afi21-102_afmcsup.pdf

DEPARTMENT OF THE AIR FORCE

HEADQUARTERS AIR FORCE MATERIEL COMMAND

WRIGHT-PATTERSON AIR FORCE BASE OHIO

Deliver and Support Agile War-Winning Capabilities

AFI21-102_AFMCSUP_AFMCGM2015-02

7 January 2016

MEMORANDUM FOR ALHQCTR/CC/CL

FROM: HQ AFMC/A4

4375 Chidlaw Road, Room C114

Wright-Patterson AFB OH 45433-5006

SUBJECT: Air Force Materiel Command (AFMC) Guidance Memorandum (GM) to AFI 21-

102_AFMCSUP, Depot Maintenance Management

1. By order of the Commander, AFMC, this is an AFMC GM immediately changing AFI 21-

102_AFMCSUP. Compliance with this publication is mandatory. There are no releasability restrictions on this publication. To the extent its direction is inconsistent with other AFMC publications, the information herein prevails, in accordance with AFI 33-360, Publications and Forms Management.

2. This GM incorporates AFI21-102_AFMCSUP_AFMCGM2015-01 dated 30 Jun 2015 along with changes to Chapter 2 - Roles and Responsibilities, Chapter 3 - Depot Maintenance Management

Processes, Chapter 6 - Depot Maintenance Support, Chapter 7 - Work Control Documents and Technical

Data, Chapter 8 - Quality Assurance (QA), Chapter 10 - Tool and Equipment Management, Chapter 12 -

Aircrew Egress Systems Maintenance, Chapter 13 - Additional Program Requirements, and Attachment 3

– Foreign Object Damage Report. Each change should be read in its entirety. Updates to the references, prescribed forms, adopted forms, and abbreviations and acronyms listings have also been included in the attachment.

3. In advance of a rewrite of AFI 21-102_AFMCSUP, the attachment to this memorandum provides guidance changes that are effective immediately.

4. The guidance in this memorandum is void 1-year from the date of this memorandum, or upon incorporation by interim change to, or rewrite of, AFI 21-102_AFMCSUP.

5. Our POCs are Mr. Greg Treadwell, HQ AFMC/A4MM, DSN 787-7932, or via email at james.treadwell.1@us.af.mil and Mr. Dave Workman, HQ AFMC/A4MM, DSN 986-2276, or via email at david.workman@us.af.mil.

DONALD E. KIRKLAND

Brigadier General, USAF

Director of Logistics, Civil Engineering and Force Protection

Attachment:

Guidance Changes mailto:james.treadwell.1@us.af.mil mailto:david.workman@us.af.mil

Attachment

Guidance Changes

(Replace) 2.7.5. (Added-AFMC) Ensure technical data accuracy IAW TO 00-5-1 (T-1) and the

AFMAN 63-143, Centralized Asset Management Procedures, Logistics Requirements Determination

Process (LRDP) Bill of Work (BOW).

(Add) 2.8.21. (Added-AFMC) Ensure corrosion control and prevention is implemented IAW AFMCI

21-117, Corrosion Control and Prevention Program and Marking of Aerospace Equipment.

(Replace) 3.7.1.1.3. (Added-AFMC) Follow AFMAN 63-143 to develop the Weapon System

Sustainment (WSS) requirements and funded customer orders.

(Replace) 6.1.1.2. (Added-AFMC) Participate in the Spares Requirement Review Board (SRRB) per

AFMAN 63-143.

(Replace) 6.1.1.3. (Added-AFMC) Provide non-parts supportability elements for the Aircraft and

Missile Requirements (AMR) as part of the LRDP per AFMAN 63-143.

(Replace) 6.1.1.6.1. (Added-AFMC) Flying hours for all FCFs shall be updated in REMIS and installed engine times shall be updated in the Comprehensive Engine Management System (CEMS) or G081, Integrated Maintenance Data System, as applicable, NLT the next duty day after occurrence IAW AFI

21-103. (T-1)

(Replace) 6.2.2. (Added-AFMC) Kitting. AFSC shall establish a process to assemble aircraft specific or commodity component specific disparate parts and non-parts into one unit to be delivered to maintenance as part of the critical path for that repair requirement. Kit content shall be developed and sustained using a List of Material that is fully integrated with the corresponding AFMAN 63-143 LRDP

BOW.

