR until the newly assigned individual demonstrates proficiency in each work area. Training will be documented in the CORs automated Training Business Area..

2.2. COR Designation Memorandum. After contract specific training is complete, COR personnel will be appointed in writing by the CO via a COR Designation Memorandum.

306 FTG OI 21-107, 9 May2012 7

Chapter 3

Quality Assurance Surveillance

3.1. Surveillance Areas. This QASP has two basic surveillance areas: technical and observation. Minimum surveillance areas, sample sizes and frequencies are listed in Attachment

4 and Attachment 5 for Technical Inspections and Attachment 7 for Observation Areas.

Inspections are scheduled, unscheduled or as-observed. Only scheduled inspections can be used to apply a rating for conform performance according to contract standards. COR will normally utilize the periodic inspection model when performing surveillance duties. However, the Chief

COR may utilize the 100 percent method at any time if deemed necessary due to (but not limited

to) trends or special interest items identified by the CO, FC, or AETC. As-observed inspections are not a scheduled inspection and occur when the COR happens to be in the contractors’ area of responsibility.

3.1.1. Surveillance Schedule. The Chief COR will develop monthly schedules based on

Attachment 4, Attachment 5 and Attachment 7 of this OI. The monthly schedules will be provided to the CO and FC for approval not later than five calendar days prior to the beginning of the period it covers. The schedules shall be marked "FOR OFFICIAL USE

ONLY" and shall not be shown to the contractor. One signed copy will be filed. Post changes to the schedule as they occur and copy the CO and FC as requested.

3.1.2. Hours of Surveillance. COR will randomly surveil the contractor during duty hours to include shift work and weekends.

3.1.3. Documentation. All evaluations will be documented on the 306 FTG Form 1, Contract Monitoring and Surveillance Report.

3.1.4. Ratings. All surveillances will be assigned a conform, non-conform, or non rating.

Conform and non-conform performance ratings will be based on the baseline guidelines established in AFI 21-101 and AETC Supplement, Chapter 18 and the contractors Quality

Control plan. The Acceptably Quality Levels (AQL) for technical inspections is located in

Attachment 6 of this OI. Observation guide AQL is three minors. In order to ensure consistency when determining severity of discrepancies, the definitions and criteria described in Attachment 1 apply.

3.1.5. Monthly Summary: The Chief COR will develop a monthly summary of COR surveillance activities and forward a copy to HQ AETC/A4MAT, OC-ALC/GKSWA and

OC-ALC/GKSKA, not later than the 15th workday of the month. The summary will address the amount of inspections scheduled, amount completed, non-conform inspections, service summary performance threshold compliance and an explanation for any missed inspections.

8 306 FTG OI 21-107, 9 May 2012

Chapter 4

Technical Inspections General Information

4.1. Technical Inspections. QAE will perform Technical Inspections (TI) on assigned aircraft and support equipment, including follow-up TIs of contractor Quality Control inspections. TIs may be In-Process or After-The-Fact (ATF) inspections. TIs are conducted using the inspection work card/maintenance manual/checklist required for the job. Also, refer to the 306 FTG COR

Technical Inspection, Document File Inspection and Aircraft Maintenance Programs Inspection checklists when conducting these inspections. TIs include forms documentation, maintenance manual currency, proper tool usage, and area foreign object (FO) checks. The minimum monthly technical inspections are listed in Attachment 4 and Attachment 5 and the AQL in

Attachment 6.

4.1.1. Additional Inspections. Additional inspections may be performed to adequately evaluate any area where quality of contractor performance has been identified as less than conform. The number of these inspections will be determined by the Chief COR based on review of contractor quality control reports or adverse trends.

4.1.2. Red X Discrepancies. Red X discrepancies discovered during technical inspections will be documented on the aircraft Air Force Technical Order (AFTO) Form 781A, Maintenance Discrepancy and Work Document, and annotated on the 306 FTG Form 1, as appropriate. When aircraft forms are documented, COR will inspect to ensure the AFTO

Form 781H, Aerospace Vehicle Flight Status and Maintenance, status of the day block is updated.

4.1.3. Quality Control Follow Up Inspections. At least eight (Soaring 6/Powered Flight

Program (PFP) 2) of TIs will be Quality Control follow-up inspections. Chief of QAE will periodically monitor the type and number of inspections to ensure a conform sample is being performed.

4.1.4. In-Process Inspections. In-Process is an inspection performed by COR during any portion of a task when an individual or group is performing a task and may be limited to a portion of the task.

4.1.5. After-The-Fact Inspections. An ATF is an inspection performed after a specific task is completed and documented. ATF inspections may be limited to a portion of a task.

4.1.6. Technical Inspection Ratings. TIs are assigned objective ratings of conform or non-conform. Discrepancy definitions and AQL for determining these ratings are defined in

Attachment 1 and Attachment 6.

