AMARG_21-109._3_Jul_13.pdf

BY ORDER OF THE COMMANDER AMARG INSTRUCTION 21-109

309TH AEROSPACE MAINTENANCE 03 JULY 2013

AND REGENERATION GROUP

Maintenance

ENGINE MANAGEMENT

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available on the 309 AMARG Portal for downloading.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: 309 AMARG/OBW Certified by: 309 AMARG/OB-CL

(Mr. Steven Schumacher) Supersedes: This is a new publication

Pages: 25

This publication implements Air Force Policy Directive (AFPD) 21-1, Air and Space Maintenance. It assigns roles and responsibilities and establishes policies, procedures, and instructions used by the 309th Aerospace Maintenance and Regeneration Group (AMARG) in the maintenance and control of propulsion units. This instruction fulfills requirements set forth in Air Force Instruction (AFI) 20-115, Propulsion Management For Aerial Vehicles; Technical Order (TO) 00-25-254-1, Comprehensive Engine Management System Engine Configuration, Status and Time Compliance Technical Order (TCTO) Reporting Procedures; TO 00-25-254-2, Comprehensive Engine Management System Manual for Data System Designator (DSD) D042;

AFI 21-101, Aircraft and Equipment Maintenance Management; Air Force Manual (AFMAN) 23-110, USAF Supply Manual, and NAVAIRINST 13700.15E, Aircraft Engine Management System (DECKPLATE), Naval Air Systems Command Instruction. This instruction applies to all 309 AMARG military, civil service and contractor personnel assigned to the 309th Support Squadron (309 SPTS), 576th Aerospace Maintenance and Regeneration Squadron (576 AMRS), 577th Commodities Reclamation Squadron (577 CMRS), 578th Storage and Disposal Squadron (578 SDS), Business Operations Division (OB) and Quality Assurance and Process Improvement Division (QP). This publication may not be supplmented. Refer recommended changes and questions about this publication to the OPR listed above using the AF Form 847, Recommendation for Change of Publication; route AF Forms 847 from the field through the appropriate chain of command. Requests for waivers must be submitted through chain of command to the OPR listed above, or as otherwise stipulated within this publication, for consideration and approval. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with Air Force Manual (AFMAN) 33-363, 2 AMARGI 21-109 03 JULY 2013

Management of Records, and disposed of in accordance with Air Force Records Information Management System (AFRIMS) Records Disposition Schedule (RDS). The use of the name or mark of any specific manufacturer, commercial product, commodity, or service in this publication does not imply endorsement by the Air Force.

Table of Contents

1. General…………………………………………………………………….. 2

2. Responsibilities……………………………………………………………..

3. Policy………………………………………………………………….…… 11

4. Procedures…………………………………………………………………. 13

5. Asset Storage Accountability And Physical Location ……………………. 20

6. Disposal …………………………………………………………………… 20

7. Engine Trailers And Transportation Devices……………………………… 21

Attachment 1 Glossary of References and Supporting Information……………………... 22

1. GENERAL. Propulsion systems, which include aircraft engines and power units, missile engines and drone engines, require selective management, due to the high cost of these end items. There will be a minimum of one primary and one alternate Engine Manager (EM) for Stock Record Account Number (SRAN) FJ2373, N65965 Organization WE5 and, if established, any other customer accounts. Customer account requirements will be specified in workload agreements in addition to the general requirements in this publication. Engine Managers are assigned to 309 AMARG/OB with a primary office location of Building 7328 and a secondary location in or near the Propulsion Section maybe established. Normally, the primary and alternate engine managers will be the same personnel for all customer accounts. Engine Management is responsible for engine, engine component, propeller and blade accountability and inventory control. This instruction applies to all assets physically located at 309 AMARG. This instruction provides guidance for all 309 AMARG unit responsibilities. For US Air Force assets, the Comprehensive Engine Management System (CEMS) is the system of record. System of record for US Navy assets is DECKPLATE. One of the Engine Management Section’s primary responsibilities is timely reporting in CEMS/DECKPLATE of asset status, condition and location at all times. 309 AMARG units must report all changes in status and condition of engines, engine components, rotor blades and propellers no later than the close of business the first duty day after the event to the 309 AMARG EM so the EM can update the system of record pursuant to customer’s technical orders, publications and Statements of Work (SOW). For the purpose of generating production work orders, all assets located at 309 AMARG will also be managed in the AMARG Business System (ABS), regardless of each customer’s requirements to manage assets in other inventory systems.

AMARGI 21-109 03 JULY 2013 3

2. RESPONSIBILITIES.

2.1. Business Office (OB)

2.1.1. Director, Business Office, will:

2.1.1.1. Appoint and train highly qualified personnel as engine managers; ensure engine management is properly staffed and resourced.

2.1.1.2. Maintain, manage and validate the engine management training plan or delegate in writing to a designated representative

2.1.1.3. Approve engine management work instructions and checklists required in this instruction

2.1.1.4. Ensure the ABS supports engine management requirements

2.1.2. Engine Manager (EM) will:

2.1.2.1. Serve as 309 AMARG single point of contact (POC) for all engine management matters and will develop and publish work instructions sheets to implement policy

2.1.2.2. Administer the base engine management program by performing the duties required in TO 00-25-254-1, AFI 21-101 AFMC Supplement 1 and this publication. Maintain currency of all engine status, condition, location and significant history related to assigned propulsion units, by processing updates and transactions for all reportable events in the appropriate system of record pursuant to each customer’s workload agreement, SOW, and/or support agreement.