(Replace) 7.1.1.1.1.1. (Added-AFMC) WCDs shall be auditable and meet the requirements of AFMAN

63-143, TO 00-5-1, TO 00-20-1, and TO 00-25-4. (T-1)

(Replace) 8.1. (Added-AFMC) AFSC shall further define and implement this chapter to standardize QA functions across the ALCs. EXCEPTION: See AFI 11-301V1, Aircrew Flight Equipment (AFE)

Program, and AFI 11-301V1 AFMC Sup, Aircrew Flight Equipment (AFE) Program, for units performing maintenance and configuration requirements of aircrew flight equipment.

(Replace) 8.2.1.1. (Added-AFMC) AFSC will implement the MSEP using the following minimum requirements. EXCEPTION: See AFI 21-200, Munitions and Missile Maintenance Management, AFI

21-202V1, Missile Maintenance Management, and AFI 21-202V2, Cruise Missile Maintenance

Management, for additional MSEP inspection requirements for units performing maintenance with

Intercontinental Ballistic Missiles (ICBMs), space launch mission assurance, and/or related systems and components.

(Replace) 8.2.1.1.2. (Added-AFMC) Define the process for control, routing, and follow-up of the

AFMC Form 77, Request for Quality Assistance (RQA) or the electronic equivalent.

(Replace) 8.2.1.3.4.1. (Added-AFMC) The AQL/standard is derived from QA performance based data.

AFSC will develop procedures for determining minimum AQL/standard levels. EXCEPTION: See AFI

21-200, AFI 21-202V1, and AFI 21-202V2 for AQLs/baselines for ICBMs, space launch mission assurance, and/or related system and components. See AFI 11-301V1 and AFI 11-301V1 AFMC Sup for units performing maintenance and configuration requirements of aircrew flight equipment.

(Replace) 8.2.1.4.3. (Added-AFMC) Routine Inspection (RI). RIs are assessments of common depot production maintenance programs and processes that require continuous evaluation. They may be evaluated independently or may be performed in conjunction with any other type of assessment (e.g., PE, QVI, etc.). The AFMC QA EIM site will contain checklists that identify the mandatory routine inspection items. Mandatory questions, when applicable to the organization, must be evaluated for the assessment to qualify as a RI. Observed deficiencies beyond the RI checklist questions shall be recorded in the

Command approved QA database under the category of RI. The following are the AFMC RI areas which must be included in the QASP (if applicable):

(Replace) 8.2.1.4.3.12. (Added-AFMC) Explosive Safety.

(Replace) 8.2.1.4.6.3. (Added-AFMC) Unsatisfactory Condition Report (UCR). An unsatisfactory condition is defined as an event/discrepancy that requires immediate supervisory intervention to ensure safety or process/product fit, form, or function reliability. Unsatisfactory conditions are deemed major and will be documented as a UCR. A condition of a minor nature shall be documented against the applicable checklist or its regulatory guidance.

(Add) 8.2.1.4.8. (Added-AFMC) Special Inspections (SI). Special Inspections when driven by the analysis of assessment data may be conducted at the discretion of the local QA or requested by

ALC/CC/CL/CD, MXG/CC, SQ/CC or work center supervisors. Additionally, observed deficiencies beyond the scope of an inspection in progress not meeting the criteria of a DSV, TDV or UCR will be recorded in command approved information system under the category of Special Inspection. SIs will be assigned a rating (QAR-1 or 3) based on severity of the observation. SIs are designed to provide a flexible tool to complement other quality assessment types.

(Replace) 8.2.1.5. (Added-AFMC) A QAR rating is a value reflecting the results of quality assessments.

These ratings shall be input into the Command approved QA database. Assessments will be rated;

however, MIs will be rated at local discretion. Deficiencies shall be classified as major or minor findings.

A minor finding is defined as an unsatisfactory condition that requires repair or correction, but does not endanger personnel, affect safety of flight, jeopardize equipment reliability, or warrant discontinuing a process or equipment operation. A major finding is defined as a condition that would endanger personnel, affect safety of flight, jeopardize equipment reliability, or warrant discontinuing process or equipment operation.