4.1.7. Technical Inspection Baselines. Assign non-conform rating when the number of minor discrepancies exceeds the AQL located in Attachment 6.

4.1.8. Special Inspections. Special Inspections are TIs directed by the Chief COR to address areas of special emphasis. These inspections may be equipment or procedure oriented.

Baselines are detailed in Attachment 6.

306 FTG OI 21-107, 9 May2012 9

Chapter 5

Observation Guides General Information

5.1. Observation Guides. Observation Guides are developed to inspect for compliance of contractors’ workcenter programs and requirements IAW the Contractor Statement of Work

(CSOW). Observation guides may include items identified or suggested by Special Inspection

Items (SIIs), cross-feed information, Logistics Compliance Assessment Program (LCAP) or

Inspector General (IG) reports, if applicable.

5.1.1. Minimum Requirements. AFI 21-101, AETC Supplement and this OI describe minimum requirements which are to be included in observation guides. Develop a separate guide for each observation area using guidance IAW AFI 21-101 and AETC Supplement, Attachment 17. Areas of inspection are not limited to the content of the observation guide.

Each minor discrepancy, where possible, will consist of a grouping of like deficiencies. The appropriate Observation Guide will be present during the evaluation being accomplished.

Changes, additions, and deletions to observation guides will be accomplished as needed.

5.1.2. Annual Review. The Chief COR reviews observation guides annually and documents the review.

5.1.3. Follow-up Inspection. If an observation guide is rated non-conform, it will be rescheduled as a follow-up inspection.

5.1.4. Waiving an Observation Guide. There may be times that the Chief COR determines surveillance is not required in an observation area and may waive that requirement based on a past record of conform performance by the contractor. A continuing record of conform performance, in this case, is defined as conform ratings on at least three consecutive observation guide evaluations. However, observation guide evaluations will not automatically be waived. The Chief COR will determine which observation guide evaluations, if any, are waived with approval by the FC and CO.

5.1.5. Observation Guide Ratings. To ensure complete and comprehensive surveillance, each area covered by an observation guide is described in Attachment 7. Each area will be assigned either a conform or non-conform rating. A non-conform rating is assigned when a major discrepancy is identified or the baseline for minor discrepancies is exceeded. To ensure consistency when determining severity of discrepancies, COR uses the guidance described in AFI 21-101 and AETC Supplement.

10 306 FTG OI 21-107, 9 May 2012

Chapter 6

As Observed Inspection General Information

6.1. As Observed Inspections. Services provided by the contractor not ordinarily surveilled by observation guides and technical inspections will be monitored by COR, and discrepancies noted will be documented “as observed” (and rated as “none”) on the 306 FTG Form 1 and initialed by a contractor representative.

306 FTG OI 21-107, 9 May2012 11

Chapter 7

Surveillance Documentation

7.1. 306 FTG Form 1, Contract Monitoring and Surveillance Report. The 306 FTG Form 1 will be the form used to document all inspections. COR will document all inspection findings immediately and notify the Maintenance Manager (MM) upon inspection completion. Route all written reports within two duty days through the Chief COR for review and forward to the

Quality Control Chief for internal routing. The MM will initial the report, document corrective actions and return the reports to COR in a timely manner. If the MM refuses to initial for any reason, the COR will note this on the form. The Chief COR will evaluate corrective actions for adequacy and close out the report when corrective actions are accepted. COR will refer to previous inspection reports for corrective action follow up. Completed reports will be provided to the FC and CO, if requested. Finalized reports will be filed in the permanent contract file.

7.2. Customer Complaint Records. The 306 FTG Form 2, Customer Complaint Record, will be used as a formal customer complaint record. The forms are managed by COR and may be located at each flying squadron’s duty desk, or in the 306 FTG Stan/Eval Publications Library https://eim.usafa.edu/unit/306ftg/ftgv/frst/Reference%20Library/Forms/AllItems.aspx. When

COR receives a complaint from a customer, the Chief COR will validate concerns by referencing applicable contract standards. Once validated, the 306 FTG Form 2 will be forwarded to the contractor for corrective action.

7.3. Corrective Action Request. If at any time during the month the inspection results indicate the number of non-conforming inspections do not meet the service summary performance threshold or contract requirements (and Chief COR determines it is not government caused), the

Chief COR will submit a Corrective Action Request (CAR) in memorandum form to the CO. If the CO determines a CAR is appropriate, send the report to the contractor. The contractor will have 15 calendar days from date of receipt to return the report to the CO with a response as to cause, corrective action, and actions taken to prevent recurrence. The CO, in consultation with the COR, evaluates the contractor's response and takes appropriate action. If non-conformance is not corrected, submit another CAR.

7.4. COR Database. All reports are tracked in the COR database. Trend analysis is available through the database and is monitored by the Chief COR for adverse trends.

