afi21-101_afmcsup_oo-alcsup.pdf

BY ORDER OF THE COMMANDER

OGDEN AIR LOGISTICS COMPLEX

AIR FORCE INSTRUCTION 21-101

AIR FORCE MATERIEL COMMAND

Supplement

4 FEBRUARY 2014

Incorporating Change 2, 13 FEBRUARY 2015

Maintenance

AIRCRAFT AND EQUIPMENT

MAINTENANCE MANAGEMENT

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for downloading or ordering on the e-

Publishing website at www.e-Publishing.af.mil

RELEASABILITY: There are no releasability restrictions on this publication

OPR: OO-ALC/QPQ

Supersedes: AFI21-101_AFMCSUP_OO-

ALCGM2, 20 June 2013

Certified by: OO-ALC/QP

(Mr. Buddy Paden)

Pages: 132

This Air Force Instruction (AFI) 21-101, Air Force Materiel Command Supplement

(AFMCSUP), Ogden Air Logistics Complex (OO-ALC) Supplement implements aircraft and equipment maintenance local management procedures to augment Air Force Materiel Command

(AFMC) policy relating to aircraft and equipment maintenance procedures. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with (IAW) Air Force Manual (AFMAN) 33-363, Management of Records, and disposed of IAW the Air Force (AF) Records Disposition Schedule (RDS). Refer recommended changes and questions about this publication 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 the appropriate functional chain of command.

SUMMARY OF CHANGES

This interim change corrects the validation/verification (val/ver) process.

http://www.e-publishing.af.mil/

2 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

1.8. (Added)

Table 10.1. (Added) PSC numbering methodology and configuration

Table 10.2. (Added) PSC numbering methodology and configuration

Table 19.1. (Added) Instructions for Completing PDMSS Generated Work Request

Worksheet

Figure 19.2. (OO-ALC Added) Example of WCD NDI Requirements ..................................... Error! Bookmark not defined.

Table 19.3. (Added) Process Flow Map for NDI Techniques/Procedures

Figure 19.4. (Added) Process Flow Map for NDI Techniques/Procedures

Figure 19.5. (Added) Rework Documentation

Figure 19.6. (Added) Other Than Re-Work Documentation

Figure 19.7. (Added) Clearing Red Circle Operation

Figure 19.8. (Added) Clearing Red Circle Operation with New Operation

Table 19.9. (Added) Instructions for Completing AFMC Form 137, Figure 19.10. (Added) Condemnation Documentation

Figure 19.11. (Added) ITS/IMPRESA/MAXIMO Supervisor and Scheduler WCD Entries

Figure 19.12. (Added) Planner Changes to Hardcopy WCD

Table 19.13. (Added) 309 AMXG Stamp Issue Prerequisite Training

Table 19.14. (Added) 309 EMXG Stamp Issue Prerequisite Training

Table 19.15. (Added) 309 CMXG Stamp Issue Prerequisite Training

Table 19.16. (Added) 309 MMXG Stamp Issue Prerequisite Training

Table 19.17. (Added) OO-ALC Stamp Number Block Assignments

Table 19.18. (Added) OO-ALC Stamp Examples

22. Depot Engineering Roles and Responsibilities

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 118

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 3

1.8. (Added) All waiver packages pertaining to OO-ALC policies shall be fully coordinated through the OO-ALC Quality Assurance Office (OO-ALC/QP), prior to receiving OO-ALC

Commander (CC) approval.

2.7.1.1. (Added) Housekeeping and contamination procedures are critical to protecting the health of workers and maintaining areas free from surface contamination. OO-ALC Break Room Checklist; OO-ALC Change and Shower

Room Checklist; and OO-ALC Regulated and Transition Area Checklist are approved workplace housekeeping checklists and are available at the following SharePoint Site

. These checklists are mandatory and will be used daily, or everyday these areas are in operation/used.

3.2.2. (Added) Establish a Quality Management System (QMS) that meets the requirements of the AS9100/9110, Quality Management Systems. Ensure management support of QMS at all functions and relevent levels.

8.3.30.1. (Added) Maintenance Group (MXG) quality assurance specialist (QAS) are aligned with the individual squadrons and maintenance functions within the group, and rotated as deemed appropriate by the group quality assurance (QA) chief.

8.4.7. (Added) Review major and minor discrepancies for trends quarterly. If frequency or severities of identified discrepancies warrant inclusion of that item into a specific technical order (TO) governing an action or inspection, the applicable QP chief or QA lead QAS will identify the deficiency to the appropriate supervisor, who must submit an

Air Force Technical Order (AFTO) Form 22, Technical Manual Change

Recommendation and Reply, or AFMC Form 202, Nonconforming Technical Assistance

Request and Reply.

8.9. (Added) The OO-ALC Activity Inspection Program procedures are outlined in the OO-

ALC Quality Plan located at

8.9.4. (Added) In addition to OO-ALC, MXG/CC/Civilian Leader (CL) directed follow-up inspection, OO-ALC/QP can also recommend specific follow-up inspections when warranted.

8.10. (Added) Maintenance Standardization and Evaluation Program. As the OO-ALC point of contact (POC), QP will implement, manage and execute the maintenance complex

QA programs.

8.23.15.1. (Added) The type (i.e., task, specific item, procedure or process) and minimum number of personnel evaluation, quality verification inspection, and routine inspection list to be conducted monthly will be included in each MXG Quality

Assurance Plan (QAP) and Quality Assurance Surveillance Plan (QASP.)

8.23.16.1. (Added) Each MXG QP will develop a group specific QAP that will identify detailed quality processes and procedures relative to the group. QAPs will provide documentation of a group’s specific day-to-day operational QA processes and procedures, not otherwise defined in the OO-ALC Quality Plan.

8.29. (Added) AFMC Form 77, Request for Quality Assistance (RQA) for processing procedures and forms accessibility information will be provided in group QAPs.