(Replace) 8.2.2.1.2. (Added-AFMC) Processing. QA personnel will input assessments into the

Command approved QA database within one work day (24 hours). Production personnel responsible for the deficiency/finding will provide a viable corrective/preventative action plan within 8 business days. A corrective/preventative action plan will be developed to prevent or minimize the potential for recurrence.

QA will review the corrective action plan and will either accept or reject the corrective/preventative action plan within 2 business days. AFSC shall further identify AFMC Form 343 processing procedures to include extension of suspense dates.

(Replace) 8.3.1.2. (Added-AFMC) All QASs, inspectors, and evaluators (i.e., QA personnel) must be trained IAW AFI 36-2232 AFMC Supplement and training requirements outlined in the AFMC GS-1910

Civilian Training Plan (CTP). EXCEPTION: See AFI 21-200, AFI 21-202V1, and AFI 21-202V2 for additional training requirements for QASs who inspect maintenance actions on ICBMs, space launch mission assurance, and/or related systems and components.

(Add) 8.3.13. (Added-AFMC) Ensure Aircrew Flight Equipment QASs are trained IAW AFI 11-301V1 and AFI 11-301V1 AFMC Sup, prior to evaluating AFE tasks.

(Replace) 8.6.1.5. (Added-AFMC) Ensure development and maintain all depot maintenance QA training to include the Depot Maintenance QA Course and the GS-1910 CTP. HQ AFMC/A4M will provide functional approval for all depot maintenance QA training.

(Replace) 10.1.1.2.1. (Added-AFMC) AFSC shall develop, implement, and maintain standardized processes and procedures to account for all TKs, tools, and dispatchable equipment. Utilize AFMC Form

309, AFMC Tool Control Inventory Record, when applicable.

(Add) 12.4.1. (Added-AFMC) Government and contractor Egress maintenance personnel who possess, as a minimum, one year of experience within the last three years performing Egress intermediate- and organizational-level maintenance, repair, inspections, etc., may be considered for a waiver to the classification training requirements. Waiver requests will be submitted to the Command Egress functional manager for review. The Command Egress functional manager will then forward the waiver to the HAF 2A6X3 Career Field Manager for final approval/disapproval. If the waiver is disapproved, the individual must complete classification training.

(Replace) 13.5.1.3.1. (Added-AFMC) Center DOP Program Manager shall provide an initial dropped object report via e-mail to HQ AFMC/A4M workflow within 24 hours of occurrence. In addition, if it involves casualties, property damage, or if adverse publicity is likely, report IAW AFI 10-206, Operational Reporting. (T-1) The safety office shall be notified of all dropped objects within 24 hours of occurrence, unless it involves casualties, property damage, or if adverse publicity is likely, and then the safety office shall be notified immediately. The DOP report format listed in Attachment 2 shall be followed.

(Replace) 13.5.1.3.2. (Added-AFMC) Center DOP Program Manager shall provide a final dropped object report via e-mail to HQ AFMC/A4M workflow. Reports shall be maintained for a minimum of 24 months (may be electronic). The DOP report format listed in Attachment 2 shall be followed.

(Replace) 13.5.1.4. (Added-AFMC) Input the data from the Center DOP reports into the DOP tracking tool and provide reports to the HQ AFMC/A4 when requested.

(Replace) 13.6.1.1.3.1. (Added-AFMC) Center FOD Prevention Program Manager shall establish a process to report cut tires to airfield management upon discovery so the taxiways and runways can be inspected for possible FOs.

(Replace) 13.6.1.1.3.2. (Added-AFMC) Center FOD Prevention Program Manager shall provide an initial FOD report via e-mail to HQ AFMC/A4M workflow within 24 hours of occurrence. The final report will be submitted to AFMC/A4M via email after investigation is complete. Reports shall be maintained for a minimum of 24 months. The FOD report format listed in Attachment 3 shall be followed.

(Delete) 13.6.1.1.3.3. (Added-AFMC) Complex/Wing/Center FOD Prevention Program Manager shall provide a completed AFMC Form 40 Foreign Object Damage Record, or electronic equivalent, monthly via e-mail to HQ AFMC/A4M workflow.