7.5. Safety Violations. The COR will document safety violations that pose a potential or immediate danger to government property or government personnel. If the violation is directly related to the evaluation being performed, it may be used on the 306 FTG Form 1 as the reason for failure. However, if a safety violation is outside the scope of the evaluation, it will be documented “as observed” (and rated as “none”) and COR will verbally notify the site supervisor.

7.6. Past Performance Reporting. The Chief COR will provide inputs to the annual

Contractor Performance Assessment Reporting rating in coordination with the FC and CO.

7.7. Acceptance of Services. The Chief COR or alternate will accept contractor services using the Wide Area Work Flow (WAWF) system. The Chief COR will validate the accuracy of the contractors monthly invoices, verify the contractor met the service summary performance thresholds and validate the contractors required monthly reports prior to accepting services in

WAWF.

https://eim.usafa.edu/unit/306ftg/ftgv/frst/Reference%20Library/Forms/AllItems.aspx

12 306 FTG OI 21-107, 9 May 2012

Chapter 8

Contractor Proposals

8.1. COR Role. The Chief COR will evaluate contractor proposals (Value Engineering and other) for accuracy and make a recommendation of acceptance or non-acceptance to the CO.

The CO approves proposals and then directs the contractor to take action.

306 FTG OI 21-107, 9 May2012 13

Chapter 9

Government-Furnished Property Surveillance

9.1. COR Surveillance. COR inspections will surveil the master listing of government-furnished equipment (GFE) to ensure it meets the requirements of the CSOW. COR retains a copy of the current and prior GFE inventory to ensure additions and deletions are annotated, as required.

9.1.1. Joint Inventory. Ensure the contractor and a government representative prior to contract assumption and upon contract completion conduct a joint signed inventory.

9.1.2. Contract Receipt. Verify that the contractor acknowledges receipt for all equipment provided by the government.

9.1.3. Adjustments to Master List. Ensure adjustments to the master listing of GFE are verified by a government representative.

14 306 FTG OI 21-107, 9 May 2012

Chapter 10

Verification and Contractor Modification Process

10.1. Contractor Request Review. The Chief COR will review and validate requests, for special GFE (reimbursable items) that the contractor wishes to procure.

10.1.1. Cost Comparison. In the event the CO determines a cost comparison is required, they will notify COR of the requirement.

10.1.2. Contract Modifications. Contract modifications are initiated and implemented by the

CO. However, the unit may initiate action that might result in a contract modification.

When the FC has approved the action, the information will then be relayed to the CO with a copy routed to AETC and 727 ACSG (Tinker) Program Managers. COR will assist as requested to determine contract cost estimates and impact if the suggestion is not accepted.

10.1.3. Verifying Invoices. COR will validate/verify invoices at the end of the month to ensure contractor work has been accomplished. The signature of the Chief COR indicates the invoice has been reviewed. Invoices must be signed prior to approving payment using the WAWF system.

306 FTG OI 21-107, 9 May2012 15

Chapter 11

Contractor Reports

11.1. Contractor Report Inspections. Contractor required reports in the CSOW Attachment E will be submitted and inspected in conjunction with the contractors monthly billing statements prior to acceptance of services in WAWF.

CHRISTOPHER E. PLAMP, Colonel, USAF

Commander

16 306 FTG OI 21-107, 9 May 2012

Attachment 1

GLOSSARY OF REFERENCES AND SUPPORTING DOCUMENTATION

References

AFPD 21-1, Air and Space Maintenance, 25 Feb 2003

AFI 21-101, Aircraft and Equipment Maintenance Management, 26 Jul 2010 and Associated