2.1.2.2.1. For USAF assets, validate all transactions have been completed in CEMS prior to updating engine removals and installations. Update CEMS automated history for all removals and special occurrences as well as correct engine time change/inspections CEMS entry errors in accordance with TO 00-25-254-1 and AFI 21-101 AFMC Supplement 1, Attachment 14, Table A14.1, Section 21.3.

2.1.2.3. Due to the unique nature of 309 AMARG’s workload, it is possible future workload will result in situations when full compliance with policy may not be possible. In such circumstances, the EM will immediately advise the Director, Business Office, in writing.

2.1.2.3.1. Initiate and forward requests for waivers or exceptions to policy as required. On a quarterly basis, validate all approved exceptions to policy are current until the workload driving the exception is complete or a waiver is no longer required for other reasons (policy change, etc).

4 AMARGI 21-109 03 JULY 2013

2.1.2.4. Provide and document annual training to all 309 AMARG production personnel of engine reporting responsibilities.

2.1.2.5. Verify all assigned assets are in the ABS on a routine basis and reconcile ABS to each customer’s system of record. ABS data will not be used as the sole information source to update any customer’s system of record.

2.1.2.5.1. Identify and submit technical change requirements for ABS to the Director, Business Office, when system limitations negatively impact compliance with EM requirements or to enhance functionality.

2.1.2.6. On a monthly basis, conduct surveillance in the Engine Management Section to validate all reportable actions were correctly reported in each customer’s system of record and the ABS and other local management products accurately reflect the information in the system of record. Maintain a written audit log to include reporting accuracy and timeliness results, date conducted, areas surveyed and corrective actions taken. Provide a monthly written surveillance summary to the Director, Business Office.

2.1.2.6.1. Develop, manage and use Discoverer query exception reports to facilitate surveillance. Maintain a work instruction that defines the purpose, design, validation and functionality of all active queries. Validations will be re-accomplished at the time of ABS system changes.

2.1.2.7. Develop, manage, and use local procedures work instructions and checklists to comply with policies and to accomplish the processes specified in this instruction. These tools will specify organizational roles and responsibilities and will provide detailed “How-To” information. Include procedures and sequencing of actions for completing CEMS, DECKPLATE, ABS and other system updates in order to implement policy and reference the paragraph(s) in this instruction they implement.

2.1.2.7.1. Provide approved local procedure work instructions to unit personnel, as required.

2.1.2.7.2. Obtain Director, Business office, approval on all new and revised local procedure work instructions. Conduct and document an annual review by 15 February of every year. Certify currency annually in writing when no changes are required.

2.1.2.8. Monitor accounts for projected inductions and losses and coordinate receiving and shipping with 309 SPTS, 578 SDS and outside organizations.

2.1.2.8.2. Coordinate on local procedures for handling, shipment and storage of shipping devices to include trailers, stands, cradles, containers, adapters and shipping systems with applicable 309 AMARG agencies.

AMARGI 21-109 03 JULY 2013 5

2.1.2.9. For asset induction, conduct a records review when the S/N validation documentation is provided by production within 5 duty days. Take appropriate action to update customer account and system of record information and, if necessary, make corrections. Notify the losing unit within 5 duty days of completing the records review for missing records or information. Update Time Change Technical Orders (TCTO) status codes per the workload agreement.

2.1.2.9.1. Provide 309 AMARG/OBWS Records Section with guidance for engine record requirements and maintenance.

2.1.2.10. Establish a close file for each asset when any of the documents in paragraph 2.1.2.10.1. are received, except for AF Form 913, Aerospace Vehicle Project Action, for aircraft with engines installed. Documents will be managed and filed pursuant to the EM Section records management plan.

2.1.2.10.1. Close files at a minimum, will contain: source documentation for transfer of possession to/from 309 AMARG, any pertinent correspondence from AFLCMC/LPSDC Engine Item Manager (EIM) or Program Manager (PM), and disposal turn-in documents.

2.1.2.11. Obtain EIM and/or PM disposition for storage and other required guidance for each Type, Model, Series and Modification (TMSM) as required pursuant to AFGM 20-06.1, Propulsion Life Cycle Management for Aerial Vehicles, AFI 20-115, Propulsion Management for Aerial Vehicles, AFI 63-101, Acquisition and Sustainment Life Cycle Management, and AFI 63-101 AFMC Supplement 1. Obtain disposition for propellers and blades when parent asset is approved for disposal or other actions, when the SOW does not already specify disposition.

2.1.2.11.1. Obtain EIM and/or PM disposition for engine serviceability and condition code when the engine preservation period expires and the workload agreement does not already specify disposition. Notify 309 AMARG/OBW Workload Office to plan and issue work orders to update asset warning tags when engineering disposition contains direction not to operate the engine without further engineering approval or when engine serviceability is unknown. EM will establish standard ABS documentation requirements for engines that cannot be operated due to an expired preservation.

2.1.2.11.2. Obtain EIM and/or PM disposition when assets are received and the asset condition and status cannot be determined per TO 00-20-1 section 3.8., because the losing unit did not provide historical data.

2.1.2.11.3. When required, in ABS, use phraseology code “5” to stop preventative maintenance requirements, at the time disposal preparation workload is actually started.

6 AMARGI 21-109 03 JULY 2013

2.1.2.12. Monitor Engine Trending and Diagnostic (ET&D) and Engine Health Management (EHM) program compliance and verify engine download data is accurately and completely transferred to CEMS.

2.1.2.13. USAF and USN accounts will be inventoried per TO 00-25-254-1, AFMAN 23-110 and NAVAIRINST 13700.15E. When the inventory is complete, the EM will resolve discrepancies. Discrepancies will be documented, corrected and verified in the applicable system of record and AMARG ABS.