(Replace) 13.6.1.1.3.4. (Added-AFMC) When FOD is discovered on a transient aircraft, depot input/output, Engine Regional Repair Center (ERRC), or Centralized Repair Facility (CRF) engine, the

Center FOD Prevention Program Manager shall notify the owning organization within 24 hours. An informational copy of the FOD report must be provided to the owning organization’s safety office/FOD monitor to ensure compliance with AFI 91-204, Safety Investigations and Reports. Aircrews must ensure proper documentation in the AFTO Form 781A, Maintenance Discrepancy and Work Document, or electronic equivalent has been completed.

(Replace) 13.6.1.1.4. (Added-AFMC) Input the data from the Center FOD reports into the FOD tracking tool and provide reports to the HQ AFMC/A4 when requested.

(Add) 13.11.4. (Added-AFMC) Industrial Engineering Technician (IET)/Planner Training. All new

IETs/Planners must successfully complete course CRXMAS0011000SU, Depot Maintenance Planning for Exchangeables or course CRXMAS0012000SU, Depot Maintenance Planning for Aircraft/Missiles.

(Add) 13.11.4.1. (Added-AFMC) All IETs/Planners must successfully complete Bill of Material (BOM) and Labor Standards recurring training, at a minimum, every two years. All training will be documented in the Training Scheduling System (TSS).

(Add) 13.12.2.1. (Added-AFMC) All personnel assigned to AFSC aircraft/missile maintenance units, military and civilian, shall use the Training Scheduling System-Production Acceptance Certification

(TSS-PAC) MIS to document recurring training requirements and certifications.

(Replace) 13.12.6.1.2. (Added-AFMC) Develop, implement, and maintain the TSS-PAC MIS.

(Add) 13.13.3.23. (Added-AFMC) Aircrew Flight Equipment IAW AFI 11-301V1 and AFI 11-301V1

AFMC Sup.

(Change) 13.14.1.1. (Added-AFMC) SCRs will be approved and maintained at the Group level.

(Replace) 13.15.1.1. (Added-AFMC) Flying hours for all FCFs shall be updated in REMIS and installed engine times shall be updated in CEMS or G081, as applicable, NLT the next duty day after occurrence

IAW AFI 21-103. (T-1)

(Replace) 13.15.2 (AFMC) AFSC shall develop, implement, and maintain standardized processes and procedures governing the FCF Program. This program is managed by the applicable production squadron and flight test organization. AFSC will ensure:

(Replace) 13.15.2.1. (Added-AFMC) A FCF Program Manager will be designated at each squadron or geographically separated Group. As a minimum, the FCF Program Manager will:

(Replace) 13.19.1.4.1. (Added-AFMC) Specify responsibilities of affected work centers for accurate and timely MIS and CEMS reporting of Time Compliance Technical Orders (TCTOs), SIs, Time Change

Items (TCIs), and other documentation requirements (e.g., borescope inspections, blade blending, and

CANN actions).

(Add) 13.26. (Added-AFMC) Sun Shade Management. AFSC shall develop, implement, and maintain standardized processes and procedures to address Sun Shade Management IAW AFI 21-136, Aircraft Sun

Shade Management.

(Add) 13.27. (Added-AFMC) Aircrew Flight Equipment (AFE) Program. AFSC shall manage AFE related maintenance programs IAW AFI 11-301 series instructions, including AFMC supplements and all applicable technical orders.

References

AFI 11-301V1, Aircrew Flight Equipment (AFE) Program, 25 February 2009

AFI 11-301V1 AFMC Sup, Aircrew Flight Equipment (AFE) Program, 14 November 2011

AFI 21-136, Aircraft Sun Shade Management, 20 July 2012

AFI 21-200, Munitions and Missile Maintenance Management, 02 January 2014

AFI 21-202V1, Missile Maintenance Management, 17 September 2014

AFI 21-202V2, Cruise Missile Maintenance Management, 29 October 2014

AFMAN 63-143, Centralized Asset Management Procedures, 12 August 2015

AFMCI 21-117, Corrosion Control and Prevention Program and Marking of Aerospace Equipment, 28