Supplements

AFMAN 33-363, Management of Records, 1 Mar 2008

T.O. 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policy and

Procedures, 1 Sep 2010

Forms Prescribed

306 FTG Form 1, Contract Monitoring and Surveillance Report, xx xxx xxxx

306 FTG Form 2, Customer Complaint Record, 8 Feb 2008

Forms Adopted

AF Form 847, Recommendation for Change of Publication, 22 Sep 2009

AFTO Form 95, Significant Historical Data, 17 Jun 2002

AFTO 244, Industrial/Support Equipment Record, 13 Jan 2011

AFTO Form 781A, Maintenance Discrepancy and Work Document, 8 Jan 2008

AFTO Form 781H, Aerospace Vehicle Flight Status and Maintenance, 15 Sep 2010

FAA Form 337, Major Repairs/Alterations, Oct 2006

Abbreviations and Acronyms

ABW — Air Base Wing

AD — Airworthiness Directives

AETC — Air Education and Training Command

AF — Air Force

AFB — Air Force Base

AFFARS — Air Force Federal Acquisition Regulation Supplement

AFI — Air Force Instruction

AFMAN — Air Force Manual

AFPD — Air Force Policy Directive

AFTO — Air Force Technical Order

ATF — After-The-Fact

AQL — Acceptable Quality Levels

BPO — Basic Post Flight

CAR — Corrective Action Request

CC — Commander

306 FTG OI 21-107, 9 May2012 17

CLS — Contractor Logistics Support

CND — Could not Duplicate

CO — Contracting Officer

COR — Contracting Officer Representative

CSOW — Contractor Statement of Work

CV — Vice Commander

DoD — Department of Defense

EMMA — Equalized Maintenance for Maximum Availability

FC — Functional Commander

FCF — Functional Check Flight

FO — Foreign Object

FOD — Foreign Object Damage

FTG — Flying Training Group

GFE — Government-Furnished Equipment

IAW — In Accordance With

IG — Inspector General

LCAP — Logistics Compliance Assessment Program

MIL — Master Inventory List

MDS — Mission Design Series

MM — Maintenance Manager

OAP — Oil Analysis Program

OEM — Original Equipment Manufacturers

OI — Operating Instruction

OJT — On-the-Job Training

PFP — Powered Flight Program

PR — Pre-Flight

QASP — Quality Assurance Surveillance Plan

QC — Quality Control

RDS — Records Disposition Schedule

SB — Service Bulletins

SE — Support Equipment

SII — Special Inspection Items

TE — Test Equipment

TIAQL — Technical Inspections Acceptable Quality Levels

18 306 FTG OI 21-107, 9 May 2012

TI — Technical Inspections

TMDE — Test, Measurement, Diagnostic Equipment

TO — Technical Order

WAWF — Wide Area Work Flow

USAFA — United States Air Force Academy

Terms

A1.1. Major Discrepancy. A condition that endangers personnel, jeopardizes equipment or system reliability, affects safety of flight, or warrants discontinuing a process or equipment operation. COR will utilize judgment and experience in determining major discrepancies. This list is not all inclusive. Any of the following conditions should be categorized as a major discrepancy:

A1.1.1. A major or Red X discrepancy is detected.

A1.1.2. Improper or untimely documentation of Red X discrepancies on aircraft or equipment forms (to include automated system entries, if used).

A1.1.3. A foreign object (FO) within 10 feet of an aircraft flight line parking or engine operating area, or within 10 feet of an aircraft or engine in a maintenance area (for example, hangars, wash rack, etc.).

A1.1.4. Test, measurement, diagnostic equipment (TMDE) overdue calibration or when calibration status cannot be verified.

A1.1.5. Violation of federal, state, or local laws and/or Department of Defense (DoD) or Air

Force (AF) environmental protection policies and directives.

A1.1.6. Technical Orders (TO) and original equipment manufacturers (OEM) violations, not using required TO or OEMs to perform tasks, or violations of mandatory directives and supplements when such may cause damage to government property or injury to government personnel.

A1.1.7. The improper use of tools or use of out-of-date maintenance technical data when such may cause damage to government property or injury to government personnel.

A1.1.8. Performance of maintenance without training or qualification on the task.

A1.1.9. Overdue time changes and inspection items; documentation errors that could affect airworthiness.

A1.1.10. Non-conformance to contract standards, e.g., service summary performance threshold.

A1.2. Minor Discrepancy. An unsatisfactory condition that requires repair or correction but does not endanger personnel, affect safety of flight, jeopardize equipment reliability, or warrant discontinuing a process or equipment operation. (NOTE: If the COR determines it is appropriate, minor discrepancies that consist of a grouping of like deficiencies may be documented as one discrepancy against the observation guide; for example, a bench stock with six co-mingled bins, ten bins not flagged, and four bins with torn labels may be documented as one discrepancy).

306 FTG OI 21-107, 9 May2012 19

A1.2.1. Suspected discrepancies, such as leaks, will be documented as “as observed” on the report. Suspected discrepancies that are later confirmed as existing will be assigned the appropriate category and the inspection report changed.

20 306 FTG OI 21-107, 9 May 2012

Attachment 2

SYMBOLS

1. Tire Pressure, High/Low. X

2. Fasteners, loose/missing forward of engine intake, or on leading edge of a panel.

NOTE: UV-18 only X

3. FO in any area where migration to safety of flight items is possible. X

4. Hydraulic & Oil Lines, loose line or obvious leaks. X

5. Hydraulic & Oil Lines, evidence of leak or damage to line (Request check). -

6. Fuel Lines, leaking or improperly installed. X

7. Safety Wire, missing or broken (Safety of Flight Items). X

8. Safety Wire, loose or improperly installed (All) and broken or missing (Non-Safety of

Flight Items).