2.1.2.13.1. Asset data plates will be used to verify serial numbers anytime they are accessible without performing maintenance (opening panels, removing preservation coatings) to access them. For USAF assets, TO 00-25-254-1 Chapter 8 procedures will be followed when asset data plates are not accessible.

2.1.2.13.2. Coordinate with 309 AMARG/OBW Workload Office to cut a Request For Quote (RFQ) when discrepancies are found during inventory (example: improperly sealed engine or storage device; bad indication of desiccant, etc).

2.1.2.13.3. EM will use CEMS or ABS to document, manage and track records review dates.

2.1.2.13.4. Coordinate EM requirements with the Aircraft Disposition Officer (ADO) for annual aircraft inventory.

2.1.2.14. Attend 309 AMARG planning meetings that involve engine workload or review/sign AFMC Form 500, Work Control Document Production Planning Team Checklist, when unable to attend.

2.1.2.15. Provide reports to EIMs and AFMC Command Engine Manager per workload agreements. Provide the RCS-MM (AR) 7759 Report, Data for Engines Installed on Excess Aircraft, per AFMCI 23-111, Reclamation of Air Force Property, Chapter 8, when aircraft with obligated engines are initially assigned to a programmed reclamation project.

2.1.3. 309 AMARG/OBW Workload Office will:

2.1.3.1. Ensure support agreements, workload agreements and SOWs involving propulsion units are coordinated with EM prior to approval and comply with TO 00-20-1, TO 1-1-686 para 3.27., customer unique publications and TMSM specific technical orders.

2.1.3.2. Coordinate with the EM and establish and manage propulsion unit preventative maintenance requirements for both installed and uninstalled engines.

AMARGI 21-109 03 JULY 2013 7

2.1.3.3. Review the Preventive Maintenance Discrepancy Report and take corrective action as required.

2.1.3.4. Advise and coordinate with EM prior to Pre-Production Planning Team meetings that involve engine workload.

2.1.3.5. Advise EM when AFMC Form 173, MDS/Project Operation Assignment, is received that requires any type of work on an engine, propeller, blade or shipping/storage device.

2.1.4. 309 AMARG/OBWP Advance Planning Cell and unit production planners will:

2.1.4.1. For all engine, engine component, propeller and rotor blade workload, develop job plans in a manner that generates Production Work Orders (PWO) against the specific engine, propeller or rotor blade asset number, not the aircraft asset number. Requirements for more than one engine, propeller or blade will not be combined into a single PWO. This policy applies to all production control numbers.

2.1.4.1.1. Design job plans to include requirements for production personnel to report/document maintenance actions at the time of maintenance for all engine-related actions, to include work on components. Include requirements to provide AFTO Form 95, Significant Historical Data, data elements (P/N, S/N, How Mal, etc), asset condition changes (example, serviceable/unserviceable) with reasons, and status changes (installed/uninstalled, engine runs) per TO 00- 20-1 and AFI 21-101 AFMC Supplement 1, paragraph 19.2.15. This requirement applies to engines in all status codes except PH and PZ (does not apply to parts removed during disposal prep when the parts will also be disposed). Additional requirements for Programmed Depot Maintenance (PDM) and Service Life Extension Program (SLEP) workloads and F100PW- 100/200/220/229 engines are contained in TO 00-20-5-1-1, Engine Historical Records, Instructions for F100PW-100/-200/-220/-229 Engine. Also, AF IMT Form 1557, F-100 EHR Report, will be used for F100PW-100 engine runs.

For all inductions and AMARG generated sorties (Operational Check Flight, Functional Check Flight, etc), production will provide a copy of the AFTO Form 781J, Aerospace Vehicle Engine Flight Document, (or equivalent for non-AF assets) immediately after post-flight updates are completed. For AF assets, EM must update all component removals in CEMS automated history, not just S/N tracked parts.

2.1.4.1.2. Job plan instructions will inform production to provide information to the EM not later than close of business the duty day following completion of the task per paragraph 2.1.4.1 of this instruction. The reporting of this information cannot wait until the completed work order goes to the scheduler for final review. The job plan will contain specific details on the physical

8 AMARGI 21-109 03 JULY 2013

location of the data plate in order to ensure the correct serial number information is obtained by the mechanic performing the work. It is critical this reporting occurs for each and every stage of maintenance, not just at the start or completion of maintenance.

2.1.4.1.3. All engine/component job plans will include instructions for production to physically verify the asset serial number data plate and document it in the PWO as early as possible in the process for that given workload for engines, blades and propellers, both installed and uninstalled. This policy applies when any maintenance is performed on the engine, propeller or blade.

2.1.4.1.4. Design job plans to instruction production to notify 309 SPTS Job Control of the new location for all uninstalled engine, propeller and rotor blade movements at the time of the movement (same as obtaining clear to tow approval for aircraft).

2.1.4.1.5. Design job plans to comply with TO 00-20-1 section 5.13.11 for documenting engine times and cycles for engine changes when applicable

2.1.4.2. For all engine and engine component workload, design job plans to include instructions for completing required engine downloads per the TMSM technical order and recording flight hours / operating time and provide to the EM. For Air Force engines, job plan will instruct production to confirm with EM that all CEMS transactions have been processed prior to releasing aircraft for flight.