4 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

9.2.1. (Added) OO-ALC Quality Assurance (OO-ALC/QPQ)will be the Office of

Primary Responsibility (OPR) for the Impoundment Program.

9.3.7. (Added) F-22 terms – Integrated Maintenance Information System (IMIS).

9.3.8. (Added) F-22 terms – Portable Maintenance Aid (PMA).

9.3.9. (Added) Integrated Missile Database (IMDB). System used to track inventory of missile motors. Specifically, within IMDB, Missile Motor Tracking and Reporting

System (MMTRS) will be referenced and documented based on guidance within this instruction.

9.4. (Added) Include major end item (MEIs) in addition to aircraft and equipment in this chapter.

9.4.4.1. (Added) An uncommand activation of onboard systems, emergency power unit, fire suppression, egress, stores cartridges etc.

9.4.4.2. (Added) Total loss of hydraulic system pressure in flight.

9.4.4.3. (Added) Lightning strike in flight.

9.4.4.4. (Added) Contaminated Fluids (i.e., in aircraft, engine, equipment, test systems, plating tanks, etc.). Fluids are considered contaminated when they possess foreign particles, material, or are contaminated from an outside source (i.e., metal, dirt, water, etc.). NOTE: Hydraulic fluid is not considered contaminated when it is crossed from another system on an aircraft.

9.4.6.7.1. (Added AMARG) When single engine aircraft declares an in-flight emergency for engine problems. All maintenance activity will cease except to make the aircraft or equipment safe for maintenance. NOTE: Aircraft, equipment or MEIs meeting impoundment criteria listed in paragraphs 9.4.11.1 thru 9.4.11.4 will be placed into a maintenance freeze status. All maintenance activity will cease except to safe the aircraft or equipment for maintenance. No other actions will be taken until an impoundment authority determines if the aircraft or equipment requires impoundment.

9.4.11.1.2. (Added) Nose landing gear/main landing gear tire blowout during taxi or take-off. NOTE: Any condition that exceeds TO or Naval Air Systems

Command (NAVAIR) limitations are considered foreign object damage (FOD).

Nicks, dents, gouges, etc., that do not exceed TO or NAVAIR limits do not meet the requirements for impound.

9.4.11.4. (Added) All OO-ALC and 514th Flight Test Squadron (514 FLTS) employees are empowered and obligated to recommend to the impoundment authority the impoundment of an aircraft, components, or support equipment when they are aware of an impounding condition.

9.4.11.5. (Added) If the reason for impoundment is determined to be reportable

IAW AFI 91-204, Safety Investigations and Reports, (this includes support equipment damage exceeding $2,000), the appropriate safety office will appoint the investigation official.

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 5

9.6.1. (Added) Add AFTO Form 95, Significant Historical Data, work control document (WCD). NOTE: For aircraft, engines, and MEIs in production phase and equipment without an AFTO Form 244 document reason for impoundment on WCD following procedures in paragraph 19.2.29 of this instruction.

9.6.1.1. (Added) For aircraft in flight test phase:

9.6.1.1.1. (Added) Initiate AFTO Form 781A, Maintenance Discrepancy and

Work Document and complete as follows:

9.6.1.1.2. (Added) Item 1: “AIRCRAFT IMPOUNDED FOR

INVESTIGATION OF:” (state problem), “SEE PAGE___ ITEM___ FOR

ORIGINAL DISCREPANCY.” Enter “IMPOUNDMENT OFFICIAL: ______,” and a RED X in the symbol block. Use of preprinted AFTO Form 781A is authorized. NOTE: Preprinted AFTO Forms 781A are not authorized for F-22 aircraft.

9.6.1.1.3. (Added) For the F-22, add an aircraft impoundment warning in IMIS forms section in the PMA on all three work center event entries under the primary job control number or WCD IAW paragraph 9.6.1.1.2

9.6.1.1.4. (Added) Enter in AFTO Form 781A Item 2: “ALL MAINTENANCE

DEFERRED UNTIL AIRCRAFT RELEASED FOR MAINTENANCE BY

IMPOUNDMENT OFFICIAL.” Enter a RED X in the symbol block. NOTE:

For F-22, annotation will be made in the IMIS forms section of the PMA.

9.6.1.1.5. (Added) Enter in AFTO Form 781A Item 3: “FORMS AND

CORRECTIVE ACTION TO BE REVIEWED BY IMPOUNDMENT

OFFICIAL PRIOR TO RELEASE FROM IMPOUNDMENT.” Enter a RED

DASH in the symbol block. NOTE: For F-22, annotation will be made in the

IMIS forms section of the PMA.

9.6.1.1.6. (Added) Draw a RED BORDER on all four sides of the impoundment

AFTO 781A. NOTE: Non-Applicable to the F-22. No Red Border is available in IMIS forms section.

9.6.1.1.7. (Added) For lost items, follow the procedures in the lost tool search package (on aircraft or off aircraft) for aircraft in production. If the aircraft is in flight test, ensure a Red X is placed on the AFTO Form 781A, a lost tool package is initiated, and the procedures of this supplement are followed. Contact tool control manager in the customer support section at (801) 586-4272, or after normal duty hours and on weekends get the lost tool/foreign object package from

OO-ALC Alert Center, (801) 777-3238, Building 849. NOTE: For F-22, annotation will be made in the IMIS forms section of the PMA.

9.6.1.2. (Added) For Missiles:

9.6.1.2.1. (Added) 309th Missile Maintenance Group (309 MMXG)

Consolidated Munitions Control Center (CMCC) personnel, in coordination with

QA, the engineering authority, and/or the applicable production supervisor will complete an (impoundment) AFTO Form 95. The AFTO Form 95 will be inserted into a protective document that allows visibility on both front and back

6 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

sides and attached to the equipment in question. The AFTO Form 95 will be completed as follows:

9.6.1.2.1.1. (Added) The AFTO Form 95: May be completely red or have a red border around entire form (use a bold/wide red marker to make the border).