9. Flight Controls, missing or improperly installed hardware or cable. X

10. Flight Controls, cable coating missing within 3” of a fairlead or pulley.

NOTE: UV-18 only X

11. Stick Boot Holes, greater than 1/8 th inch. NOTE: Gliders only X

12. Gauges, missing/broken slippage marks or gauges loose enough to fall out in flight. X

13. Gauges, loose, but not loose enough to fall out in flight. /

14. Static Ports Clogged, NOTE: UV-18 only X

15. Throttle linkage binding. X

16. Component Removal X

17. When aerospace vehicle, equipment, or support equipment (SE) is considered unsafe or unserviceable X

18. When work or inspections are performed in or around the air intake areas of jet or gas turbine engines. The inspection to clear the Red X will be accomplished prior to engine operation. EXCEPTION: Scheduled inspections which require intake inspection as items of the Mission Design Series (MDS) specific -6 TO work cards such as thruflight, postflight, etc. do not require separate Red X documentation on the AFTO FORM 781A.

X

19. When work or inspections are performed in aerospace vehicle engine exhausts.

EXCEPTION: Scheduled inspections which require exhaust inspection as items of the

MDS specific -6 TO work cards such as thruflight, postflight, etc. do not require separate

X

306 FTG OI 21-107, 9 May2012 21

Red X documentation on the AFTO FORM 781A.

22 306 FTG OI 21-107, 9 May 2012

20. Upon removal of any component or assembly that affects safety of flight or safe operation of the equipment.

X

21. When the removal and replacement of any component or assembly is such that improper reinstallation would affect safety of flight or create an operational hazard X

22. When a major scheduled inspection (e.g. isochronal, phase, periodic, programmed depot maintenance, etc.) is in progress for an aerospace vehicle or SE.

X

23. When egress maintenance safety pins (over and above normal aircrew/ground safety pins) are installed to facilitate maintenance as required in the applicable maintenance TO.

X

24. When maintenance is in progress on the mechanical or electrical portions of fuel tank jettison, or internal or external stores release, such as for pods, pylon tow reels.

X

25. When maintenance is performed on the fuel system or any fuel system component while installed on the aerospace vehicle, engines, AGE, or auxiliary power unit.

X

26. When fuel tank or fuel cell is open for maintenance X

27. When fuel tank or fuel cell maintenance involves installation of plugs or caps on the fuel or vent lines X

28. When a jumper wire or other type of shorting device is installed in an electrical system while performing maintenance.

X

29. When equipment is improperly serviced or contaminated with the wrong type, grade, or proportion of fuel, oil, or hydraulic fluid according to applicable TOs.

X

30. When an aerospace vehicle pilot static system is inoperative, plugged, or taped. X

31. When aerospace vehicle weight and balance is unknown. X

32. When the oil analysis program (OAP) laboratory recommends and the appropriate maintenance supervisor agrees to take grounding action, until a second oil sample can be examined that confirms or negates the first sample of excessive wear metals.

X

33. When rig pins are installed (identify number of pins installed in accordance with applicable TO).

X

34. When wind gust locks are installed. X

35. When egress final inspection is required. X

36. When flight control or throttle control systems are being adjusted and/or rigged. X

37. When it is suspected or known that an aerospace vehicle or piece of equipment has become contaminated with a nuclear, biological or chemical contaminant.

306 FTG OI 21-107, 9 May2012 23

38. When an engine blade requires blending. X

39. When vermin are suspected to be on the aerospace vehicle and cannot be located. X

40. Use a Red X when a scheduled inspection renders the SE unsafe or unserviceable. X

41. When items are lost, suspected to be lost, or cannot be accounted for in areas of aerospace vehicles and equipment (cockpits, flight control or throttle control areas, engine bays, fuel cells, etc.) that present a FO hazard and could result in damage or injury to personnel

X

42. When AEROSPACE EQUIPMENT is impounded X

43. Enter a Red X for each warning tag that is installed as part of a maintenance process.

One AFTO Form 781A entry may contain several warning tags only if they pertain to the same discrepancy.

4-6

NOTE: This is not all inclusive of all write-up categories and symbols that may be used.

24 306 FTG OI 21-107, 9 May 2012

Attachment 3

ADDITIONAL DISCREPANCIES

A3.1. Tool Boxes/Test Equipment (TE)/ Support Equipment (SE)

A3.1.1. These inspections are rated conform or non-conform. This is not an all-inclusive list. The following will be considered Major discrepancies and will result in a non-conform rating:

A3.1.1.1. Missing tools/items/hardware not annotated on AFTO 244, Industrial/Support

Equipment Record or a Doss generated form.

A3.1.1.2. Required forms not annotated or missing.

A3.1.1.3. Any missing or overdue inspections.

A3.1.1.4. No Master Inventory List (MIL).

A3.1.1.5. MIL does not match contents (includes spare components).

A3.1.1.6. Unsecured tools/tool box.

A3.1.1.7. Equipment not calibrated or overdue calibration.

A3.1.1.8. Personal Drawer containing tools/consumables not identified on MIL.

A3.1.1.9. Grease guns/oil cans not marked with type of lubricant they contain.

A3.1.1.10. Tools not etched or identified in toolbox.

