Attachment 4 - OC-ALC Operating Instruction 21-103.pdf

BY ORDER OF THE COMMANDER

OKLAHOMA CITY AIR LOGISTICS

COMPLEX

OKLAHOMA CITY AIR LOGISTICS

COMPLEX INSTRUCTION 21-103

20 APRIL 2022

Maintenance

EQUIPMENT-MAINTENANCE/

INSPECTION AND DOCUMENTATION

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: 776MXSS/CL Certified by: 76MXSG/CL

(Paul W. Victorian)

Supersedes: OC-ALCI21-203

14 October 2014

Pages: 74

This publication implements AFSCMAN21-102. The publication establishes responsibilities and procedures for the Air Force Technical Order (AFTO) Form 244/245, Industrial/Support

Equipment Record or computer-generated equivalent, for equipment delayed discrepancies, corrective actions, record service, periodic and special inspections, record inspection status and historical data in accordance with (IAW) Technical Orders (TOs), Air Force Occupational Safety and Health (AFOSH) Standards (Stds) and local standards. It provides guidance and procedures throughout the Oklahoma City Air Logistics Complex (OC-ALC) 21-103. This instruction prescribes responsibilities and provides general instructions for Preventative Maintenance (PM) and Predictive Maintenance (PdM) of Support Equipment (SE). This includes recording the cost of equipment repair and modification IAW AFSCMAN 21-102. The instruction applies to all personnel within the Oklahoma City Air Logistics Complex (OC-ALC). In the event of conflicting guidance, the most stringent requirements will take precedence. Refer recommended changes and questions about this publication to the Office of Primary Responsibility (OPR) using the Air Force

(AF) Form 847, Recommendation for Change of Publication; route AF Forms 847 from the field through the appropriate chain of command. This publication may be supplemented at any level, but all supplements must be routed to OPR for coordination prior to certification and approval or this publication may not be supplemented. The authorities to waive wing/unit level requirements in this publication are identified with a Tier (“T-0, T-1, T-2, T-3”) number following the compliance statement. See AFI 33-360, Publications and Forms Management, for a description of the authorities associated with the Tier numbers. Submit requests for waivers through the chain http://www.e-publishing.af.mil/

2 OC-ALCI21-103 20 APRIL 2022

of command to the appropriate Tier waiver approval authority, or alternately, to the Publication

OPR for non-tiered compliance items. Refer recommended changes and questions about this instruction to the office of primary responsibility (OPR) using the AF Form 847, Recommendation for Change of Publication; route AF Forms 847 from the field through appropriate functional’s chain of command. Requests for waivers must be submitted to the OPR listed above for consideration and approval. Ensure that all records created as a result of processes prescribed in this instruction are maintained in accordance with (IAW) Air Force Instruction 33-322, Records

Management and Information Governance Program, and disposed of IAW Air Force Records

Information Management System (AFRIMS) Records Disposition Schedule (RDS) located at https://www.my.af.mil/afrims/afrims/afrims/rims.cfm. The use of the name or mark of any specific manufacturer, commercial product, commodity, or service in this instruction does not imply endorsement by the Air Force.

SUMMARY OF CHANGES

This Publication has been significantly updated and must be reviewed in its entirety. (1) There have been multiple additions, deletions, and rewording to procedures, specifically in Chapter 2,

(2) Multiple Orgs and e-mail addresses have been updated, (3) A full chapter (Chapter 10) has been added, (4) References and Versions have been updated, and Forms have been added.

Removed references to FEMWEB and replaced with updated instructions on the use of FEM.

Updated AF Instruction and form references.