9.6.1.2.1.2. (Added) Block 1: Mission design series, type model and series and asset classification. (Minuteman: LGM30G).

9.6.1.2.1.3. (Added) Block 3: Enter the equipment serial number.

9.6.1.2.1.4. (Added) Block 4: Enter date.

9.6.1.2.1.5. (Added) Block A: Insert a RED X.

9.6.1.2.1.6. (Added) Block B: Enter ‘IMPOUNDED’ using BOLD/WIDE letters. Then add a clear and concise statement indicating the reason for impoundment, the name of the impoundment authority with phone number, and name of the assigned impoundment official and phone number.

9.6.1.2.1.6.1. (Added) Document any special procedures, limitations, and/or restrictions associated with handling, transportation, or storage.

9.6.1.2.1.6.2. (Added) Part number for any part removed.

9.6.1.2.1.6.3. (Added) Serial number for any part removed.

9.6.1.2.1.7. (Added) Block C: Work center where asset is located. NOTE:

(Added) Should a missile motor or booster be impounded; the description on the reverse side of the AFTO Form 95 will be the exact verbiage as entered into the IMDB (tab: MMTRS) under the ‘Remarks’ section. This exact verbiage will also be used in paragraph 9.6.1.2.1.8 email traffic.

9.6.1.2.1.8. (Added) The CMCC will provide an email to OO-ALC POCs for entry into IMDB, as applicable. Descriptive comments shall be placed in the ‘Remarks’ section pertaining to the missile motor or booster in question.

9.6.1.3. (Added) For Engines/ Equipment: NOTE: (Added) If F-16/A-10/F-22/C-

130 or T-38 engines are called to perform inspections on installed engines on impounded aircraft, the technicians will perform tasks IAW the applicable TO, and sign off all applicable AFTO Forms 781A discrepancies under the aircraft impoundment. If the engine is removed, engine shop procedures outlined in Section

9.6.1.3 of this chapter will be followed. NOTE: For F-22, this will be accomplished in the IMIS forms section of the PMA.

9.6.1.3.1. (Added) When impounding, enter on AFTO Form 244, Industrial

Support/Equipment Record, the reason for impoundment, outlined in red, and enter a Red X in the symbol block.

9.6.1.3.2. (Added) Releasing authority will review forms and corrective action and clear the Red X on AFTO Form 244.

9.6.2.1. (Added) The OO-ALC Alert Center, (801) 777-3238 will be notified when an impoundment decision has been made within the OO-ALC.

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 7

9.6.2.2. (Added) 309 AMARG job control will initiate checklist/event notification to levels of 309 AMARG supervision by email.

9.6.2.3. (Added) Contact the 309 MMXG CMCC, (801) 777-6618 or (801) 586-

3781 for impoundment within the 309 MMXG. CMCC will notify OO-ALC Alert

Center, (801) 777-3238, and 309 MMXG QA.

9.6.2.4. (Added) Contact the 309th Aircraft Maintenance Group (309 AMXG)

Maintenance Operations Center (AMXG/MOC) for impoundment within the 309

AMXG. 309 AMXG/MOC will notify the OO-ALC Alert Center. NOTE: If the

AMXG/MOC is closed, notify the OO-ALC Alert Center.

9.6.3. (Added) Impoundment official will:

9.6.3.1. (Added) Review and complete all sections of applicable and developed checklist.

9.6.3.2. (Added) Attend the aircrew debriefing (if possible), or be debriefed by aircrew (if required).

9.6.3.3. (Added) Review the aircraft binder (AFTO Forms 781A) and record jacket to determine if the aircraft has a history of the discrepancy and if maintenance was performed on that system, or in that area. NOTE: For F-22, this will be accomplished in the IMIS forms section of the PMA.

9.6.5.4.1. (Added) Make an entry in the AFTO Form 781A to ensure all recoverable stored data is collected prior to application of electrical power, if applicable. NOTE: For F-22, this will be accomplished in the IMIS forms section of the PMA.

9.6.6.1.1. (Added) All parts removed pertaining to the impoundment will be assessed for the necessity of product quality deficiency report or engineering inspections procedures outlined in T.O. 00-35D-54-WA-1. This will be coordinated through OO-ALC/QA office.

9.6.7.1. (Added) Prior to impound official releasing an aircraft or equipment for maintenance, the impound official will conduct a preliminary assessment to ensure no non-impound related maintenance will be performed that will hinder the investigation or correction of an impounded aircraft or equipment.

9.6.7.2. (Added) The impound official may release the aircraft for maintenance once an action plan has been formed to determine the cause and correction of impound, and once a preliminary assessment has been accomplished to assess feasibility of non-impound maintenance. Enter “AIRCRAFT RELEASED FOR MAINTENANCE

IAW AFI 21-101, Aircraft and Equipment Maintenance Management, Chapter 9 in the corrective action block of the AFTO Form 781A entry made in paragraph

9.6.1.1.4 of this instruction. Signature of the impoundment official is required in the

‘Inspected By’ block only. NOTE: For F-22, this will be accomplished in the IMIS forms section of the PMA.

9.6.7.3. (Added) Ensure all work done on aircraft is properly documented in the active AFTO Forms 781A, and the appropriate depot work control document.

NOTE: For F-22, this will be accomplished in the IMIS forms section of the PMA.

8 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

9.6.7.4. (Added) Review the applicable maintenance forms with impoundment team members and technicians to ensure impoundment problem has been solved.

9.6.7.5. (Added) After reviewing the AFTO Forms 781A, sign off the corrective action “FORMS AND CORRECTIVE ACTION C/W (Complied with). Signature of the impoundment official is required in the ‘Inspected By’ block only. NOTE: For

F-22, this will be accomplished in the IMIS forms section of the PMA.