A3.2. Active Forms/Document File Inspections:

A3.2.1. These include AFTO Form 244, AFTO Form 95, Significant Historical Data, AFTO Forms 781 series, etc. Minor discrepancies will be rated against the baseline. The following will be considered Major discrepancies and will result in a non-conform rating:

A3.2.1.1. Required inspection/operational check listed in maintenance manual not documented.

A3.2.1.2. Multiple Red X discrepancies annotated on single discrepancy block.

A3.2.1.3. Required “corrected by” or “inspected by” not signed off for Red X discrepancy.

A3.2.1.4. Improper symbol entered and cleared for Red X discrepancy.

A3.2.1.5. Erased symbols.

A3.2.1.6. Missing pages or forms.

A3.2.1.7. Improperly cleared could not duplicate (CND), repeat, or recur discrepancy.

A3.2.1.8. Red X conditions not documented.

A3.2.1.9. Symbol not entered in discrepancy block.

A3.2.1.10. Overdue Time change items.

A3.2.1.11. Overdue inspection not annotated.

A3.2.1.12. AFTO Form 781H, Aerospace Vehicle Flight Status and Maintenance, status today does not match the current AFTO Form 781As.

A3.2.1.13. Significant historical data incomplete/missing.

306 FTG OI 21-107, 9 May2012 25

Attachment 4

TECHNICAL / SPECIAL INSPECTIONS

A4.1. Technical Inspections

A4.1.1. Hourly/Annual and Equalized Maintenance for Maximum Availability (EMMA)

Inspections: Inspect a minimum of nine scheduled inspections. As a minimum, 50% of all carded/checklist items for each maintenance action surveyed must be inspected. Include review of equipment forms for proper documentation, TO/OEM Manual for proper and current usage, proper tool usage and after maintenance FO checks applicable to the task being surveilled.

A4.1.1.1. Method of Surveillance: Periodic.

A4.1.1.2. Lot Size: Determined by the contractor projected monthly inspection schedule.

A4.1.1.3. Sample Size: Nine; one EMMA, two annuals (Soaring 1/PFP 1), and six

(Soaring 4/PFP 2) of any combination of hourly inspection (e.g., 50 Hour, 100 Hour, 1000 Hour) if inspections were completed during the inspection cycle.

A4.1.1.4. Performance Requirement: Performance is conform when two or less discrepancies are discovered during a 50 Hour inspection, three or less minor discrepancies are discovered during the Hourly/Annual inspections and five or less minor discrepancies are discovered during the EMMA inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.1.5. Sampling Procedure: When possible, aircraft are selected on a rotating basis.

A4.1.1.6. Inspection Procedure: All inspections will be accomplished using the applicable manufacturer’s maintenance manual. Only aircraft related discrepancies will be annotated in the AFTO 781 series forms. All discrepancies will be annotated on

306 FTG Form 1.

A4.1.2. Basic Post Flight (BPO)/Pre-Flight (PR): Inspect eight (four BPO (Soaring 2/PFP

2) and four PR (Soaring 2/PFP 2)) of any inspections performed. Inspect a minimum of 50% of all carded/checklist items for each inspection surveyed.

A4.1.2.1. Method of Surveillance: Periodic.

A4.1.2.2. Lot Size: Determined by the contractor projected monthly inspection schedule.

A4.1.2.3. Sample Size: four BPO, four PR (any MDS in Soaring Section).

A4.1.2.4. Performance Requirement: Performance is conform when two or less minor discrepancies are discovered for a BPO or PR. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.2.5. Sampling Procedure: Aircraft are selected on a rotating basis.

A4.1.2.6. Inspection Procedure: All inspections will be accomplished using the applicable manufacturer’s maintenance manual. Only aircraft related discrepancies will be annotated in the AFTO 781 series forms. All discrepancies will be annotated on

306 FTG Form 1.

26 306 FTG OI 21-107, 9 May 2012

A4.1.3. Engine Build-Up/Install Inspections: Inspect all engine build-up and installations

100% of the time. Inspect a minimum of 50% of all carded/checklist items for each inspection surveyed.

A4.1.3.1. Method of Surveillance: 100%.

A4.1.3.2. Lot Size: Determined by the contractor projected monthly inspection schedule.

A4.1.3.3. Sample Size: 100% inspections.

A4.1.3.4. Performance Requirement: Performance is conform when three or less minor discrepancies are discovered during the engine build-up and installations inspections.

Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.3.5. Sampling Procedure: Due to the frequency of engine build-up and installations, 100% of all aircraft will be inspected.

A4.1.3.6. Inspection Procedure: All inspections will be accomplished using the applicable manufacturer’s maintenance manual. Only aircraft related discrepancies will be annotated in the AFTO 781 series forms. All discrepancies will be annotated on

306 FTG Form 1.

A4.1.4. Major Repair/Alteration Inspections: Any major repairs or alterations will require a visual inspection from COR. The inspection will focus on the repair, proper documentation to include FAA Form 337, Major Repairs/Alterations and the use of commercial maintenance manuals.