Chapter 1—AFTO FORM 244, DOCUMENTATION REQUIREMENTS 6

1.1. AFTO Form 244 General Information and Documentation Requirements

1.2. AFTO Form 244 Block Identification

1.3. AFTO Form 244 Symbols

1.4. AFTO Form 244 Maintenance and Disposition Instructions

Chapter 2—EQUIPMENT MAINTENANCE 12

2.1. Maintenance Concept:

2.2. Maintenance Program Determination

2.3. Preventive Maintenance

2.4. Predictive Maintenance

2.5. Responsibilities

Chapter 3—FACILITIES AND EQUIPMENT MAINTENANCE SYSTEM 23

3.1. FEM System Definition

3.2. Responsibilities

Chapter 4—LOCALLY MANUFACTURED OR DEVELOPED/MODIFIED SUPPORT

EQUIPMENT 24

4.1. General

https://www.my.af.mil/afrims/afrims/afrims/rims.cfm

OC-ALCI21-103 20 APRIL 2022 3

4.2. Duties and Responsibilities

Chapter 5—HOIST INSPECTION AND DOCUMENTATION 27

5.1. General

5.2. Duties and Responsibilities

5.3. Inspection

5.4. Annual Certification/Inspections

5.5. Removal and Installation of Fixed Hoists

5.6. Use of Hoists

Chapter 6—LIFTING AND RESTRAINING DEVICES INSPECTION AND

DOCUMENTATION 29

6.1. General

6.2. Responsibilities

6.3. Certification Procedures

6.4. NDI Requirements

Chapter 7—TRAILER INSPECTION AND DOCUMENTATION 33

7.1. Background

7.2. Description of PM

7.3. Operator PM

7.4. Monitor Maintenance

7.5. Six Month Scheduled PM

7.6. Unscheduled Maintenance or Wheel Bearing Pack (WBP)

7.7. Repair Centers

7.8. Trailer Configuration Changes or Modifications

7.9. Trailer Painting Requirements

7.10. Responsibilities

Chapter 8—MOBILE MAINTENANCE

STANDS/FIXTURES/CARTS/PLATFORMS/TABLES/ CABINETS AND

DEXION CARTS SECURING 35

8.1. General

8.2. Push Carts

Chapter 9—OVERHEAD CRANE OPERATIONS 36

9.1. Roles and Responsibilities

9.2. Maintenance of Overhead cranes

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9.3. Historical Records

9.4. Training/Safety Briefings

Chapter 10—TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT 40

10.1. Test, Measurement and Diagnostic Equipment (TMDE)

10.2. Requirements

10.3. Roles and Responsibilities

10.4. Care of TMDE

Chapter 11—AEROSPACE GROUND AND SUPPORT EQUIPMENT 53

11.1. Roles and Responsibilities

11.2. Aerospace Ground Equipment Movement

11.3. Hydraulic Test Stands (HTS)

11.4. AGE Maintenance and Scheduling

11.5. AGE Inventory Additions and Deletions

11.6. Corrective Maintenance

11.7. Time Compliance Technical Order (TCTO)

11.8. AGE Liquid Oxygen (LOX)/Gaseous Oxygen (GOX) Carts

11.9. Trailer Maintenance

11.10. Record Keeping

11.11. AGE Blasting and Painting

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 56

Attachment 2—COMPLETION INSTRUCTIONS FOR AFSC FORM 388, MACHINE

TOOL AND EQUIPMENT HISTORICAL RECORD 63

Attachment 3—SUPPORT EQUIPMENT 64

Attachment 4—DEPOT INDUSTRIAL PLANT EQUIPMENT (DIPE) REPAIR AND

DOCUMENTATION GUIDE 65

Attachment 5—NON-DEPOT INDUSTRIAL PLANT EQUIPMENT (NON-DEPORT)

REPAIR AND DOCUMENTATION GUIDE 66

Attachment 6—ON- CONDITIONAL MAINTENANCE (OCM) REPAIR AND

DOCUMENTATION GUIDE 67

Attachment 7—OC-ALC FORM 105, OVERHEAD AND MOBILE CRANE OPERATOR

INSPECTION CHECKLIST 68

Attachment 8—OVERHEAD AND MOBILE CRANE OPERATIONS MAINTENANCE

AND INSPECTION SCHEDULE 70

OC-ALCI21-103 20 APRIL 2022 5

Attachment 9—OVERHEAD AND MOBILE CRANE OPERATOR ANNUAL SAFETY

BRIEFING OUTLINE 71

Attachment 10—76 MXSG LIST OF UNSUPPORTED EQUIPMENT 74

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Chapter 1

AFTO FORM 244, DOCUMENTATION REQUIREMENTS

1.1. AFTO Form 244 General Information and Documentation Requirements.

1.1.1. Overdue Test, Measurement and Diagnostic Equipment (TMDE). Owning work center shall not use the AFTO Form 244/245 to document overdue calibrations. Use the AFTO Form

350, Repairable Item Processing Tag, for this purpose.

1.1.2. AFTO Form 244/245 entries will only be in black (pencil or ballpoint pen), unless otherwise specified.

1.1.3. Minimum signature consists of the first name initial, last name (not necessarily in this order), and employee number, or USERID or equivalent/FAA (Federal Aviation

Administration) certification number. Electronic signatures may be used in lieu of these requirements.

1.1.3.1. The OC-ALC may use a production stamp in place of the employee number.

1.1.3.2. Contractors will use their FAA certification number or equivalent in place of the employee number.

1.1.4. All “symbol” block entries will be made in red.

1.1.5. Red symbol entries will never be erased, even when entered in error.

1.1.6. All “date” entries will be eight digits in order of year, month, and day (yyyymmdd) i.e., 20010306.

1.1.7. Documents will be legible, complete, correct, and clean.

1.1.8. Equipment owners are authorized to maintain the AFTO Form 244 in a file or book for their equipment (e.g., DIPE) in a central location such as the supervisor and/or work leader’s office. It is the user’s responsibility to review equipment documentation prior to use to ensure that all inspections are current and any discrepancies have been identified on the AFTO Form

244, Part V.

1.1.9. Specific inspection criteria for any equipment will be IAW equipment/general TOs, Original Equipment Manufacturers (OEM) manual, AFOSH Standards, engineering documents, similar equipment inspection work cards, or local instructions.

1.1.10. Entries will be documented in a sequential order (i.e., either “top-to-bottom” or “left-to-right”).

1.2. AFTO Form 244 Block Identification.

1.2.1. AFTO Form 244, part I, provides a means to identify the SE for which the form is maintained.

1.2.1.1. Block 1. Enter the nomenclature/model number (e.g., air compressor/MC2A).

1.2.1.2. Block 2. Enter the assigned AF registration/serial number. Leave blank if not applicable.

OC-ALCI21-103 20 APRIL 2022 7

1.2.1.3. Block 3. Enter the identification number (a locally defined equipment-type identifier, for DIPE enter the Oklahoma City (OC) number), if assigned. Leave blank if not assigned.

1.2.1.4. Block 4. Enter the field number. Leave blank if not applicable.

1.2.1.5. Block 5. Enter the Work Unit Code (WUC) if one is assigned. Leave blank if not applicable.

1.2.1.6. Block 6. Enter the assigned organization/work center (e.g., 76

AMXG/MXAATA).

1.2.1.7. Block 7. Enter the date the form was initiated to the ‘left” of the word “TO.”

Once the form is closed out or the equipment is turned into supply/salvage enter the close out date to the right of the word “TO” (e.g., “20040430 TO =” new/current form, “20040430 TO 20041230” = closed out form).

1.2.1.8. Block 8. Leave blank if not applicable. This block may be used for 76 MXSG/CC specific requirements.

1.2.2. AFTO Form 244, part II, provides a means to document the accomplishment of daily or prior to use (Daily/PU) specific operator maintenance (OM) or inspections as outlined on the

AFMC Form 306, Preventive Maintenance Instruction (or equivalent), OEM manual, commercial off-the-shelf (COTS) manual, checklist, work card or applicable weapon system peculiar TO and AFOSH std. Daily/PU is defined: These actions are to be reviewed prior to use. Signing off on these actions means you have accomplished all actions required prior to the use of the equipment and you have read, understand, and will accomplish those actions required during and after use. These actions are to be reviewed by each shift using the equipment with appropriate actions being accomplished as directed by the AFMC Form 306.

These actions and associated sign offs need only be accomplished once per calendar day on those days the equipment is used regardless of multiple shift use.