10.2.1.3. (Added) Warranty Tools. Tool Crib/Production Support Center (PSC) tool issue centers will maintain an active warranty tool program. No attempt to repair and/or modify any warranty tool will be made by either users or program managers.

10.2.1.9.1. (Added) Rag Control Procedures. The following procedures will be used for control of rags and paper products.

10.2.1.9.1.1. (Added) Applicable groups will establish specific requirements for control of paper products in critical FOD areas when used in a closure or final assembly. Any paper products used will meet with all FOD requirements and the Base Hazardous Waste Management Plan.

10.2.1.9.2.3. (Added) Each MXG will be responsible to ensure cloth rags are controlled and accountable when used in maintenance processes in critical

FOD areas that require closure procedures or final assembly. Rag issue points

(i.e., PSCs, Hazardous Material Dispensing Areas, Mics) will have the responsibility for the issuance and receipt of cloth rags (as required above) used in that functional area.

10.2.1.9.2.3.1. (Added) The rag issue point will verify and record the number of cloth rags issued to an individual in a written or electronic rag tracking log. Across OO-ALC many different issuing points exist under different titles (including even PSCs).

10.2.1.9.2.3.2. (Added) Cloth rags will be controlled IAW this supplement, all FOD requirements, and the base Hazardous Waste Management Plan.

Cloth rags (when used in a closure or final assembly process) will be returned to the issue point, counted and verified by the PSC or functional equivalent. When cloth rags are returned, the person receiving them will annotate in the written or electronic rag tracking log that the items have been returned. AFMC Form 310 Lost Found/Item Report must be initiated for any cloth rag (when used in a closure or final assembly) that cannot be accounted for.

10.2.1.9.2.3.3. (Added) All employees performing maintenance in FOD critical areas, on aircraft, engines and accessories, or providing a service to these organizations will perform an inspection of the work area, prior to closing out a task, or moving to another area to ensure that cloth rags have not been inadvertently left in the area.

10.2.1.18. (Added) The supplemental list is a listing of all items kept in tool kits

(TKs) that are not listed on the Tool Kit Custody Receipt Listing (TKCRL).

Supplemental listings will contain at a minimum, the national stock number (NSN)

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 9

and/or part number (if applicable), nomenclature, size (if applicable), quantity, drawer location, and TK identification (ID). The supplemental list will be signed and dated by both the employee and the supervisor immediately after the last entry on the list.

A copy of the supplemental list will be kept with the TKCRL, and on file by the supervisor. Use AF Form 3126, General Purpose 8½ x 11 or AF Form 3136 General

Purpose 11 x 8½.

10.2.1.19. (Added) Tools removed from a TK used by more than one person will be tracked by one of the following methods: AFMC Form 62, CTK Inventory and

Control Log or electronic equivalent; by using an electronic keyed device on a TK, (swiping of the tool card to sign in or out of the TK). The following information will be provided through a printable report: tool nomenclature, date out/in, location or end item of use, and name of borrower.

10.2.1.19.1. (Added) The owning organization’s test measurement diagnostic equipment (TMDE) monitor will be responsible for routing precision measurement equipment (PME) items for calibration. PME items maintained in a

TK will either be individually shadowed within the TK, or be placed in containers. If placed in containers, the container will be controlled IAW paragraph 10.5.1.3.1.1

10.2.1.19.2. (Added) TMDE monitors will issue a receipt to be kept in the TK for tools removed for calibration, certification or repair.

10.2.1.20. (Added) Cleco Control Procedures. Clecos, wedge lock fasteners, and other similar holding devices (hereafter ‘clecos’) are considered tool items, and will be marked with the TK ID number, controlled, and subject to inventory and lost tool procedures. Clecos will be shadowed in the TK either individually, in containers, or on trays. If clecos must remain on an aircraft or component for multiple shifts, an informational note will be made in aircraft record and/or in the Work Control

Document (WCD) task description block of the specific WCD operation number where the clecos were installed. This installation note will be stamped and dated by the technician who installed the clecos on the aircraft or component. When the clecos are removed, another informational note will be made indicating clecos removed.

The removal statement will be stamped and dated by the technician that removed the clecos. Total quantity of clecos installed/removed will be reflected in the informational note.

10.2.1.21. (Added) Tools used to support temporary duty (TDY), only if taken from an existing CTK or individual tool kit (ITK), will have an AF Form 1297, Temporary

Issue Receipt, documenting, tool NSN, nomenclature and quantity of tools. AF Form

1297 will be present with tools to serve as a TKCRL. A copy will be left in the existing kit to ensure accurate inspection and inventory records are maintained. All copies will be signed by employee and supervisor and a line will be drawn through the unused portion of the list. If TMDE is included in the tools taken TDY, a copy of the AF Form 1297 will be given to the TMDE monitor for their records. All inventories of such tools will require the AFMC Form 309, AFMC Tool Control

Inventory Record, for daily and supervisor inventories.

10 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

10.2.1.21.1. (Added) Tools checked out of a tool crib/PSC to support a TDY will be requested on a OO-ALC Form 515, Tool Request, and tracked in the

Electronic Facility Equipment Management System (EFEMS). A copy of the

OO-ALC Form 515 will be used as a TKCRL for the duration of the TDY. TKs left in place at TDY locations will be inventoried and transferred between team chiefs on a OO-ALC Form 515. A copy of the OO-ALC Form 515 will be forwarded to the issuing tool crib by the returning team chief upon his/her return.

While TDY, team chiefs will coordinate with the issuing tool crib on broken/replacement tools.

10.2.1.22. (Added) Long Term Storage. Groups requiring long term storage will establish secure areas for TK storage.

10.2.1.23. (Added) Procedures for contract field teams when performing maintenance at the OO-ALC/AMARG.

10.2.1.23.1. (Added) Depot On-Site Contractor Augmentee Team employees performing depot maintenance functions will be issued tools from Tool Crib/PSC, and will comply with all applicable tool control regulations.