A4.1.4.1. Method of Surveillance: 100%.

A4.1.4.2. Lot Size: Determined by the contractor projected monthly inspection schedule.

A4.1.4.3. Sample Size: 100%.

A4.1.4.4. Performance Requirement: Performance is conform when two or less minor discrepancies are discovered during the Major Repairs/Alterations inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum

AQL.

A4.1.4.5. Sampling Procedure: One of the major repairs/alterations and documentation will be inspected.

A4.1.4.6. Inspection Procedure: All inspections will be accomplished using approved repair procedures. All discrepancies will be annotated on 306 FTG Form 1.

A4.1.5. Unscheduled Maintenance Inspections: COR will perform unscheduled maintenance evaluations on all aircraft systems. COR will utilize the commercial maintenance manuals as a guide for their inspections. A minimum of eight events per month should be inspected. Inspect a minimum of 50% of the work/maintenance accomplished using repair action procedures. If the unscheduled maintenance action consists of component removal and replacement, the inspection may consist of observing an operations check of the component.

A4.1.5.1. Method of Surveillance: Periodic.

306 FTG OI 21-107, 9 May2012 27

A4.1.5.2. Lot Size: Determined by the contractor projected monthly inspection schedule.

A4.1.5.3. Sample Size: Eight (Soaring 6/PFP 2) of any unscheduled maintenance events performed.

A4.1.5.4. Performance Requirement: Performance is conform when two or less minor discrepancies are discovered during the inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.5.5. Sampling Procedure: Aircraft are selected on a rotating basis, inasmuch as possible.

A4.1.5.6. Inspection Procedure: All inspections will be accomplished using the applicable manufacturer’s maintenance manual. Only aircraft related discrepancies will be annotated in the 781 series forms. Discrepancies will be annotated on 306 FTG

Form 1.

A4.1.6. Airworthiness Directives (AD), Service Bulletins (SB) Inspections Initial: All initial

ADs and SBs will be inspected during the initial maintenance/inspection action using the criteria contained within the directive. Special emphasis will be placed on applicability and timely completion.

A4.1.6.1. Method of Surveillance: 100%.

A4.1.6.2. Lot Size: Determined by the issue of the AD/SB.

A4.1.6.3. Sample Size: 100%.

A4.1.6.4. Performance Requirement: Performance is conform when two or less minor discrepancies are discovered during the inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.6.5. Sampling Procedure: Due to the infrequency of initial AD/SB, 100% of

AD/SB Compliance will be inspected per MDS. The proper maintenance action will be validated on one aircraft and documentation validated by checking historical records and aircraft forms.

A4.1.6.6. Inspection Procedure: All inspections will be accomplished using the applicable manufacturer’s maintenance manual and instructions contained in the AD/SB.

All discrepancies will be annotated on 306 FTG Form 1.

A4.1.7. Airworthiness Directives, Service Bulletins Inspections Recurring: Recurring AD and SB will be inspected using the criteria contained within the directive. Special emphasis will be placed on applicability and timely completion.

A4.1.7.1. Method of Surveillance: Periodic.

A4.1.7.2. Lot Size: Determined by the issue of the AD/SB.

A4.1.7.3. Sample Size: Two of any inspection/action performed.

A4.1.7.4. Performance Requirement: Performance is conform when two or less minor discrepancies are discovered during the inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.7.5. Sampling Procedure: Recurring AD/SB will be inspected on a rotating basis inasmuch as possible. After the proper procedure is validated on the aircraft, the AD/SB documentation will be validated by checking historical records and aircraft forms.

28 306 FTG OI 21-107, 9 May 2012

A4.1.7.6. Inspection Procedure: All inspections will be accomplished using the applicable manufacturer’s maintenance manual and instructions contained in the AD/SB.

All discrepancies will be annotated on 306 FTG Form 1.

A4.1.8. Forms Documentation/Document File Inspections: COR will evaluate aircraft document files using T.O. 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policy and Procedures. All like minor discrepancies will be grouped together as one discrepancy. Any discrepancies already identified/recorded by the contractors QC will not be considered a chargeable discrepancy.

A4.1.8.1. Method of Surveillance: Periodic.

A4.1.8.2. Lot Size: All aircraft forms and document files. A document file is defined as the records of a single MDS.

A4.1.8.3. Sample Size: Three aircraft document files per month.

A4.1.8.4. Performance Requirement: Performance is conform when three or less minor discrepancies are discovered per document file. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.8.5. Sampling Procedure: Three aircraft document files will be inspected from the previous month’s files.

A4.1.8.6. Inspection Procedure: Inspections will include review of pulled aircraft forms and historical documents. Discrepancies found in the historical documents file will be sent to the contractor for corrective action. Actual discrepancies will not be corrected, except for items of a historical nature. Contractor documentation errors on forms initiated at other than the home station or generated by non-maintenance personnel will not be charged but must be corrected if the deficiency affects historical information. All discrepancies will be annotated on 306 FTG Form 1.