2.1.4.2.1. As of the date of this publication, the following engines require downloads: F100-PW-220 (F-15 & F16), F110-GE-100 (F-16), F101-GE-102

(B-1B), TF34-GE-100A (A-10), F108-GE-100 (KC-135R, RC-135, AE3007H

(Global Hawk) engines. Downloads are required after each green run/engine run, functional check flight, operational check flight or engine times cycles/total accumulated cycles update. Engines will be downloaded and processed in the CETADS work center computer, then reconciled to the Base Engine Manager (BEM) host computer and recorded in CEMS pursuant to the applicable 00-25-257 series Technical Order, Engine Health Management Plus (EHM+) User’s Manual Instructions.

2.1.4.2.2. Contact the EM prior to creating a job plan for an engine TMSM not listed in Paragraph 2.1.4.2.1.

2.1.4.3. For all engine workload, design job plans to include instructions for providing the engine preservation date to the EM when the engine is preserved (this is not the arrival date).

2.1.4.4. Advise EM when AFMC Form 173 is received that requires any type of work on an engine, propeller, rotor blade, or storage device.

AMARGI 21-109 03 JULY 2013 9

2.1.5. OBW ADO will:

2.1.5.1 Notify the EM in a timely manner but not later than 1 duty day prior to authorizing the Defense Logistics Agency (DLA) to begin work or transport engines from 309 AMARG. The EM must be able to physically verify S/Ns at the time assets change ownership and/or are physically removed from 309 AMARG property.

2.2. 309 AMARG production units (576 AMRS, 577 CMRS, 578 SDS, and 309 SPTS) will:

2.2.1. For both installed and uninstalled assets, notify EM in writing no later than the first duty day following maintenance, any changes in status or condition, and any accomplished engine runs. For engine component removals, the ABS removed component inventory (C03) will be updated against the engine asset number, not the aircraft. Planners will comply with Section 2.1.4. of this instruction. Supervisors and schedulers will ensure PWOs include required instructions for production personnel to document S/N verification and maintenance actions at the time of maintenance for all AFTO Form 95, Significant Historical Data, data elements (P/N, S/N, How Mal, etc) and engine status and condition changes. Production personnel will record this information in the work order per TO 00-20-1, AFI 21-101 AFMC Supplement 1 and 309 AMARG publications. Units will provide a hard copy or scanned copy via email to the EM. The EM cannot accept information re-typed into an email or via phone.

Production units must provide the signed PWO (or applicable source document) completed by the personnel who accomplished the work.

2.2.1.1. For Air Force engines, units are responsible to confirm with EM that all CEMS transactions have been processed prior to releasing aircraft for flight.

2.2.1.2. Maintain physical control of uninstalled engines assigned to unit temporary storage locations. Immediately notify EM if any asset is moved without unit’s knowledge or is not found at its last known location. See section 5 of this instruction.

2.2.1.3. Respond to all EM requests for information within two duty days.

Promptly update all ABS PWO ops related to engine work from Waiting Approval (WAPR) to In-Progress (INPRG) and from INPRG to Complete (COMP). Do not leave engine related ops WAPR when being worked and do not change status from WAPR directly to COMP if the task has been worked.

2.2.1.4. When applicable, use the local procedure work instructions approved and provided by the EM to accomplish responsibilities set forth in this instruction.

2.2.1.5. Immediately notify EM when an engine asset projected to arrive in serviceable conditions is received in an unserviceable condition. Notify Job Control of any apparent damage.

10 AMARGI 21-109 03 JULY 2013

2.2.1.6. Do not make changes to propulsion unit ABS asset record notes without EM approval. Notes are used to provide Higher Headquarters reports; therefore, they must contain certain information.

2.2.1.7. Coordinate with 578 SDS Production Support Flight for uninstalled engine movement requirements.

2.2.1.8. Each shop identified in section 5 of this instruction will support EM inventory process requirements. EM will provide further guidance and schedules prior to inventory start.

2.2.1.9. Notify Job Control of uninstalled engine, rotor blade and propeller movements at the time of movement.

2.2.2. 578 SDS is the single POC for uninstalled engine movement within 309 AMARG and is responsible for physical control of uninstalled engines assigned to 578 SDS storage locations

2.3. 309 SPTS will:

2.3.1. Store and manage unobligated propeller and blade assets

2.3.2. Update storage locations in the ABS when reported to Job Control by units by the end of the shift in which the report was received

2.3.3. Transportation will inform Job Control when engine, blade and propellers are received and shipped on the date those actions take place

2.4. Quality Assurance/Process Improvement will:

2.4.1. Notify the EM when unsatisfactory conditions for propulsion units are found

2.4.2. Provide the EM a copy of all initial, interim and final Foreign Object Damage reports concerning propulsion units and components.

2.5. 577 CMRS will:

2.5.1. Accomplish the group’s ET&D and EHM program. Make recommendations to the CC and EM per AFI 21-101. Maintain a trained primary and alternate ET&D manager.

2.5.2. Use approved AFTO forms, OO-ALC test cell engine run sheets or local forms to document test cell engine runs.

2.6. Tasked production unit will:

AMARGI 21-109 03 JULY 2013 11

2.6.1. Perform engine asset preventative maintenance actions as directed by Workloading Office.

2.6.2. Immediately process AFMC Form 173 upon discovery of discrepancies using 309 AMARG local procedures. Discrepancies that affect engine preservation and serviceability based on preservation will be corrected as soon as possible but within 30 days. Assets in Type 1000 and 1500 storage category will be prioritized ahead of type 2000 and 4000 storage assets.

3. POLICY.

3.1. Engines, propellers and blades that arrive with an aircraft are obligated to that aircraft/engine unless specified otherwise in the SOW or this instruction. This obligation applies whether assets are installed or uninstalled, serviceable or unserviceable.