1.2.2.1. Time Column. Enter the time (in 24-hour military time) the service/prior to use inspection was accomplished. If the unit is equipped with a running time meter, the metered time may be entered in place of the time of day. For SE inspected at hourly intervals, enter the daily/accumulated time.

1.2.2.2. Inspector’s Initials Column. Enter the first initial, last initial of the individual completing the inspection.

1.2.2.3. Date Column. Enter the date (yyyymmdd) the inspection was accomplished.

1.2.3. AFTO Form 244, part III, provides a means to document the accomplishment of specific

OM or inspections other than Daily/PU as outlined on the AFMC Form 306 (or equivalent), OEM, COTS manual, checklist, work card, or applicable weapon system peculiar TO and

AFOSH std. These actions must be accomplished at their set interval regardless of equipment usage. Due-by dates are defined by the last time the action was accomplished plus the defined interval. Actions are required to be accomplished within that interval.

1.2.3.1. Inspection Requirement. In this column, enter the type of inspection due (e.g., weekly, monthly, etc.), periodic inspection, special wheel bearing packing, lubing etc. Any specific operator inspections/maintenance, other than Daily/PU, will be documented in part

III. Initials for the technician performing specific OM will not be required in part III.

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1.2.3.2. Interval. In this column, enter the next scheduled inspection interval (e.g., 30-, 60-, and 180-day, or 500-hour, etc.).

1.2.3.3. Date Due. In this column, enter the next inspection due in the next open date due block.

1.2.3.4. Date Completed. Enter the hour/date inspection was completed. Enter a new inspection due date in next Date Due block.

1.2.4. AFTO Form 244, part IV. This form provides a means to document a quality control or supervisory review of the form. Supervisors may also designate, in writing, an individual who will satisfy the review requirement. The letter will be maintained by the work center supervisor. Ensure all the applicable blocks are filled out correctly, operator specific PM inspections are being accomplished on time and documented, and discrepancies corrected are signed off correctly. The interval for this review is every 6 months. This section will not be used for documenting inspection of completed maintenance actions.

1.2.4.1. Employee Number. Enter reviewer’s employee number or first name initial, last name and grade (preferred method) or production stamp.

1.2.4.2. Date. Enter the date (yyyymmdd e.g., 20010306) the review was accomplished.

1.2.5. AFTO Form 244/245, part V. This form provides a means to document equipment discrepancies and corrective actions. The following conditions will be recorded in this part of the form.

1.2.5.1. Delayed discrepancies that cannot be corrected as part of the maintenance actions in progress will be scheduled for follow-on maintenance actions.

1.2.5.2. Use a Red X when an inspection renders the SE unsafe or unserviceable.

1.2.5.3. Overdue inspection, including portions of inspections not accomplished during the scheduled inspection (e.g., work card and/or work card items not completed by the end of the due period).

1.2.5.4. Overdue time change, Master Configuration Lists (MCLs) and Time Compliance

Technical Orders (TCTOs).

1.2.5.5. Discrepancies discovered by the operator during operation of the system/equipment.

1.2.5.6. Part V will be completed as follows:

1.2.5.6.1. Block 9—TO. Enter the TO number or manufacturer’s manual number/title that covers the item identified in block 1.

1.2.5.6.1.1. If a TO or AFOSH std is used, enter the document number.

1.2.5.6.1.2. If an OEM manual or COTS manual is used, enter the manual number or title.

1.2.5.6.2. Block 10—NSN. Enter the assigned National Stock Number or part number for item identified in block 1. Leave blank if not applicable.

1.2.5.6.3. Block 11 and Block 12. These blocks are left blank, unless approved for use by Major Command (MAJCOM).

OC-ALCI21-103 20 APRIL 2022 9

1.2.5.6.4. Date Discovered. In this column, enter the date the discrepancy is discovered; the original date is brought forward to the new form when entries are carried forward from an old form.

1.2.5.6.5. Discovered By. In this column, the individual discovering the discrepancy will include his/her minimum signature.

1.2.5.6.6. Sup Doc Number. In this column, enter the base supply document number(s). This block is not required for units using Maintenance Information Systems

(MIS) or if directed by the maintenance group commander. When two or more supply document numbers are needed to adequately define base supply support for repairing a discrepancy, add all additional supply document numbers needed to correct the discrepancy after the statement of the discrepancy. If necessary, use of the next open discrepancy block is authorized. If the next block is used all adjacent blocks will be lined through. As these requisitions from base supply are received by the requester, draw a single line through the document number to show its receipt.

1.2.5.6.7. Symbol. In this column, enter the applicable red symbol for the discrepancy.

1.2.5.6.8. Discrepancy. In this column, enter the discrepancy or maintenance action required. Only one defect will be entered in each block for each job control or work order number; however, use as many blocks as necessary to completely describe a single discrepancy.

1.2.5.6.9. Job CON/WO Number. In this column, enter the job control or work order number assigned to the discrepancy.

1.2.5.6.10. Corrective Action. In this column, enter the description of the corrective action taken. For Red X and Red Dash discrepancies, include TO (including page and paragraph/figure number or function number), if applicable, or equivalent, in the

“Corrective Action” block and enter the date in the “Date Corrected” block. Depot

Industrial Plant Equipment (Depot Industrial Plant Equipment [DIPE]) is excluded from this requirement since the TO reference is listed on the equipment. Maintenance group commanders may specify additional minimum TO reference. If more space is needed to make this entry, use the next open block.

1.2.5.6.11. Date Corrected. In this column, enter the date (yyyymmdd e.g., 20010306) the discrepancy is corrected.

1.2.5.6.12. Corrected By. In this column, the individual who corrects the discrepancy will sign his/her signature in this block.

1.2.5.6.13. Inspected By. In this column, the individual clearing a Red - (dash) or Red

X will enter his/her minimum signature in this block and last name initial over the Red symbol in the symbol column.

1.2.6. AFTO Form 245. This form provides a continuation to part V of the AFTO Form 244.

This form will be completed using the same instructions as provided for part V of the AFTO

Form 244.

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1.3. AFTO Form 244 Symbols.

1.3.1. Symbol entries will be made in RED to make the important warning signals stand out clearly. All manually entered symbols must be entered in RED, except black name initials placed over the RED symbol.