10.2.1.24. (Added) Other Contractors.

10.2.1.24.1. (Added) Other contractors performing functions in industrial areas within OO-ALC will be required to have a method for controlling and accounting for tools used, and will be written into their contracts. This program must be outlined in the contractor’s quality plan and must be coordinated with the respective contracting officer and contract functional manager or his/her designated representative. All contractors working within OO-ALC will be required to inventory their tools at the beginning of the shift, at the end of each task, and at the end of each shift to check for any lost or missing tools. Any lost tools not found must be reported immediately to the contracting officer, production area supervisor, and MXG tool manager. Control and issue of government provided contractor TKs, kit template, and ID numbers will be accomplished using OO-ALC Form 516, Establish or Revise Tool Lists or

Appendages, and OO-ALC Form 515.

10.3.1.1.1. (Added) Group TCM (if applicable):

10.3.1.1.2. (Added) Monitors quality trends and provides periodic data to the

Complex TCM, their respective product group QA personnel, and Maintenance

Support Squadron/Authorized Contractor and assigned group squadron leaders.

10.3.1.1.3. (Added) Open and track AFMC Form 310 Lost/Found tool or item reports; ensure 5-day work suspense for closure. Forwards AFMC Forms 310 reports to complex TCM upon completion.

10.3.1.1.4. (Added) Review to ensure all OO-ALC Form 515 and 516 are properly documented with all of the following: list of required tools, including

NSN, nomenclature, issue quantity, and drawer location prior to signature of group TCM. Once properly documented, the group TCM will submit Work

Orders in EFEMS to be routed to the Tool Warehouse or Authorized Contractor.

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 11

10.3.1.1.5. (Added) Provide tool control and accountability guidance to managers, quality, and employees on approved policies and procedures regarding the tool program.

10.3.1.1.6. (Added) Forwards memo to Complex Report of Survey (ROS) Program

Manager when dollar threshold is exceeded on lost tools, to initiate a Report of

Survey. Property in Possession of the Air Force, and AFMAN 23-220, Reports of

Survey for Air Force Property, for all tools issued which cannot be turned-in due to loss, damaged or destroyed.

10.3.1.1.7. (Added) All Group TCMs will perform tool box inspections IAW assigned requirements as directed by Group QP Chiefs (in QASP) to sample overall program health. Discrepancies will be documented in Quality Information

Management Standard System (QIMMS) or Maintenance One (MX1) databases.

10.3.5.2. (Added) . The Maintenance Support Squadron or Authorized Contractor is responsible for foaming/shadowing of all new TKs ordered. Additional requests may be made for further foaming/shadowing support through this organization.

10.3.5.2.1. (Added) Cut-outs will facilitate ease of inventory and be in the general shape of the item within +/- 1” variance.

10.3.6.2. (Added) 309th Maintenance Support Group (309 MXSG)/authorized contractors will ensure each TK can be locked to prevent unauthorized access. This may be accomplished by using tool containers that have an integral locking system, or any other locking device (i.e., padlocks, cables, or a lock bar).

10.3.6.2.1. (Added) Individuals will secure/lock tools, TKs, or equipment anytime the tool or TK is left unattended (not being watched or looked after). If a tool or item can be removed from a TK without an employee’s knowledge, then the TK is not secured.

10.3.6.3.2. (Added) Expendable items are items that must be frequently replaced due to high use, excessive wear, breakage, or otherwise become unfit for use.

Supervisor approval is required before any expendable is added to a TK, and shall be controlled as follows: Such items requiring replacement due to usage or breakage will be exchanged on a one-for-one basis as soon as possible. Every attempt will be made to recover and return all pieces of broken expendable tools to tool crib/PSC prior to replacement. If the tool or a significant portion (as determined by the supervisor) is lost, a copy of a completed AFMC Form 310 must be presented before a replacement tool may be issued.

10.3.6.8. (Added) TKCRL Management. The tool issue center located in tool crib/PSC will manage the TKCRL. During the TK issue, the tool crib attendant and the employee will ensure the TKCRL, and TK quantities match, tools/items are marked per marked column, and are accurate to include drawer locations. The employee and tool crib attendant will sign the TKCRL. The master will be kept by

Maintenance Support Squadron/Authorized Contractor. One copy will be provided for the first line supervisor to be maintained on file, and one copy will be placed in a protective container (plastic bag, binder, etc.) and provided to the employee for retention in the TK. Out of stock items will be reflected on the TKCRL, annotated

12 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

back ordered, and placed on back order. When these items are received, the responsible employee and tool crib attendant will initial and date all three copies of the TKCRL. The TKCRL master copy will be used as the turn-in document for employees when they leave an organization, or when they terminate employment.

Pen and ink changes to the TKCRL (i.e. piece count, backorders, etc.) will be accomplished by tool crib/PSC tool issue center personnel only, and will be reflected on all three copies. The tool crib attendant and kit owner will initial these changes.

10.3.6.8.1. (Added) Tools on back order will be tracked in EFEMS, and a receipt issued to the TK owner. The receipt will be date stamped to provide back order visibility. On new kit issues the appropriate quantity will be annotated on the TKCRL for the backordered item.

10.3.6.8.1.1. (Added) TKs with attached issued containers/side box will be listed on TKCRL.

10.3.6.8.1.2. (Added) Maintenance stamps and their caps, when maintained in the TK, will be marked IAW Chapter 19 of this supplement, shadowed and put on the supplemental list as stamp and cap.