3.1.1. When obligated in ABS, engines and helicopter rotor blades are a child to the parent aircraft, while propellers are a child to the parent engine. Obligated engines, propellers and blades also assume the same storage status as the parent asset, unless specified otherwise in the SOW, and will normally change status with the parent asset.

3.1.2. In general, during induction, helicopter blades are removed for storage and propellers remain installed. Normally uninstalled propellers will be de-obligated from the engine at the time of removal. Exceptions will be managed per special instruction from the customer/asset owner.

3.1.3. Engines will not be obligated to or installed in aircraft other than for which they were originally authorized without prior written direction from SPO, EIM and with engineering approval. Prior coordination with CEMS PMO is required to assess possible impacts to status and inventory reporting.

3.1.4. Uninstalled engines will not be submitted with aircraft to DLA for disposal.

Uninstalled engines will be submitted separately for disposal in order to maintain a clear audit trail and proof of destruction. Engines removed during aircraft disposal preparation will be transported to the Can Yard for processing.

3.2. Job plans will be structured in a manner that records the workload being accomplished against the engine asset number, not the aircraft asset number. Requirements for more than one engine will not be combined into a single PWO.

3.3. The EM must approve and process all engine departures, decommissions and de-obligations. Changes will not be made in the ABS without prior EM approval. Generally, engines will not be lost from the customer’s inventory account when components of the engine have been reclaimed and shipped, until disposition for the engine core has been provided.

12 AMARGI 21-109 03 JULY 2013

3.4. For AF assets, aircraft will not be flown or delivered until the engine and engine components are correctly updated in CEMS. Units are responsible to confirm with EM that all transactions have been processed prior to releasing aircraft for flight.

3.5. The owning service will submit an AMARG Priority Removal request for reclamation of an engine or engine component. For component removals, the C03 inventory will be updated against the engine, not the aircraft. Currently, the Priority Removal system does not provide a list of donor engines from which to reclaim parts as it does for aircraft; however, per AFMCI 23-111, Chapter 8, this information is provided by the agency approving the priority removal.

3.6. The responsible production unit and Workloading will coordinate with EM regarding Type 1000 assets that AMARG does not have the capability to repair or when repair is not economically feasible. Engines in Type 1000 storage will not be stored with deferred discrepancies (open, not repaired) without prior EM coordination.

3.7. Engines with an expired engine preservation as defined in TO 00-20-1 Chapter 4 and the customer’s SOW will not be operated without engineering approval.

3.8. Engine records remain with the aircraft jacket file until the engine is de-obligated. The EM will review and remove the engine records from the aircraft jacket file at the time of de-obligation and file them in the uninstalled engine records area.

3.8.1. Engine records will not be physically stored with uninstalled engines in cans, ETUs, trailers or any other storage device.

3.8.2. After 309 AMARG induction requirements are completed, EM or designated representative will dispose of the losing unit’s optional base-specific AFTO Forms 95 that are not required per TO 00-20-1 section 9.5.

3.8.3. EM will generate an AFTO Form 95 to document missing records per TO 00-20- 1 section 9.6.

3.8.4. Upon induction of installed and uninstalled AF engines, the hard copy AFTO Form 95s for engine and components will be annotated to indicate the initial records review was completed and history is now being maintained in CEMS. After this point, there is no requirement to print and place updated copies of AFTO Form 95 in engine records. Entries on the paper AFTO Form 95 will no longer be made. Printed CEMS records for engines and components will be provided with any associated AFTO Form 95s when asset is removed from storage for reclamation, regeneration or withdrawal.

3.9. Uninstalled engine storage locations in ABS will be the same format as a supply location, “nnAnnnAnnnA”. Positions 1, 2 and 3 (nnA) are the area followed by an alpha that identifies the area. Positions 4, 5, 6 and 7 (nnnA) are the row followed by an alpha to describe the engine position when engines are stacked (A is bottom A, B is one up, and so on). Positions 8, 9, 10 and 11 (nnnA) are the spot followed by an alpha to describe engine

AMARGI 21-109 03 JULY 2013 13

position when engines back to back (depth; A is the front, B is one back, and so on). This format applies to long-term storage locations in Lots 1, 2, 3 and 4. It does not apply to temporary storage locations described in Section 5 of this instruction. Format changes will be coordinated with 309 AMARG/OB.

4. PROCEDURES.

4.1. Engine Inductions

4.1.1. Arrival - Installed engines

4.1.1.1. 578 SDS will:

4.1.1.1.1. Provide the EM with flight hours / operating time for all inductions and verify records were received.

4.1.1.1.2. Notify the EM if records were not received with the asset or for any other unusual or abnormal circumstances.

4.1.2. Arrival - Uninstalled engines

4.1.2.1. The EM will:

4.1.2.1.1. Coordinate required actions based on customer SOW with applicable 309 AMARG POCs.

4.1.2.2. 309 SPTS Supply and Special Assets Sections will:

4.1.2.2.1. Perform incoming inspection for obvious damage to engine and transportation devices and comply with TO 00-85-20-WA-1; provide EM with copies of the Certified Bill of Lading, DD Form 1348-1A, and the Engine Records. Notify Job Control of asset arrival.