1.3.2. Red X entries on the AFTO Form 244, for support equipment, can only be cleared by the shop supervisor/work leader or appointee (designated in writing).

1.3.3. RED (X) Symbol.

1.3.3.1. A Red X indicates that the SE is considered unsafe or unserviceable and will not be used until the unsatisfactory condition is corrected and symbol is cleared.

1.3.3.2. EXCEPTION. SE with a Red X condition may be operated as necessary to troubleshoot or repair the discrepancy.

1.3.4. RED – (Dash) Symbol.

1.3.4.1. A RED Dash indicates that a required scheduled inspection, special inspection or operation check is overdue.

1.3.4.2. Also used to indicate that the condition of the equipment is unknown and a more serious condition may exist.

1.3.5. RED / (Diagonal) Symbol.

1.3.5.1. A RED Diagonal indicates that an unsatisfactory condition exists on the equipment but is not sufficiently urgent or dangerous to warrant discontinuing use of the equipment.

1.3.6. Changing RED Symbols (After an Original Entry).

1.3.6.1. Symbols/Initials once entered will NEVER be erased even if entered in error.

1.3.6.2. Reasons for changing a RED symbol:

1.3.6.2.1. Condition is more serious than previously entered.

1.3.6.2.2. Condition is less serious than previously entered.

1.3.6.2.3. Symbol/Initials were entered in error.

1.3.7. Clearing RED Symbols:

1.3.7.1. The black last name initial entered over the symbol in the “Symbol” block indicates that the individual whose name appears in the signature block related to the particular entry has accomplished the required maintenance or has inspected the equipment, work accomplished, or system specified and has found the deficiency cleared.

1.3.7.2. The individual who signs off a RED symbol for a specific maintenance task must be authorized, familiar with the task, and knowledgeable of the technical orders required to accomplish the task.

1.3.7.3. When the initial is entered, consider the discrepancy indicated by the symbol cleared and discrepancy has been corrected.

OC-ALCI21-103 20 APRIL 2022 11

1.3.7.4. When a Red Dash or Red Diagonal is entered in error on a discrepancy or work document, the individual discovering the incorrect entry enters the following statement in the “Corrective Action” block: “Symbol/Initial entered in error, discrepancy and correct symbol/initial reentered on page ___, item ____,” or “Symbol entered in error, no discrepancy exists,” and enter their minimum signature. When required, re-enter the discrepancy, and correct symbol in the next open “Discrepancy” block on the form.

1.3.7.5. If the erroneous symbol is a Red X, the individual discovering the incorrect entry will enter the applicable statement identified in paragraph 1.3.7.4 If they are authorized to clear these symbols, they will complete the “Inspected By” block and initial over the symbol. If they are not authorized to clear these symbols, they will sign the “Corrected

By” block. The individual authorized to clear these symbols will place their last name initial over the symbol and complete the “Inspected By” block.

1.3.7.6. If the erroneous item is an initial, clear the discrepancy by entering “Initial entered in error, see Page ___Item___,” sign the “Corrected By” block and reenter the discrepancy in the next open block.

1.4. AFTO Form 244 Maintenance and Disposition Instructions.

1.4.1. When carrying the “Discovered By” block forward, print the first initial, last name and grade of the individual that originally discovered the discrepancy.

1.4.2. When closing out the AFTO Form 244, the current date will be entered in block 7

(following the “TO”) and carried forward (CF) will be entered in the Date Completed block of part III followed by the closer’s initials. For each open discrepancy, enter in the corrective action block CF and the closer’s first name initial, last name and grade.

1.4.3. Completed AFTO Form 244/245 or computer-generated equivalent will be kept on file by the shop supervisor for one-year. AFTO Form 244/245 or computer-generated equivalent will be destroyed after one year.

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Chapter 2

EQUIPMENT MAINTENANCE

2.1. Maintenance Concept: This chapter provides guidance for maintenance procedures and practices to ensure reliability and mission support capability of Depot Industrial Plant Equipment

(DIPE), Non-DIPE, and On-Condition Maintenance (OCM) equipment.

2.2. Maintenance Program Determination.

2.2.1. Types of Equipment. The 776th Maintenance Support Squadron (776 MXSS) and 76

MXSG/MXDE Engineering, with the aid of the maintenance groups, determines which equipment requires specific operator maintenance (OM) and the equipment to be included in the preventive maintenance (PM) and predictive maintenance (PdM) programs, and Corrective

Maintenance (CM) managed by the 776 MXSS.

2.2.1.1. DIPE is defined as permanently affixed/fixed location equipment not readily movable or other equipment as determined by the 776 MXSS Equipment Specialists. DIPE will be identified with an identification number (OC number). The following criteria will be applied to determine if equipment will be included in the maintenance management PM and/or PdM program.

2.2.1.1.1. Equipment creating an unsafe or hazardous environment if failure occurred, due to lack of PM and/or PdM, will be included.

2.2.1.1.2. All weapon-specific equipment having specific PM and/or PdM requirements delineated by an applicable TO will be included.

2.2.1.1.3. Equipment subject to breakdown repairs that are expensive compared to PM and/or PdM will be included.

2.2.1.1.4. Equipment critical to production and where failure would result in costly downtime will be included.

2.2.1.1.5. Equipment not critical to the depot maintenance process (e.g., small drill press) that can be repaired without regard to downtime or equipment availability should be excluded.

2.2.1.1.6. Equipment of small dollar value, where the cost of PM and/or PdM is likely to exceed the cost of replacement upon failure, should be excluded.

2.2.1.2. Attachment 10 contains a list of examples of items that will be excluded. The list is not all inclusive and EXCEPTIONS: can/may be made.

2.2.1.3. Non-DIPE is defined as any support equipment that is not classified as DIPE and does not have an OC identification number, AFSCMAN21-102, Depot Maintenance

Management, Chapter 15.

2.2.1.4. OCM is defined as depot machinery and shop equipment that does not have periodic, recurring inspections and does not have an OC identification number.