10.3.7.2.1. (Added) At a minimum, shop machinery accessories and attachments storage cabinets/drawers will be marked to identify the contents. Shop machinery accessories/attachments and/or end items used to adjust or operate equipment that is used for TDY support shall be marked (laser, etching or permanent marker) with Hill or Randolph AFB Bldg. # and office symbol. Items that cannot be marked by laser, etching or permanent marker will be identified with a metal tag lasered or etched with HILL or Randolph AFB Bldg. # and office symbol, and secured to item in a way that it is not easily removed. Shop machinery accessories/attachments and or end items used to adjust or operate equipment when used to support a TDY, will have an AF Form 1297 initiated with a description of all items issued along with an AFMC Form 309. The AFMC Form

309 will be annotated at the end of shift inventory each day the items are used during the TDY.

10.3.9.1. (Added) The sharp edge of blades will not be exposed when not in use (i.e.

buried in foam, put in a container, etc.). If used, tweezer tip protectors or razor blade covers, need to be accounted for on the TKCRL or the Supplemental list.

10.3.13. (Added) Non-Mobile TKs. For TKs that use drawers of a workbench, workstation, cabinet or Vidmar to store assigned tools, clearly mark each drawer that is part of the TK. TKs will be marked ‘Drawer 1’, ‘Drawer 2’, etc.

10.3.15. (Added) Personal Protective Equipment (PPE) kept in ITKs will be marked with the ITK number. Each item will be listed on the supplemental list and shadowed.

10.3.15.1. (Added) PPE not stored in an ITK will be stored in a personal or PPE locker. These items will be marked with the last name and first initial of the owning individual. NOTE: Shop PPE – PPE that is intended for shop use i.e., face shield for shop use at a drill press, will be marked with the organizational symbol.

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 13

10.3.15.2. (Added) All non-disposable PPE will be exchanged on a one-for-one basis. AFMC Form 310 will be initiated for all lost non-disposable PPE in high FOD critical areas.

10.5.1.3.1. (Added) Tools, impractical or too small to mark will be identified on the OO-ALC Non-Marked list. This list will be approved, signed and dated by the complex tool program manager and kept on file in the tool issue centers. The

Complex TCM will also post the list on the Tool SharePoint site. All tools/items listed in MARKED column as ‘Y’ are required to be marked with the TK number.

Tool sets/kits with multiple miscellaneous tools will be listed in the MARKED column as ‘Y’. If the kit/set contains tools which are listed on the OO-ALC Non-

Marked list, they are not required to be marked with TK number. All other tools within the kit will be marked with TK number. NOTE: Asterisks located in the

DESCRIPTION column may apply to older TKCRLs. Tools impractical to mark but are large enough to make a representative impression may be individually shadowed.

10.5.1.3.1.1. (Added) Containers (cases, pouches, tubes, boxes, etc.) will be shadowed and marked, lasered, or etched with the TK number, and quantity.

Lids or caps will be marked and listed on TKCRL/supplemental list only if they can be separated from the container making two individual pieces. If an identification number becomes illegible, the TK owner will remark container by end of shift.

10.5.7.1. (Added) Upon taking custody of an ITK, the kit owner will externally mark the kit with their last name, first initial and organizational symbol in any order.

ITKs will also be marked with the TK ID number on the inside of the TK in an area not visible from the outside of the TK. TK owners are responsible to update changes to organizational symbols if and when they occur. CTKs will be marked on the outside of the TK with the ID number and the organizational symbol. DTKs will be marked on the outside of the TK with the ID number and the organizational symbol.

10.5.7.1.1. (Added) All TKs will be assigned a TK ID and each tool in the TK will be marked (excluding tools on the Non-Marked list) with the TK ID number, prior to initial issue. Tools being replaced will be marked prior to replacement by assigned tool crib personnel. Tools will be laser marked where possible and is the preferred method.

10.5.7.1.2. (Added) External mounted devices (i.e., such as vices) will be marked under the mounting block to prevent the TK number from being easily viewed, and will be subject to inspection requirements and lost tool reporting procedures.

10.5.7.1.3. (Added) Tools made of a material incapable of laser or etching (i.e., rubber, rawhide, plastics etc.) shall be marked with a permanent marker. If the marking becomes illegible, the tool will be remarked before the end of the shift.

10.5.7.1.4. (Added) Military units will mark their mobility TKs for deployment

IAW AFI 10-403, Deployment Planning and Execution.

14 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

10.5.7.2. (Added) See Table 10.1 for PSC numbering methodology and configuration.

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 15

Table 10.1. (Added) PSC numbering methodology and configuration

Building Number/Tool Crib TK ID#

Bldg. 265 Tool Crib 3 HLMB

Hanger 1 Tool Crib 12 HLA10

Bldg. 225 Tool Crib 14 HLSE

Bldg. 225 Tool Crib 15 HLSM

Bldg. 233 Tool Crib 16 HLFT

Bldg. 5 Tool Crib 17 HLEN5

Bldg. 680 Tool Crib 19 HLCB

Bldg. 590 Tool Crib 20 HLAS

Bldg. 238 Tool Crib 22 HLBB2

Bldg. 204 Tool Crib 23 HLF22

Bldg. 748 Tool Crib 26 HL748

Bldg. 674 Tool Crib 74 HL674

10.5.7.2.1. (Added) See Table 10.2 for OO-ALC Geographically Separated Unit

(GSU) marking methodology.

Table 10.2. (Added) PSC numbering methodology and configuration

Code OO-ALC GSU

HLRA AMXG-Randolph

HLSCP EMXG-Kadena

HLV MMXG-Vandenberg

FWHR MMXG-FE Warren

MBMRM MMXG-Malmstrom

MPSR MMXG-Minot

10.6.1. (Added) Locally Manufactured/Modified Tools (LM/MTs). Each MXG will be responsible to approve and control special tools and locally manufactured/modified tools

(tools that have been made or modified for a specific job function).

10.6.1.1. (Added) When procuring tools to be modified, a OO-ALC Form 515 must be completed by the requestor, describing the tool to be modified, reason for the modification and intended use. The OO-ALC Form 515 must then be signed by the supervisor, prior to being taken to the tool crib/PSC. The procured tool will be reviewed by engineering for modification.