4.1.2.2.2. If damage is discovered, notify Job Control and follow 309 AMARG and 355 FW local procedures.

4.1.2.2.3. Contact 578 SDS Scheduling when assets are off-loaded and ready for movement.

4.1.2.3. 577 CMRS will:

4.1.2.3.1. Support 578 SDS as required for paragraph 4.1.2.4.1. requirements.

4.1.2.4. 578 SDS will:

14 AMARGI 21-109 03 JULY 2013

4.1.2.4.1. Generate work orders to inspect engines and verify serviceability of Can, ETU and/or trailers and adaptors; Notify the EM if the asset and/or container/device are unserviceable

4.1.2.4.2. Comply with para 2.2 of this instruction.

4.1.2.4.3. Ensure wrapped uninstalled engines and engines in shipping/storage devices are properly identified with engine TMSM and serial number IAW T.O. 2J-1-18. If the engine has an afterburner in the transportation device, also annotate this on the container.

4.1.2.4.4. Provide all records received with the asset to the EM.

4.2. Engine Regeneration and Withdrawal

4.2.1. OBW will:

4.2.1.1. Provide EM with asset S/Ns scheduled for work.

4.2.1.2. Notify EM when aircraft is planned for overland withdrawal where the engines will be removed, regardless if engines will be shipped with or without the aircraft.

4.2.1.3. For US Navy assets, OBW Workloader coordinates with EM and completes DECKPLATE Engine Transaction Report (ETR) pursuant to the SOW.

4.2.2. The EM will:

4.2.2.1. Coordinate transfer of engines with gaining organization.

4.2.2.2. De-obligate engine from aircraft when required; review engine records and verify accuracy and completeness prior to shipment.

4.2.3. The unit assigned the workload management responsibility and/or producing the workload will:

4.2.3.1. Comply with para 2.2 of this instruction.

4.2.3.2. Comply with TO 00-20-1 section 5.5 for installed engines if aircraft 781 forms are still active.

4.2.3.3. For shipper assets, provide the EM shipping information to include funds cite(s) and SRAN(s) as early as possible, but no later than 5 duty days prior to shipping date.

4.2.3. The Propulsion shop will:

AMARGI 21-109 03 JULY 2013 15

4.2.3.1. Comply with paragraph 2.2 of this instruction.

4.2.3.2. Responsible for and maintain records for assets with a storage location of Engine Shop or KSPAN07.

4.2.3.3. Provide the records to the EM when all maintenance actions are complete and asset is being moved to a new storage location.

4.3. Engine Priority Removal

4.3.1. The EM will:

4.3.1.1. Approve Forms 44; review engine records to verify accuracy and completeness prior to shipment.

4.3.1.2. De-obligate engine from aircraft, when required.

4.3.2. Tasked production unit:

4.3.2.1. Comply with paragraph 2.2 of this instruction.

4.3.3. 577 CMRS will:

4.3.3.1. Coordinate Forms 44 with EM for approval.

4.4. Engine Shipments

4.4.1. The EM will:

4.4.1.1. De-obligate engine from aircraft when required.

4.4.1.2. For shippers, prepare a DD Form 1348-1A, Issue/Turn-in Document; and provide to 309 SPTS transportation specialist. Form must contain the engine, shipping adapter and trailer S/Ns and fund cite.

4.4.1.3. Review engine records to verify accuracy and completeness prior to shipment.

4.4.1.4. Maintain master log for 309 AMARG document numbers per TO 00-25- 254-1; provide document numbers to unit POCs.

4.4.1.4. When TAC code F8KA is used, verify Tinker AFB POC has approved.

4.4.2. Applicable squadron Production Support Flight will:

16 AMARGI 21-109 03 JULY 2013

4.4.2.1. Obtain engine records from EM and secure records with asset prior to turning over to 309 SPTS Transportation.

4.4.3. Tasked Production workcenters responsible for preparing assets for shipment will comply with TO 00-85-20-WA-1, TO 2J-1-18 and TO 2-1-18; Prepare and provide AFTO Form 20, when required, to 309 SPTS.

4.4.4. 309 SPTS Transportation Office will:

4.4.4.1. Provide the EM documentation required by 309 AMARG local procedures for all shipments.

4.4.4.2. Notify Job Control on the date the driver signs for the assets.

4.5. Helicopter Blades

4.5.1. Inductions

4.5.1.1. The OBW will:

4.5.1.1.1. Assign asset identification numbers to each blade and obligate each blade to parent helicopter; resolve discrepancies reported by 578 SDS with

OBW.

4.5.1.1.2. Coordinate, establish and manage preventative maintenance requirements.

4.5.1.2. 578 SDS Receiving will:

4.5.1.2.1. Comply with paragraph 2.2 in this publication.

4.5.1.2.2. Uninstalled Blades: Open and physically inspect containers; validate blade quantities and serial numbers; clearly tag the outside of the container with the blade serial number, aircraft asset number and aircraft serial number.

Fill out the tags pursuant to AMARGI 23-202, Tagging and Labeling Materiel.

4.5.1.2.3. Installed blades: physically verify main blade and tail rotor blade serial numbers; review the aircraft records to validate the serial number information and AMARG Form 43, Aircraft Examination and Evaluation Data, against the actual serial number on the blade.

4.5.1.2.4. For installed and uninstalled blades: notify OBW of any discrepancies; annotate and provide AMARG Form 43 to 309 SPTS Scheduling.

AMARGI 21-109 03 JULY 2013 17

4.5.1.2.5. Prepare AMARG Form 22, Components/Items Missing and/or Removed from Aircraft, for removed blades and provide to 309 SPTS Scheduler.

4.5.1.2.6. Radioactive Material (RAD) Removal: inspect to identify and remove RAD pursuant to 309 AMARG local procedures and tag each RAD component; generate AMARG Form 2, Radioactive Material Transfer Record, and AMARG Form 22 for each removed RAD component; install protective Lucite caps at the earliest possible opportunity.