May 2014

Prescribed Forms

(Add) AFMC Form 77, Request for Quality Assistance (RQA)

Adopted Forms

(Delete) AFMC Form 40, Foreign Object Damage Record

(Delete) AFMC Form 77, Request for Quality Assistance (RQA)

Abbreviations and Acronyms

AFE--Aircrew Flight Equipment

ICBM--Intercontinental Ballistic Missile

TSS--Training Scheduling System

TSS-PAC--Training Scheduling System-Production Acceptance Certification

(Replace) Attachment 3 (Added-AFMC)

FOREIGN OBJECT DAMAGE (FOD) REPORT

Figure A3.1. Foreign Object Damage (FOD) Report

MEMORANDUM FOR Date

FROM: Unit Designation/Office Symbol, Street, Base and Zip Code

SUBJECT: Foreign Object Report. FOD program report number (unit,-F-, year, and month, followed by sequence number : example, 301FW-F-060501)

Type of Report: Initial/Update/Final

Date and Time of Incident:

Unit (ALC,MXG,MXS) and Base of Incident:

- Production Machine Gate(s) Affected

- Procedures, TOs, WCDs Affected

- Gate Performance Metric and Quality Metric Affected

- Organizational Funding Source Affected

Origin of Sortie:

When discovered (Preflight, Postflight, In-Coming, Test Cell, etc.)

Owning Unit, Base and MAJCOM

MDS and Tail Number (N/A for Test Cell incidents)

Engine Type, Make, Series, Modification (TMSM)

Engine S/N:

Engine Position (If Applicable):

Time Since Overhaul:

Description of Incident:

Material Failure: (Yes or No)

Tech Data Deficiency: (Yes/No)

Preventable/Non-Preventable:

Investigation Findings:

- Production Machine Gate(s) Identified as Probable Cause

- Procedures, TOs, WCDs Identified for Correction

- Gate Performance Metric and Quality Metric Updated

- Organization Responsible for Funding Repair

Action Taken to Prevent Recurrence:

Parts Cost: Labor Cost: Total Cost:

Additional Comments (if necessary):

///Sign///

FOD Monitor, Unit Designation

///Sign///

AFSC FOD Prevention Program

Manager

BY ORDER OF THE SECRETARY

OF THE AIR FORCE

AIR FORCE INSTRUCTION 21-102

16 JULY 2012

AIR FORCE MATERIEL COMMAND

Supplement

19 DECEMBER 2014

Maintenance

DEPOT MAINTENANCE MANAGEMENT

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for downloading and ordering on the e-Publishing website at http://www.e-Publishing.af.mil.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AF/A4LM

Supersedes: AFI21-102, 19 Jul 1994

Certified by: AF/A4L

(Maj Gen John B. Cooper)

Pages: 101

(AFMC)

OPR: HQ AFMC/A4MM

Supersedes: AFI 21-101 AFMCSUP, 26 April 2012; AFMCI 21-105, 30 April 2008; AFMCI 21-109, 18 May 2009; AFMCI 21-120, 02 May 1996; AFMCI 21-127, 23 June 2005; AFMCI 21-130, 15 November 2007; AFMCI 21-

136, 06 February 2003; AFMCI

21-140, 13 May 2005; AFMCI

21-156, 25 August 2004; and

AFMCI 21-185, 15 May 2012.

Certified by: HQ AFMC/A4D

(Eugene A. Jeunelot, Jr.)

Pages:

This Air Force Instruction (AFI) provides directive guidance for depot maintenance management. For policies and procedures used in planning and administering depot level contract maintenance programs, refer to AFI 63-101, Acquisition and Sustainment Life Cycle

Management. This instruction implements Air Force Policy Directive (AFPD) 21-1, Air and

Space Maintenance, and provides additional guidance on requirements contained in AFPD 63-

1/20-1, Acquisition and Sustainment Life Cycle Management, and AFPD 13-5, Air Force

Nuclear Enterprise. This AFI applies to all major commands (MAJCOMs), the Air National http://www.e-publishing.af.mil./

2 AFI21-102_AFMCSUP_I 19 DECEMBER 2014

Guard (ANG), Air Force Reserve Command (AFRC) and their subordinates. Refer recommended changes and questions about this publication to the Office of Primary

Responsibility (OPR) using the Air Force (AF) Form 847, Recommendation for Change of

Publication. This publication may be supplemented, but supplements must be provided to the

OPR of this publication for review prior to publication. Records created as a result of processes prescribed in this publication are maintained in accordance with (IAW) AFMAN 33-363, Management of Records, and disposed of IAW the AF Records Disposition Schedule (RDS) located at https://www.my.af.mil/afrims/afrims/afrim/rims.cfm.