10.6.1.2. (Added) LM/MTs will be controlled. Approved and authorized LM/MTs may be in a TK, but must be marked with the TK number, shadowed, and identified on the supplemental list.

10.6.1.3. (Added) Tools listed and issued to a TK will not be modified. Dressing or sharpening of tools is allowed IAW TO 32-1-101, Use and Care of Hand and

Measuring Tools and does not constitute a modification.

10.7.2.1.1. (Added) Replacement. A limited stock of replacement tools will be maintained by 309 MXSS. The supervisor will ensure quantities and types of

16 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

tools in stock are not excessive and/or co-mingled. Tool bin labels will include

NSN or part number, unit of issue, item description, and maximum bin levels.

Stock levels may be adjusted in support of special projects, special operating requirements, or if existing demand data is insufficient to support mission requirements. A single occurrence of a mission limiting status is not sufficient reason to establish an adjusted stock level, but may be an indicator to review demand data for accuracy. Up to a 90-day level of items that are subject to wear and breakage may be maintained to replace unserviceable items. When bin levels drop below determined minimum levels, new stock will be ordered. Tool crib/PSC will stock standard size (e.g. 3/16”, 1/4”, 5/16”) drill bits, and a nominal amount of standard size machine and hand reamers under 1” diameter.

10.7.2.6. (Added) An appointment must be made with tool crib/PSC, prior to TK issue and turn-in. During TK issue both the issuing tool attendant and the receiving mechanic/technician will verify each tool listed on the TKCRL for accuracy of tools issued, serviceability, and proper TK marking. Tool Crib Attendants will ensure employees read and return the signed original AFMC Form 311, Certificate of

Responsibility for Government Property, to the tool crib/PSC, prior to receiving a tool issue. Tool crib/PSC will retain a copy of the EFEMS work order, the AFMC Form

311, and the master (official) TKCRL signed by the employee, which will be maintained by the tool crib.

10.7.2.6.1. (Added) ITKs are issued for use to a single individual. CTKs are issued to a supervisor for use by their crew. Dispatchable Tool Kits (DTKs) are issued from the PSC to perform a specific task, or for use by a specific Air Force

Specialty Code and is designed to be used outside the tool room or work center.

One individual is responsible for the DTK. All appropriate inspections are applicable to the TK.

10.7.2.6.2. (Added) TK Content Determination. The production/project engineer or planner, production supervisor and technicians (users), define the composition of templates required for new workloads. These templates must be approved through the product/project group engineering and planning section at squadron-level, prior to submission for implementation. A OO-ALC Form 516 is required to establish a new template, or to revise or delete an established template.

Each type of standardized template will be assigned a template number. The OO-

ALC Form 516 is initiated by the supervisor and will include the following: a complete list of required tools, NSNs, nomenclatures, issue quantities, drawer locations (i.e., Drawer 1, Drawer 2) and will be signed by a second level supervisor or equivalent before they are forwarded to the Group TCM.

Supporting commercial data, (source, part number, catalogue page or screen print) will be provided for adding non-stock listed parts.

10.7.2.6.3. (Added) Since the supervisor is ultimately responsible for TKs under his/her control, the supervisor or designated representative (a non-Bargaining

Unit) will sign the AFMC Form 309 verifying the required 365-day inspection has been properly completed. This may include TKs assigned directly to the supervisor. Previous AFMC Forms 309 will be stored/filed until a supervisor review has been accomplished on the current AFMC Form 309.

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 17

10.7.2.6.4. (Added) CTKs will be inventoried and transferred from supervisor to supervisor as needed. The TK will be updated to match template changes as required. When a supervisor is not available or has been replaced, the CTK must be transferred to the second-level supervisor until a permanent supervisor is assigned or turned into the tool crib.

10.7.2.6.5. (Added) A separate AFMC Form 309 will be maintained in each TK for each shift that uses that TK. Previous AFMC Forms 309 will be stored/filed until a supervisor review has been accomplished on the current AFMC Form 309.

10.7.2.8. (Added) TK Issue. OO-ALC Form 515 is signed by the first-level supervisor for ITKs (second-level supervisor for CTKs) and forwarded to the group

TCM to ensure all information is correct. Once OO-ALC Form 515 is complete it will be used to order TKs from tool warehouse. The group TCM or alternate will submit work order requests electronically in the Electronic Federal Equipment

Management System (EFEMS) to tool crib/PSC with a reasonable need date.

10.7.2.8.1. (Added) Template Change. Template changes will be acceptable once a calendar year if needed. If more than one change is required during the year it should only be for new workloads and/or a change of workload; if the additional template change is for any other purpose, a letter of justification will need to be provided from the squadron director to the group TCM for approval.

Templates may be changed to ensure the right number of tools, proper tool to complete a given task, skill or work area, or a combination thereof to attain configuration control/standardization. Template changes will be documented on

OO-ALC Form 516, and forwarded to the group TCM. The group TCM will forward any required template changes to the tool warehouse/tool issue center so the template may be updated. Issued TKs will be reconfigured to meet new template requirements if the template is revised. TK composition should be the same for all employees possessing the same skill who are working in the same work center.

10.7.2.8.2. (Added) TK turn in. When an employee is permanently reassigned to a new work center or moves from his/her current job assignment, the TK will be turned into the tool center or transferred to the supervisor. The tool crib attendant and employee will inventory the kit for accuracy of tools returned and proper TK marking. Tool attendant and mechanic/technician will sign an EFEMS transaction report. A copy will be provided to the mechanic/technician for their

TK turn-in receipt once all tools have been accounted for.

10.7.2.8.3. (Added) Items listed on the supplemental list will be turned-in to current supervisor. Inventory, control, and lost tool procedures will apply to supplemental items.

10.7.4. (Added) Applicable MXG will be responsible to establish procedures and/or operating instructions that provide tool control guidance for their respective PSCs.