4.5.1.2.7. Turn all RAD components to 309 SPTS Special Assets for storage.

4.5.1.3. 309 SPTS Scheduling Section and Special Assets will:

4.5.1.3.1. Support 578 SDS; store RAD components; accomplish ABS C03 inventory updates; input stock number and quantity entries into the owning aircraft's C03 inventory (INV-6/SR-01).

4.5.1.3.2. Update blade status changes in both ABS Asset Record and C03 listing.

4.5.1.3.3. Coordinate with OBW to validate ABS records.

4.5.1.4. 578 SDS Production Support Flight will:

4.5.1.4.1. Schedule blade transport to required locations; cut work orders to build blade containers; provide asset record to OBW for review.

4.5.1.4.2. Place and verify all the required information is placed on the outside of the containers by clearly stenciling and tagging with metal tags pursuant to AMARGI 23-202. Extra tags may be required to record the blade serial numbers. Contact 309 SPTS Scheduler prior to moving blade containers to storage.

4.5.1.5. 309 SPTS Woodmill will:

4.5.1.5.1. Construct, seal and stencil blade containers; ensure all the required information is placed on the outside of the containers by clearly stenciling and tagging with metal tags pursuant to AMARGI 23-202.

4.5.2. Withdrawal

4.5.2.1. The OBW will:

18 AMARGI 21-109 03 JULY 2013

4.5.2.1.1. For Priority Removal actions, resolve S/N discrepancies reported by production.

4.5.2.2. OBW Planner will:

4.5.2.2.1. For Priority Removal actions, process the removal request for all storage assets and develop the required job plan. Job Plan will include inspection to identify if any container repairs are necessary prior to shipment.

Job plan will include instructions to retrieve asset records and include with shipment.

4.5.2.3. 577 CMRS will:

4.5.2.3.1. For Priority Removal actions, notify OBW Planner when request is received.

4.5.2.3.2. Comply with paragraph 2.2 of this instruction; retrieve blade records to ship with any blades going out unless otherwise indicated.

4.5.2.3.3. Assist 309 SPTS Scheduler and EM in resolving serial number discrepancies.

4.5.2.4. OBW Records Section will:

4.5.2.4.1. Perform records review to verify currency and completeness prior to release to production

4.5.2.4.2. For US Army assets, prepare a Department of Army Form 2410, Component Removal And Repair/Overhaul Repair, when blades are shipped separate from the aircraft or when blades are assigned to a different aircraft.

Annotate the aircraft records for blade removals and reassignments to another aircraft.

4.6. Aircraft Propellers.

4.6.1. Inductions

4.6.1.1. The EM will:

4.6.1.1.1. Assign asset identification numbers to each propeller and obligate to parent engine.

4.6.1.1.2. Resolve discrepancies reported by 578 SDS with OBW.

4.6.1.1.3. Coordinate, establish and manage preventative maintenance requirements.

AMARGI 21-109 03 JULY 2013 19

4.6.1.2. 578 SDS will:

4.6.1.2.1. Comply with paragraph 2.2 of this publication.

4.6.1.2.2. Receiving Section will validate the AMARG Form 43 information against the actual serial number on the propeller; file AMARG Form 43 in the aircraft record.

4.6.1.2.3. When propeller is going into the storage account, notify 309 SPTS Scheduler of propeller movement to storage area.

4.6.2. Withdrawal

4.6.2.1. The EM will:

4.6.2.1.1. For Priority Removal requests accomplish CEMS updates; resolve S/N discrepancies reported by production

4.6.2.2. OBW Planner will:

4.6.2.2.1. For assets in storage, develop the required job plan. Job Plan will include inspection to identify if any container repairs are necessary prior to shipment. Job plan will include instructions to retrieve asset records and include with shipment.

4.6.2.3. 578 SDS will:

4.6.2.3.1. Comply with paragraph 2.2 of this publication.

4.6.2.3.2. Storage Services will Spray-lat propeller hub on fixture for storage/shipment; clearly tag propeller with National Stock Number (NSN);

notify 578 SDS Scheduler to arrange transportation of propeller from wood mill to shipping.

4.6.2.4. The 577 CMRS will:

4.6.2.4.1. Comply with paragraph 2.2 of this instruction; retrieve records to ship with asset, unless directed otherwise.

4.6.2.4.2. Complete work order(s) to remove propeller and install propeller into storage/shipping fixture; wrap propeller hub with barrier paper; notify 578 SDS Scheduler to arrange transportation of propeller from aircraft to wood mill.

4.6.2.5. 309 SPTS Woodmill will:

20 AMARGI 21-109 03 JULY 2013

4.6.2.5.1. Notify 578 SDS Scheduler to arrange transportation of fixture from Woodmill to aircraft.

4.6.2.6. OBW, Records will:

4.6.2.6.1. Perform records review to verify currency and completeness prior to release to production.

5. ASSET STORAGE ACCOUNTABILITY AND PHYSICAL LOCATION CONTROL.

5.1. The EM maintains overall responsibility for accountability, control and accurate engine location information. Each work center listed below is responsible for the engines in their location, which are authorized for temporary storage:

5.1.1. 578 SDS Can Yard (in ABS use “canyard”)

5.1.2. 577 CMRS Propulsion (in ABS use “EngineShop”)

5.1.3. KSPAN/KSPAN07, controlled by Engine Shop (in ABS use “EngineShop”)

5.1.4. 309 SPTS Receiving (in ABS use “Receiving”)

5.1.5. 577 CMRS Reclamation (in ABS use “Reclamation”)

5.1.6. 309 SPTS Woodmill (in ABS use “Woodmill”)

5.1.7. 576 AMRS Flight Line and Shelter (in ABS use “FL(x)” where x is spot number)

5.2. 578 SDS Can Yard is also authorized for long-term storage. Can Yard has the authority to temporarily establish additional temporary storage locations and will notify the EM when new locations are opened and closed.