OC-ALCI21-103 20 APRIL 2022 13

2.3. Preventive Maintenance.

2.3.1. PM consists of equipment maintenance actions performed on a periodic basis according to a specific set of instructions and a predetermined time schedule. The objective of a PM is to protect the equipment capability and investment by removing causes of failure and making adjustments to compensate for normal wear before failures occur.

2.3.2. PM for OC-ALC equipment will be performed by the operator, 776 MXSS or contractor personnel, on a periodic basis according to a predetermined schedule. The description of operator PM and level of accomplishment is as follows:

2.3.2.1. Operator PM consists of two categories, general and servicing, and is performed by the operator on each shift (or if only used periodically) upon the initial starting of equipment.

2.3.2.1.1. General Operator PM applies to all equipment to ensure serviceability of equipment prior to use. This consists of a review of equipment documentation for current status (AFTO Form 244, DD Form 1577-2, Unserviceable [Repairable] Tag-

Material, or the user interface to Facilities and Equipment Maintenance [FEM] System, if applicable) and a Daily/PU visual inspection of equipment for conditions such as malfunctions, damage, cleanliness, proper lubrication, and potential safety/fire hazards.

Any of these conditions that cannot be corrected by the operator will be called to the attention of the supervisor for corrective action. No daily certification of this inspection is required to be documented on AFTO Form 244. Equipment will be cleaned and lubricated at intervals consistent with equipment care and good housekeeping standards.

2.3.2.1.2. Servicing Inspection includes, but is not limited to, maintenance of a critical nature which, if neglected, could result in costly equipment damage or create an unsafe condition. The performance of this maintenance will be documented on AFTO Form

244, Part II, for daily specific operator PM and Part III, for all other specific PM requirements. The inspection requirements are listed on the AFSC Form 306 (or equivalent), applicable equipment/general TO and AFOSH Stds, commercial operator manuals, etc.

2.3.2.1.3. The shop supervisor/appointee (appointed by letter) will monitor both general and specific operator maintenance to ensure accomplishment by reviewing the

AFTO Form 244 for accuracy and completeness. The supervisor/appointee will document the review on Part IV of the AFTO Form 244 every six months (paragraph

1.2.4.).

2.3.2.2. 776 MXSS PM is performed by the Plant Management Flight (776

MXSS/MXDVA) and the Metrology and Calibration Flight (METCAL) Flight (76

MXSS/MXDCA) on a scheduled basis (e.g., monthly, quarterly or yearly).

2.3.2.3. PM performed on DIPE by contractors will be tracked and documented on the

AFTO Form 244 or in the FEM System.

2.3.2.3.1. Existing contracts include the requirement for the contractor to document

PM on the AFTO Form 244 and in the Facilities and Equipment Maintenance (FEM)

System.

14 OC-ALCI21-103 20 APRIL 2022

2.3.2.3.2. All new contracts that are awarded are to include the requirement for the PM to be documented in the FEM System.

2.4. Predictive Maintenance. Work is a process of using electrical and mechanical testing and diagnostic devices to predict when a piece of equipment is deviating from its normal operating parameters. It is also designed to protect equipment capability and investment by removing causes of failure and making adjustment to compensate for normal wear before failure or an unsafe condition occurs. The Predictive Maintenance Team will provide necessary trending data and analytical reports to management and initiate a work order in the FEM system.

2.4.1. Predictive Maintenance Includes:

2.4.1.1. Infrared Thermography: Infrared thermography can detect electrical anomalies such as loose connections, overloaded circuits, and failed motors. It can also detect failing bearings, steam systems, coupling and alignment problems, air leaks, fluid levels, and blocked heat exchangers.

2.4.1.2. Oil Analysis: Immediate benefits are from the decrease in oil purchases by changing the oil based on condition versus changing the oil based on time. Impending equipment failures such as failed bearings and gears can be detected.

2.4.1.3. Vibration Analysis: The vibrations that exist in all rotating machinery have unique “signatures”. Detailed analysis makes it possible to identify abnormal signals and determine appropriate corrective action.

2.4.1.4. Ultrasonic Analysis: Identifies various types of leaks, e.g., compressed air, process gases, vacuum, steam, hydraulic and refrigerants. These are used to trend mechanical operations and detect electrical discharges such as corona, tracking and arcing.

2.4.1.5. Laser Alignment: Positioning two or more machine components so that their rotational centerlines are collinear at the coupling point under operating conditions. The

PdM team may assist technicians with the operation of laser shaft alignments.

2.4.1.6. Motor Analysis: Identifies and analyzes electrical defects using all major electric tests including surge, polarization index, DC hipot, megohm, and winding resistance. It also identifies power quality issues, machine and motor performance and estimates energy savings, detects voltage levels and unbalance, rotor cage condition, efficiency, under/over current, harmonic and total distortion, torque ripple, and load history.

2.5. Responsibilities.

2.5.1. Maintenance groups (76 AMXG, 76 CMXG, 76 MXSG, 76 PMXG, 76 SWEG) will:

2.5.1.1. Submit a primary and alternate Contract Maintenance Liaison (CML) to 76

MXSG/MXDEQ, which will be reviewed annually for accuracy. The most current copy of this appointment letter will be maintained on the 76 MXSG SharePoint site located at:

https://org2.eis.af.mil/sites/22249/SitePagesR/Home.aspx.

2.5.1.2. Complete an Automated DD Form 2875, System Authorization Access Request

(SAAR), at https://dd2875.robins.af.mil/NewForm.aspx) for managing FEM work orders for tasks accomplished by contractors on DIPE within their group. This will ensure that FEM accurately reflects equipment status (i.e., Red X, Red / & Red -) at all times.

https://org2.eis.af.mil/sites/22249/SitePagesR/Home.aspx https://dd2875.robins.af.mil/NewForm.aspx

OC-ALCI21-103 20 APRIL 2022 15

2.5.1.2.1. The Contracting Officer Representative (COR) and the primary or alternate contract requestor (primary or alternate person listed as having requested the contract action) will be responsible for ensuring that contractor maintenance is satisfactorily accomplished and the equipment is in serviceable condition before accepting the equipment. If the original primary and or alternate contract requestors are no longer responsible for that equipment then the COR shall communicate with equivalent replacement contract requestors. When the maintenance is accomplished by contractors required to use FEM, but the contractor does not have access to FEM, documentation for the acceptance of work accomplished by contractors will be forwarded by the COR. The COR will forward the documentation to the group primary or alternate CML or to the primary or alternate contract requestor for one-time maintenance contracts. The primary or alternate person receiving the documentation will then attach this documentation to the asset via either FEM or obsolete and close the work order(s) in FEM.