10.7.4.1. (Added) PSC End of Shift Inventory. At the end of each shift, PSC will print EFEMS Current Temporary/Special Issues Report and verify physical status.

18 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

File report and annotate page 1 of AFMC Form 309 (Tool Control Inventory Record) in daily shift inventory binder.

10.7.4.1.2. (Added) The annual inventory of tools and equipment in all tool cribs or PSCs will be documented by attaching a cover letter to the inventory listing used to conduct the inventory that contains the following information: the crib inventoried, the date the inventory was conducted, names of the individuals who participated in the inventory, discrepancies found, corrective actions taken and the supervisor’s name and signature.

10.7.4.1.3. (Added) When permanently changing a group resource center code

(RCC), ensure information (i.e., tool card) provided to the tool crib/PSC has been updated for the purpose of tracking loaned tools and equipment.

10.7.4.1.4. (Added) DTKs. DTKs assigned and maintained within a tool crib/PSC will require an AFMC Form 309 to document inspections as follows:

When the TK is issued and returned to the tool crib/PSC during the same shift/day, the responsible mechanic along with the tool crib/PSC attendant will perform a joint inventory. If the TK is not returned during the same shift or day, the responsible mechanic will complete all required inspections and annotate page

1 of the AFMC Form 309. Pages 2 and 3 may be used as required and page 4 will be used to document lost tools. At least once every 365 days the PSC/tool crib supervisor or designee (that is the alternate supervisor, wage leader, or military equivalent) must inspect the DTKs assigned to a PSC/tool crib and document on page 4 of AFMC Form 309.

10.7.4.2.1.1. (Added) Temporary loaned tools will only be loaned to employees and supervisors with a valid tool card. Tools checked out from the tool crib or PSC may be stored in the employee’s ITK, but not in their personal drawer. These items will not be on loan for more than five calendar days. If tools are required for more than five calendar days, the location of the tool must be physically verified and the loan must be renewed.

10.7.4.2.1.2. (Added) The tool crib/PSC will notify the supervisor/mechanics and Group TCM of delinquent tools on the EFEMS web page. Supervisors can also check the site and notify employees of delinquent tools. Employees with delinquent loaned tools will not be allowed to check out additional tools until the delinquent tool has been reconciled.

10.7.4.2.1.3. (Added) Tool crib employees will notify supervisor and Group

TCM regarding over-due tools via e-mail.

10.7.4.2.1.4. (Added) Tool management employees will post a list regarding overdue tools at the tool crib or issue point.

10.7.5.2.1. (Added) Point of Use Station (POUS). Items are added to POUS machines after production supervisor has given written approval. Written approval will be verified by Quality Assurance Evaluator (QAE) for content.

Initial stock lists are coordinated between material and production personnel.

NOTE: Recoverable tools and items issued through the tool warehouse/crib will not be stored in or issued from POUS.

AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014 19

10.7.5.3. (Added) Usage reports will be distributed each month to third-level supervision. The usage report must reflect the following minimum requirements:

issued product, name of technician, quantity of issue, time/date of issue, and location of issue. Usage reports will be used to identify highly pilferable items. Reports will be kept a minimum of 2 years. NOTE: It is the responsibility of MXG supervision to identify high pilfered items. If identified as high pilfered, these items will be issued as a one-for-one swap.

10.7.5.3.1. (Added) If PPE is identified as high pilfered (by MXG supervision), these items will be controlled as a one-for-one swap through supervisor issue.

10.7.5.3.2. (Added) POUS machines will be inventoried by the owning organization on a quarterly basis and identity tags verified for content.

Minimum/maximum levels are reviewed at this time; slow or dead stock will be removed. Inventory accuracy is verified by QAE.

10.8.1.8. (Added) Lost Tools. Tools identified as missing from a TK, tool cribs or a

PSC will be reported immediately to the supervisor by the employee who lost a tool

(or item) on an AFMC Form 310. The supervisor will also contact the group TCM immediately for official reporting. The tool (or item) owner will document the loss on page 4 of AFMC Form 309. The supervisor will ensure AFMC Form 310 Block

17a is signed by the second level supervisor (if applicable), 17b signed by the third level supervisor (if applicable), and 17c is signed by the Group TCM. Block 18 will be signed by the squadron director, deputy, or higher. The lost tool/item package

AFMC Form 310 has a 7-workday suspense back to the group TCM once it is issued.

The group TCM will ensure the AFMC Form 310 is complete, and has been properly coordinated.

10.8.1.8.1. (Added) The person issued the tool/item must search the immediate work area for the missing tool/item, and immediately report it to their supervisor.

The supervisor must conduct a search of the areas including inside equipment where the tool may have been used.

10.8.1.8.2. (Added) If a tool is lost across groups or in an area not usually assigned to the TK owner, the immediate supervisor or alternate supervisor of that area must be notified along with their applicable TCM. This will make supervisors aware of a lost tool in their area of responsibility so appropriate lost tool procedures may be taken. NOTE: The employee who lost the tool will report to their owning organization’s TCM for accomplishment of Lost Tool

Report. The TCM will supply a courtesy copy to the TCM of the affected area.

For example: an EMXG employee loses a tool in AMXG. The EMXG employee would notify the AMXG supervisor and AMXG TCM. The EMXG TCM would initiate the lost tool/item report and would also provide a courtesy copy to the

AMXG TCM.

10.8.1.8.3. (Added) In every case, an AFMC Form 310 will be provided to issuing tool room for tool/item replacement and be maintained in the master TK file. The group TCM will maintain a copy of the AFMC Form 310, and copies will be forwarded to the employee, the TK owner’s supervisor, and the Complex

TCM. Follow AFMAN 23-220, Reports Of Survey for Air Force Property, if

20 AFI21-101_AFMCSUP_OO-ALCSUP 4 FEBRUARY 2014

applicable. For lost…