5.3. Uninstalled engines will not be left uncontrolled outside of these areas without prior EM approval.

6. DISPOSAL.

6.1. OBW will:

6.1.1. For US Navy, complete required DECKPLATE ETRs pursuant to the SOW.

6.1.2. Issue RFQ as required; notify EM when funding is approved.

6.2. The EM will:

6.2.1. Coordinate with OBW when disposal disposition is received.

AMARGI 21-109 03 JULY 2013 21

6.2.2. Change ABS status codes as engines move through the disposal process.

6.2.3. Provide disposal documents to the OBW ADO.

6.2.4. Process loss in CEMS/DECKPLATE when valid destruction certificate is received; for Air Force assets, update CEMS automated history.

6.3. The 578 SDS Production Support Flight will:

6.3.1. Notify the EM when engine-related work starts and is completed

6.4. The ADO will:

6.4.1. Coordinate with Defense Logistics Agent DLA Disposition Services (Tucson) to process items for disposal and update ABS status code when DLA accepts assets.

7. ENGINE TRAILERS AND TRANSPORTATION DEVICES.

7.1. Aerospace Ground Equipment (AGE) ensures all 309 AMARG assigned engine trailers are maintained. All other trailers temporarily located at, but not assigned to 309 AMARG will be managed in ABS, in addition to each customer’s system of record as required by service specific policy and workload agreements.

ROBERT S. LEPPER, Colonel, USAF Commander

22 AMARGI 21-109 03 JULY 2013

Attachment 1

GLOSSARY OF REFERENCES & SUPPORTING INFORMATION

References

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

AFI 20-115, Propulsion Management for Aerial Vehicles, 12 Jan 2012

AFGM 20-06.1, Propulsion Life Cycle Management for Aerial Vehicles, 26 Oct 2012

AFI 21-101, Aircraft and Equipment Maintenance Management, 24 Sept 2012

TO 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policies and Procedures, 15 Jun 2011

TO 00-25-254-1, Technical Manual, Comprehensive Engine Management System Engine Configuration, Status and TCTO Reporting, 1 Feb 2012

TO 00-25-254-2, Comprehensive Engine Management System Manual for Data System Designator (DSD) D042

TO 00-25-257 Series, Engine Health Management Plus (EHM+) User’s Manual Instructions

NAVAIRINST 13700.15E, Naval Air Systems Command Instruction, Aircraft Engine Management System (DECKPLATE), 10 November 2008

AMARGI 23-202, Tagging and Labeling Materiel, 10 January 2005

TO 1-1-686, Technical Manual, Desert Storage Preservation and Process Manual for Aircraft, Aircraft Engines, and Aircraft Auxiliary Power Unit Engines, 31 January 2012

TO 2J-1-18, Preparation for Shipment and Storage of Gas Turbine Engines, 1 Sept 2010

TO 2-1-18, Aircraft Engine Operating Limits and Factors, 1 Jun 2009

AFMAN 23-110, USAF Supply Manual, 1 April 2012

AFMCI 23-111, Reclamation of Air Force Property, 9 Feb 2012

AFMAN 33-363_AFGM 1.2, Management of Records, 23 October 2012

AFI 63-101, AFMC Supplement 1, Acquisition and Sustainment Life Cycle Management, 17 Jan

AMARGI 21-109 03 JULY 2013 23

Prescribed Forms

None

Adopted Forms

AMARG Form 2, Radioactive Material Transfer Record

AMARG Form 22, Components Items Missing and or Removed from Aircraft

AMARG Form 43, Aircraft Examination and Evaluation Data

AFTO Form 95, Significant Historical Data

DA Form 2410, Component Removal And Repair/Overhaul Repair

DD Form 1149, Requisition and Invoice/Shipping Document

DD Form 1348-1A, Issue/Turn-in Document

Acronyms

ABS – AMARG Business System

ADO – Aircraft Disposition Office

AGE – Aerospace Ground Equipment

AF – Air Force

AFMC- Air Force Material Command

AFPD – Air Force Policy Directive

AMARG – Aerospace Maintenance and Regeneration Group

CEMS – Comprehensive Engine Management System (Air Force)

CETADS – Comprehensive Engine Trending and Diagnostics System

DECKPLATE – US Navy engine management business system

DLA – DS - Defense Logistics Agency - Disposition Services (Tucson) – Disposal Office located in Tucson

EIM – Engine Inventory Manager

24 AMARGI 21-109 03 JULY 2013

EM – Engine Manager

EMDL – Engine Manager Data List

ETR – Engine Transaction Report

MDS – Mission Design Series

NAVAIRINST- NAVAIR Instruction

NSN- National Stock Number

OBW – 309 AMARG Business Operations Workload Section

PH - Prep for Disposal In Work [Scheduling]

PZ - DRMS Aircraft – Still on AMARG Property [ADO]

POC – Point of Contact

PM - Program Management

PWO – Production Work Order

RAD – Radioactive

RDS – Records Disposition Schedule

RFQ – Request for Quote

SOW – Statement of Work

SRAN – Stock Record Account Number

TCTO – Time Change Technical Order

TMSM – Type Model Series and Modification

TO – Technical Order