2.5.2. Engineering organization within the applicable maintenance groups will:

2.5.2.1. Complete Parts I and II of AFSC Form 388, Machine Tool and Equipment

Historical Record, and forward, with a copy of maintenance/parts manuals or applicable

TOs, and a completed OC-ALC Form 493, Lockout/Tagout (Control of Hazardous Energy) worksheet (if required by AFMAN 91-203) to Production Support (776 MXSS/MXDXA) for DIPE only (see Attachment 2 for complete instructions). Use 776 MXSS/MXDXA

Equipment Specialists workflow e-mail address

776mxss.mxdxa.equipmentspecialist@us.af.mil for routing electronic versions or deliver in person to the Equipment Engineering office in Building 3001, located at Post

2U73.

2.5.2.1.1. Failure to provide these items will result in the rejection of the request and the assignment of an OC number in FEM.

2.5.2.2. Notify 776 MXSS/MXDXA when modifications have been made to TOs that affect DIPE maintenance requirements. Use 776 MXSS/MXDXA Equipment Specialists workflow e-mail address 776mxss.mxdxa.equipmentspecialist@us.af.mil .

2.5.2.3. Notify 776 MXSS/MXDXA when modifications need to be made to the contents of the AFSC Form 306 for DIPE in their organization. Use 776 MXSS/MXDXA

Equipment Specialists workflow e-mail address

776mxss.mxdxa.equipmentspecialist@us.af.mil.

2.5.2.4. Ensure any modifications made to equipment, such as installation of safety guards, interlocks, etc., are brought to the attention of 776 MXSS/MXDXA. Subject modifications can then be incorporated into the AFSC Form 388 and the appropriate PM requirements can be determined. 776mxss.mxdxa.equipmentspecialist@us.af.mil

2.5.2.4.1. Equipment Modifications that affect the safety, environment impact, operation, maintenance plans, or production capability of an asset shall be coordinated with 76 MXSG/MXDEQ equipment utilizing OC-ALC Form 115.

2.5.2.5. Ensure that all engineering requests/inquires relative to equipment in the FEM system reference the 76 MXSS identification number (e.g., OC number) assigned to the particular piece of equipment.

mailto:776mxss.mxdxa.equipmentspecialist@us.af.mil mailto:776mxss.mxdxa.equipmentspecialist@us.af.mil mailto:776mxss.mxdxa.equipmentspecialist@us.af.mil

16 OC-ALCI21-103 20 APRIL 2022

2.5.2.6. Determine if equipment that is no longer in use for an extended period (e.g., intermittent workload) will be needed for future workload.

2.5.2.6.1. If the equipment is not going to be needed to support future workloads, it must be either transferred to another organization or turned into DLA Distribution

Services (formerly known as the Supply/Defense Reutilization Marketing Office

[DRMO]).

2.5.2.6.2. If the equipment is needed to support future workloads, it must be determined whether Maintenance Support and/or Operator PM will be continued or suspended.

2.5.2.6.2.1. If PM is to be suspended, notify 776 MXSS/MXDXA via the 776

MXSS/MXDXA Equipment Specialists workflow e-mail address

776mxss.mxdxa.equipmentspecialist@us.af.mil. The FEM equipment record will be changed to reflect a not in use (NIU) and Red X status.

2.5.2.6.2.2. When equipment is returned to service, notify 776 MXSS/MXDXA so that PM can be re-established. Use 776 MXSS/MXDXA Equipment Specialists workflow e-mail address 776mxss.mxdxa.equipmentspecialist@us.af.mil.

2.5.2.6.2.3. Ensure corrosion preventive measures are accomplished, as needed, while not in use.

2.5.2.7. Determine required PM actions and frequencies for non-DIPE and provide the requirements to the shop supervisor on AFSC Form 306, applicable equipment/general TO, commercial operator manual, work card, or checklist. If the AFSC Form 306 is used, the forms will be maintained by the applicable engineering organization.

2.5.3. The maintenance group shop supervisor/appointee will:

2.5.3.1. Depot Industrial Plant Equipment (DIPE).

2.5.3.1.1. Assist 776 MXSS/MXDXA in determining required PM actions and frequencies.

2.5.3.1.2. Ensure there is an operator AFSC Form 306, Preventive Maintenance

Instructions (or equivalent) on or near the applicable DIPE prior to putting the DIPE into service/use. If missing, contact 776 MXSS/MXDXA to receive a replacement via the Equipment Specialists workflow e-mail address

776mxss.mxdxa.equipmentspecialist@us.af.mil. For DIPE with specific operator

PM that is put into service/use prior to receiving the AFSC Form 306 from 776

MXSS/MXDXA, ensure that the guidance (manual, technical order, AFOSH standard, etc.) is with the equipment and that the accomplishment is documented on the AFTO

Form 244, Parts II and/or III.

2.5.3.1.2.1. Supervisor/operator will verify that PM tasks contained on the AFSC

Form 306 can be accomplished prior to placing the DIPE into serviceable use condition for production. Any condition which cannot be corrected by the operator will be called to the attention of the supervisor to facilitate correction by

Maintenance Support Group (MXSG).

mailto:776mxss.mxdxa.equipmentspecialist@us.af.mil

OC-ALCI21-103 20 APRIL 2022 17

2.5.3.1.3. Ensure all specific operator maintenance is performed by the operator/appointee at the frequencies prescribed on the AFSC Form 306 and documented on the AFTO Form 244, Part II and/or Part III, IAW paragraphs 1.2.2 and

1.2.3 of this instruction.

2.5.3.1.4. Accomplish the supervisory review of the AFTO Form 244 IAW paragraph

1.2.4..