A4.1.9. Training (Task or Certification): COR will conduct task or certification training inspections to determine effectiveness of the contractor training program. COR will focus on new hire personnel who received training within the past 60 days.

A4.1.9.1. Method of Surveillance: Periodic.

A4.1.9.2. Lot Size: Determined by contractor task or certification training conducted within the past 60 days.

A4.1.9.3. Sample Size: One inspection performed.

A4.1.9.4. Performance Requirement: Performance is conform when three minor discrepancies are discovered during the inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.9.5. Sampling Procedure: One inspection performed on contractor task or certification training conducted within the past 60 days.

A4.1.9.6. Inspection Procedure: Conduct an in-process technical inspection. Rate on whether or not the task was conducted IAW training standard, e.g., OEM manual, checklist, etc. All discrepancies will be annotated on 306 FTG Form 1. This is not a personnel evaluation.

A4.1.10. Area FO Inspections: COR will conduct area FO inspections in the contractor maintenance facilities, flight line areas and aircraft hangars. The inspections will focus on compliance with the contractor foreign object damage (FOD) program and current CSOW.

306 FTG OI 21-107, 9 May2012 29

A4.1.10.1. Method of Surveillance: Periodic.

A4.1.10.2. Lot Size: Area FO inspections in the contractor maintenance facilities, flight line areas and aircraft hangars at Peterson Air Force Base (AFB) and USAFA.

A4.1.10.3. Sample Size: Five (Soaring 4/PFP 1) inspections performed.

A4.1.10.4. Performance Requirement: Performance is conform when one minor discrepancy is discovered during the inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.1.10.5. Sampling Procedure: Five inspections performed on the area FO inspections in the contractor maintenance facilities, flight line areas, and aircraft hangars.

A4.1.10.6. Inspection Procedure: Rate on whether or not inspections meet contract requirements. All discrepancies will be annotated on 306 FTG Form 1.

A4.2. Special Inspections

A4.2.1. Tools and Test Equipment Inspections: COR will perform inspections on

Government Furnished Tools, Contractor Personal tools and Test Equipment using applicable instructions and technical manuals. These inspections will focus on required equipment inspections being accomplished, calibration, and proper use/documentation of

AFTO Forms 244 (or government approved contractor developed form). COR will accomplish tool control inspections IAW the Contractor's Tool Control Program. Inspections will be performed on maintenance dispatch tool boxes/pouches and in-shop tool boxes/pouches. Inspections will include checks of tool box inventories, lost/missing tools, overage of tools, etching, shadowing, and special tools storage, calibration, and inventory.

FO found in toolboxes (even in toolboxes that are dispatched) is not considered a major discrepancy.

A4.2.1.1. Method of Surveillance: Periodic.

A4.2.1.2. Lot Size: Determined by the number of tool boxes, test equipment, and special tools maintained.

A4.2.1.3. Sample Size: Seven (Soaring 5/PFP 2) inspections performed.

A4.2.1.4. Performance Requirement: Performance is conform when three or less minor discrepancies are discovered during the inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.2.1.5. Sampling Procedure: Seven inspections will be performed sampling tools and test equipment.

A4.2.1.6. Inspection Procedure: Rate on whether or not inspections meet contract requirements. All discrepancies will be annotated on 306 FTG Form 1.

A4.2.2. Functional Check Flight (FCF) Inspections: COR will focus on the contractor’s QC

FCF program and the maintenance that generated the FCF.

A4.2.2.1. Method of Surveillance: Periodic

A4.2.2.2. Lot Size: Determined by the amount of occurrences on a monthly basis.

A4.2.2.3. Sample Size: Two of any FCF flown.

30 306 FTG OI 21-107, 9 May 2012

A4.2.2.4. Performance Requirement: Performance is conform when no more than one discrepancy is discovered during the inspections. Non-conform performance is when one major or the minor discrepancies exceed the maximum AQL.

A4.2.2.5. Sampling Procedure: Two inspections will be performed in conjunction with the requirements listed in the contractor QC plan.

A4.2.2.6. Inspection Procedure: Rate on whether or not inspections meet contract requirements. All discrepancies will be annotated on 306 FTG Form 1.

A4.2.3. Rag Control Inspections: The COR will conduct inspections on contractor rag control procedures. COR will focus the inspection on accountability of all rags issued and returned.

A4.2.3.1. Method of Surveillance: Periodic.

A4.2.3.2. Lot Size: Determined by the number of rags received and distributed.

A4.2.3.3. Sample Size: Four (Soaring 3/PFP 1) inspections performed.

A4.2.3.4. Performance Requirement: Performance is conform when no more than one minor discrepancy is discovered during the inspections.