2.5.3.1.5. Monitor the user interface to FEM daily and ensure all equipment with past due PM (Red X condition) is removed from service by tagging the equipment with a

DD Form 1577-2. For equipment other than hoists and cranes, PM is considered past due when the due date exceeds the month due or by one frequency cycle, whichever is less. For hoists and cranes, PM is considered past due on the first day of the month following the month documented on the sticker on the item.

2.5.3.1.6. Use FEM to initiate repair trouble calls and set priority of work orders

(paragraph 3.5.4).

2.5.3.1.6.1. Priorities. FEM will contain the red symbols for maintenance support and contractor repair actions on DIPE except contractor repair actions by contractors that are not required to use FEM. These symbols will be monitored using FEM and cleared when the work order is closed. Documentation of these trouble call/work orders on AFTO Form 244/245, Part V will not be required.

2.5.3.1.6.2. Priority Code 5 = Red X. This is repair work that demands immediate response to prevent injury to personnel due to a safety hazard. Equipment will be immediately removed from service by temporarily tagging with an AF Form 982, Do Not Start Tag, until Maintenance Support determines the need for and accomplishes lockout tag out in accordance with Air Force Manual (AFMAN) 91-

203, Air Force Consolidated Occupational Safety Standard.

2.5.3.1.6.3. Priority Code 4 = Red X. This is repair work that demands immediate response to correct critical workload stoppage or involves risk of major damage to government property. Equipment items in this category will be removed from service and tagged with a DD Form 1577-2.

2.5.3.1.6.4. Priority Code 3 = Red /.

2.5.3.1.6.4.1. Red / = This is repair work of a routine nature that is not significantly urgent to warrant removing the equipment from service.

2.5.3.1.7. Send an e-mail notification to 776 MXSS/MXDXA when DIPE is removed or relocated via the Equipment Specialists workflow e- mail address

776mxss/mxdxa.equipmentspecialist@us.af.mil . Relocation notification will include the identification number (e.g., OC number), building/post location, routing symbol, and point of contact. Removal notification will include the identification number (e.g., OC number) and point of contact.

2.5.3.1.8. Notify production engineering office when modifications need to be made to the contents of the AFSC Form 306 for DIPE in their organization.

mailto:mxdxa.equipmentspecialist@us.af.mil

18 OC-ALCI21-103 20 APRIL 2022

2.5.3.1.9. Release equipment, in a timely manner to 76 MXSG or contractor personnel, to ensure that PM and Corrective Maintenance (CM) are completed promptly and as scheduled.

2.5.3.1.10. Ensure the accomplishment of calibration on Precision Measurement

Equipment (PME) items (gages, meters, etc.) attached to DIPE is accomplished IAW

TO 00-20-14, Air Force Metrology and Calibration Program, section 3.

2.5.3.1.10.1. Remove DIPE from service and attach a DD Form 1577-2 annotating

“Overdue Calibration” to equipment.

2.5.3.1.10.2. The supervisor/work leaders of the owning/using organization will ensure serviceability and remove/discard the DD Form 1577-2 after the PME technician has completed the calibration actions.

2.5.3.1.11. Ensure an AFTO Form 244/245 is maintained for DIPE under their control that has specific operator PM identified (an AFTO Form 244 is not required on DIPE that does not have specific operator PMs documented on AFSC Form 306).

2.5.3.1.12. Notify production engineering office when DIPE is no longer in use for an extended period (e.g., intermittent workload). Attach a DD Form 1577-2 with the annotation “NOT IN USE; ALL PM SUSPENDED” to the DIPE in a visible location.

2.5.3.1.13. Notify production engineering office when not in use DIPE needs to be returned to service. The DD Form 1577-2 will remain on the DIPE and the equipment will not be used until all PMs are accomplished and the form is removed by 76 MXSS maintenance organization.

2.5.3.1.14. Notify the Bioenvironmental Engineering Flight (BEF) 72 AMDS and

Environmental Compliance Office (76 MXSG/MXDEU) and when a change occurs in parts processed, media, and/or hazardous material used in the process (e.g., blast media, chemicals) which changes the occupational health assessment as reported in the shop’s current Industrial Hygiene Assessment letter from BEF. IAW Air Force Instruction

32-7086 Oklahoma City Air Logistics Complex Supplement (AFI32-7086_OC-

ALCSUP), Hazardous Materials Management, chemicals/HAZMAT must be approved before being brought on base.

2.5.3.2. Non-DIPE.

2.5.3.2.1. Coordinate with Production Engineering Office to determine required PM actions and frequencies. The PM requirements will be referenced on AFSC Form 306, applicable equipment/general TO, and AFOSH standards, commercial operator manual, work card, or checklist.

2.5.3.2.2. Ensure the applicable PM requirements are on or near the equipment. If missing, contact your Production Engineering Office to receive a replacement.

2.5.3.2.3. Ensure all specific operator maintenance is performed by the operator/appointee at the prescribed frequencies and documented on the AFTO Form

244, Part II and/or III, IAW paragraphs 1.2.2 and 1.2.3 of this instruction.

2.5.3.2.4. Accomplish the supervisory review of the AFTO Form 244 and document in Part IV, IAW paragraph 1.2.4 of this instruction

OC-ALCI21-103 20 APRIL 2022 19

2.5.3.2.5. Annotate all unscheduled discrepancies on the AFTO Form 244/245, Part V, IAW paragraph 1.2.5. of this instruction.

2.5.3.2.6. Use FEM to initiate repair trouble calls and set priority of work orders for repairs that cannot be accomplished by the owning work center (paragraph 3.5.4).

Documentation of these trouble call/work orders must be annotated on AFTO Form

244/245, Part V. (Note: If the trouble call/work order is cancelled by 76 MXSG, the original write-up is still valid until appropriate actions are taken to fix the discrepancy.)

The original write-up will be cleared by the individual/organization who accomplishes the repair IAW Chapter 1. Priorities are as follows:

2.5.3.2.6.1. Priority Code 5 = Red X. This is repair work that demands immediate response to prevent injury to personnel due to a safety hazard. Equipment will be immediately removed from service by temporarily tagging with an AF Form 982, until MXSG determines the need for and accomplishes lock-out tag-out IAW

AFMAN 91-203.

2.5.3.2.6.2. Priority Code 4 = Red X. This is repair work that demands immediate response to correct critical workload stoppage or involves risk of major damage to government property. Equipment items in this category will be removed from service and tagged with a DD Form 1577-2.

2.5.3.2.6.3. Priority Code 3 = Red X or Red /.

2.5.3.2.6.3.1. Red /. This is repair work of a routine nature that is not significantly urgent to warrant removing the equipment from service.

2.5.3.2.7. Ensure the accomplishment of calibration on PME items (gages, meters, etc.), attached to Non-DIPE is completed IAW TO 00-20-14, Air Force Metrology and

Calibration Program, Section 3.

2.5.3.2.7.1. When necessary remove Non-DIPE from service and attach a DD

Form 1577-2 annotating “Overdue Calibration” to equipment.

2.5.3.2.7.2. The supervisor/work leaders of the owning/using organization will ensure serviceability and remove/discard the DD Form 1577-2 after the PME technician has completed the calibration actions.

2.5.3.2.8. Ensure all discrepancies are signed off in accordance with Chapter 1.

2.5.3.2.9. Ensure AFSC Form 306 is developed by Group Engineering if inspection requirements are not identified in other approved tech data sources and AFTO Form

244/245 is maintained for equipment under their control.

2.5.3.3. OCM Depot Machinery and Support Equipment.

2.5.3.3.1. In conjunction with production, engineering functions will review and document which equipment items require only OCM. An OCM equipment master listing, signed by the approving engineering office and production supervisor, will be maintained by the production supervisor.

20 OC-ALCI21-103 20 APRIL 2022

2.5.3.3.2. Ensure all unserviceable/repairable OCM equipment are removed from service and tagged with a DD Form 1577-1, Unserviceable (Condemned) Tag-Materiel, or DD Form 1577-2 with the discrepancy and work order number (if applicable) annotated on the back of the form.

2.5.3.3.3. Use FEM to initiate repair trouble calls and set priority of work orders for repairs that cannot be accomplished by the owning work center (paragraph 3.5.4).

Priorities are as follows:

2.5.3.3.3.1. Priority Code 5 = Red X. This is repair work that demands immediate response to prevent injury to personnel due to a safety hazard. Equipment will be immediately removed from service by temporarily tagging with an AF Form 982, until MXSG determines the need for and accomplishes lock-out tag-out IAW

AFMAN 91-203.

2.5.3.3.3.2. Priority Code 4 = Red X. This is repair work that demands immediate response to correct critical workload stoppage or involves risk of major damage to government property. Equipment items in this category will be removed from service and tagged with a DD Form 1577-2.

2.5.3.3.3.3. Priority Code 3 = Red /.

2.5.3.3.3.3.1. Red /. This is repair work of a routine nature that is not significantly urgent to warrant removing the equipment from service.

2.5.3.3.4. Ensure the DD Form 1577-2 is removed and discarded when the discrepancy has been corrected.

2.5.4. 776 MXSS/MXDXA will:

2.5.4.1. Perform the following tasks on newly acquired DIPE:

2.5.4.1.1. Assign and permanently attach a MXSG identification number (e.g., OC number) and annotate the number on the AFSC Form 388. Coordinate with the predictive maintenance team for insertion of the applicable predictive maintenance technologies and actions required.

2.5.4.1.2. Add DIPE to FEM by the identification number (e.g., OC number), noun, model, serial number, national stock number, priority code, manufacturer, location, owning organization, date installed, purchase date, and acquisition cost as available.

This is the FEM Equipment File, which is a facsimile of the AFSC Form 388.

2.5.4.1.3. Develop required specific operator, 776 MXSS/MXDVA, 76

MXSS/MXDCA, or contractor PM on new equipment as needed by utilizing sources such as TOs, vendor’s manuals, industrial standards and other available data. AFSC

Form 306 (or equivalent) or FEM will be used to document these instructions.

2.5.4.1.4. Add a statement to FEM, that will print on all work orders, warning the technicians of occupational health hazards associated with materials used in the process the equipment will be used for, as identified by the supervisor.

OC-ALCI21-103 20 APRIL 2022 21

2.5.4.1.5. Develop PM automated scheduling through FEM for the MXSG shops or the contractor shop (if available) that is responsible for performing the PM actions. For contractors required to use FEM, but do not have access to FEM, the PMs will be scheduled for the maintenance group (paragraph 2.5.1.1.1). A shop identifier (Crew

ID) will be created in FEM for the MXSG shops, contractor, or maintenance groups as appropriate.

2.5.4.1.6. Place a copy of the operator AFSC Forms 306 (or equivalent) on applicable

DIPE and identification tag on all DIPE.

2.5.4.2. Perform the following tasks on existing DIPE:

2.5.4.2.1. Review requests to modify the contents of the AFSC Form 306 for DIPE received from the maintenance group engineering organizations and implement modifications as needed (776 MXSS/MXDXA has final determination concerning the contents of the AFSC Form 306 for DIPE).

2.5.4.2.2. Accomplish all FEM updates and inventory changes except work order record completion which is accomplished by the 776 MXSS shop, the contractor shop

(if available) that is responsible for performing the PM actions or, for contractors who do not have access to FEM, by the maintenance group (paragraph 2.5.1).

2.5.4.2.3. When equipment is to be removed for turn-in, delete the item from FEM.

2.5.4.2.4. Provide necessary analysis and status reporting to management.

2.5.5. The METCAL Flight (76 MXSS/MXDCA) and/or the Plant Management Flight 776

MXSS/MXDVA) will:

2.5.5.1. DIPE.

2.5.5.1.1. Perform PM, PdM, and CM according to the work schedule in FEM.

2.5.5.1.2. When work is completed, finalize the FEM work order IAW MXSG OI 21-

100. Provide feedback to 776 MXSS/MXDXA concerning changes that need to be made to the AFSC Form 306 (or equivalent) or to FEM records (equipment location changes, PM action changes, materials needed to accomplish the PM actions, etc.).