(AFMC) This supplement implements and extends the guidance of AFI 21-102, Depot

Maintenance Management, and provides directive guidance for depot maintenance management.

For policies and procedures used in planning and administering depot level contract maintenance programs, refer to AFI 63-101/20-101, Integrated Life Cycle Management, AFI 63-138, Acquisition of Services, and Air Force Materiel Command Instruction (AFMCI) 21-149, Contract Depot Maintenance (CDM) Program. The Air Force Sustainment Center (AFSC) will develop directives as mandated by AFI 21-102 and this supplement, and provide them to the

OPR of this instruction for review prior to publication. Only current and verified technical data, as authorized by TO 00-5-1, Air Force Technical Order System, shall be used for depot maintenance. This publication does not apply to the Air National Guard Bureau (ANG) or the

Air Force Reserve Command (AFRC) and their units. However, if an AFRC unit is assigned or associated with AFMC where AFMC is the lead, this guidance would be applicable. 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. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with (IAW) the Air Force Manual (AFMAN) 33-363, Management of Records, and disposed of IAW the Air Force Records Information Management System (AFRIMS) Records

Disposition Schedule (RDS). This publication may be supplemented at any level, but all direct

Supplements must be routed to the OPR of this publication for coordination prior to certification and approval. The authorities to waive wing/unit level requirements in this publication are identified with a Tier (“T-0, T-1, T-2, T-3”) number following the compliance statement. See

AFI 33-360, Publications and Forms Management, for a description of the authorities associated with the Tier numbers. Therefore, unless otherwise stated, requirements throughout this instruction are mandated for compliance with a waiver authority level of Tier two (T-2) as defined in AFI 33-360. Submit requests for waivers through the chain of command to the appropriate Tier waiver approval authority, or alternately, to the Publication OPR for non-tiered compliance items.

SUMMARY OF CHANGES

This publication has been substantially revised and must be reviewed in its entirety. It defines depot maintenance, details depot maintenance responsibilities, and provides guidance for depot purchased equipment maintenance and maintenance requirements work packages. It also includes depot maintenance execution guidance that was previously found in AFI 21-101, Aircraft and Equipment Maintenance Management. This publication supersedes the portion of

AFI 21-101 addressing depot maintenance requirements.

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

AFI21-102_AFMCSUP_I 19 DECEMBER 2014 3

CHAPTER 1—DEPOT MAINTENANCE MANAGEMENT 8

1.1. Depot Maintenance

1.1. (AFMC) AFMC shall:

1.2. Aircraft and Equipment Readiness

1.3. Maintenance Discipline

1.4. Technical Orders (TOs)

1.5. Modification Management

1.6. Maintenance Information Systems (MIS)

1.7. Nuclear Weapons Related Materiel (NWRM)

1.8. Duty Shifts and Rest Periods

1.9. Civilian Visitors

1.10. Statutory Framework

1.11. (Added-AFMC) Metrics and Reporting

CHAPTER 2—ROLES AND RESPONSIBILITIES 12

2.1. Assistant Secretary of the Air Force for Financial Management and Comptroller

(SAF/FM) shall:

2.2. Assistant Secretary of the Air Force for Installations, Environment and Logistics

(SAF/IE) shall:

2.3. Deputy Chief of Staff for Logistics, Installations, and Mission Support (AF/A4/7) shall:

2.4. Deputy Chief of Staff for Operations, Plans and Requirements (AF/A3/5) shall: . 12

2.5. Commander, AF Materiel Command (AFMC/CC) shall:

2.6. Lead/Using Commands shall:

2.7. (Added-AFMC) Commander, Air Force Life Cycle Management Center

(AFLCMC/CC) shall:

2.8. (Added-AFMC) Commander, Air Force Sustainment Center (AFSC/CC) shall: . 19

CHAPTER 3—DEPOT MAINTENANCE MANAGEMENT PROCESSES 22

3.1. Business Planning Process (BPP)

3.2. Depot Maintenance Activation

3.3. Depot Maintenance Workload Transition

3.4. Capital Investment

3.5. Depot Manufacturing

3.6. Depot Maintenance Strategic Planning

4 AFI21-102_AFMCSUP_I 19 DECEMBER 2014

3.7. (Added-AFMC) Requirements Review and Depot Determination (R2D2) Process.

3.8. (Added-AFMC) Depot Maintenance Plant Management

CHAPTER 4—DEPOT PURCHASED EQUIPMENT MAINTENANCE 31

4.1. Equipment Maintenance

4.2. Purpose

4.3. AFMC

4.4. DPEM Process Overview:

Table 4.1. Commodity Groups/Repair Group Categories

CHAPTER 5—SAFETY 36

5.1. General Safety Guidance

5.1. (AFMC) Engineering controls, rather, than PPE:

5.2. Air Force Occupational, Safety, and Health (AFOSH) Guidance

CHAPTER 6—DEPOT MAINTENANCE SUPPORT 37

6.1. Depot Maintenance Production Support

6.1. (AFMC) AFLCMC:

6.2. Depot Maintenance Supply Support and Materiel Control

CHAPTER 7—WORK CONTROL DOCUMENTS AND TECHNICAL DATA 44

7.1. Work Control Documents (WCD)

7.2. Standard Depot Maintenance Program

7.2. (AFMC) AFSC shall:

CHAPTER 8—QUALITY ASSURANCE (QA) 46

8.1. General

8.1. (AFMC) AFSC shall:

8.2. Maintenance Standardization and Evaluation Program (MSEP)

8.3. Quality Assurance Program

8.3. (AFMC) Quality Assurance Program

8.4. Activity Inspection Program

8.4. (AFMC) Activity Inspection Program

8.5. Additional Quality Programs

8.5. (AFMC) AFSC shall:

8.6. (Added-AFMC) Depot Maintenance QA Responsibilities

AFI21-102_AFMCSUP_I 19 DECEMBER 2014 5

8.7. (Added-AFMC) Dull Sword Investigation and Reporting

8.8. (Added-AFMC) Joint Deficiency Reporting

CHAPTER 9—IMPOUNDMENT PROCEDURES 57

9.1. Aircraft, Major End Item, and Equipment Impoundment

9.2. Impoundment Terms and Responsibilities:

9.3. Impoundment Program

9.3. (AFMC) AFSC shall:

9.4. Reasons for Impoundment of Aircraft, Major End Item, or Equipment

9.5. Impoundment Process and Procedures

9.5. (AFMC) AFSC shall:

CHAPTER 10—TOOL AND EQUIPMENT MANAGEMENT 60

10.1. Tool and Equipment Management

10.1. (AFMC) AFSC shall:

10.2. Industrial Shop Machinery Accessories/Attachments

10.3. Tool Marking Procedures

Table 10.1. ALC/Aircraft Maintenance and Regeneration Group (AMARG) ID Number

Marking Codes

10.4. (Added-AFMC) Training

CHAPTER 11—MAINTAINING COMMERCIAL DERIVATIVE AIRCRAFT 63

11.1. Background Information and Objective

11.2. Certification Requirements

11.3. Inspection Requirements

11.4. Deviations from Inspection Requirements

11.5. Component Overhaul and Time Change Intervals

11.6. Airframe Overhaul

11.7. Aircraft and Component Modifications

11.8. Aircraft and Component Modifications

CHAPTER 12—AIRCREW EGRESS SYSTEMS MAINTENANCE 65

12.1. Egress Maintenance Program

12.1. (AFMC) AFSC shall:

12.2. Facilities

12.3. Safety Requirements

12.4. Classification Training

6 AFI21-102_AFMCSUP_I 19 DECEMBER 2014

12.5. Initial Certification of Egress and Non-Egress Personnel Who Augment Egress

Technicians or Perform Quality Assurance Evaluations of Egress Systems

12.6. Decertification

12.7. Recertification

12.8. Using Newly Assigned Uncertified Egress Personnel

12.9. Egress/Cockpit Familiarization Training

12.10. Egress Systems Inspections and Documentation

12.11. Cannibalization actions

CHAPTER 13—ADDITIONAL PROGRAM REQUIREMENTS 68

13.1. Aircraft and Equipment Decontamination

13.2. Housekeeping

13.3. Aircraft Grounding (Materiel Defect) Program

13.3. (AFMC) AFSC shall:

13.4. Cannibalization Program

13.5. Dropped Object Prevention (DOP) Program

13.5. (AFMC) HQ AFMC/A4:

13.6. Foreign Object Damage (FOD) Prevention Program

13.6. (AFMC) There are two categories of FO areas:

13.7. Communications

13.8. Maintenance Recovery Teams (MRTs)

13.9. Self-Inspection Program

13.10. Senior Leaders’ Maintenance Course (SLMC)

13.11. Maintenance Training

13.12. Maintenance Certification Program

13.13. Special Skills Qualifications (SSQs)

13.13. (AFMC) AFSC shall:

13.14. Special Certification Roster (SCR)

13.14. (AFMC) AFSC shall:

13.15. Functional Check Flight (FCF) Program

13.16. Weight and Balance (W&B) Program

13.16. (AFMC) AFSC shall:

13.17. Aircraft Structural Integrity Program (ASIP)

13.17. (AFMC) AFSC shall:

AFI21-102_AFMCSUP_I 19 DECEMBER 2014 7

13.18. Repair Network Integration (RNI) [RESERVED]

13.18. (AFMC) Repair Network Integration (RNI)

13.19. (Added-AFMC) Engine Management

13.20. (Added-AFMC) Maintenance Operations Center (MOC)

13.21. (Added-AFMC) Depot Field Team (DFT)

13.22. (Added-AFMC) Aerospace Vehicle Distribution Officer (AVDO)

13.23. (Added-AFMC) Test Cells and Hush Houses

13.24. (Added-AFMC) Aircraft Battle Damage Repair (ABDR)

13.25. (Added-AFMC) Commercial Calibration Services

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 83

Attachment 1—(AFMC) GLOSSARY OF REFERENCES AND SUPPORTING

INFORMATION 93

Attachment 2—(Added-AFMC) DROPPED OBJECT PREVENTION (DOP) PROGRAM

REPORT 100

Attachment 3—(Added-AFMC) FOREIGN OBJECT DAMAGE (FOD) REPORT 101

8 AFI21-102_AFMCSUP_I 19 DECEMBER 2014

Chapter 1

DEPOT MAINTENANCE MANAGEMENT

1.1. Depot Maintenance. This instruction provides guidance for the management of AF depot maintenance. The AF maintains three organic depots, all within Air Force Materiel Command.

This AFI requires AFMC to develop, implement, and sustain AF depot maintenance.

1.1. (AFMC)AFMC shall: Provide command level policy, guidance, and staff coordination for all activities required to operate depot maintenance activities for Air Force weapon systems.

1.1.1. (Added-AFMC) AFMC units performing F-35 depot maintenance activities may use

Time Compliance Technical Data (TCTD).

1.1.1.1. (Added-AFMC) TCTDs are F-35 joint program instructions provided by the

Joint Program Office (JPO). They are developed with Service/Partner participation and provide source documentation for Air Force repair instructions specific to the F-35.

1.2. Aircraft and Equipment Readiness. Aircraft and equipment readiness is the maintenance mission. The maintenance function ensures assigned aircraft and equipment are safe, serviceable, and properly configured to meet mission needs. Maintenance actions include, but are not limited to, inspecting, repairing, overhauling, modifying, preserving, refurbishing, troubleshooting, testing, and analyzing condition and performance. Supervisors must emphasize safety, quality, and timeliness in the performance of maintenance. The concept of quality maintenance must be fostered by each supervisor and technician to ensure the integrity and skill of maintainers are not degraded. To the greatest extent possible, maintenance is accomplished on a preplanned scheduled basis. Planning provides the most effective and efficient use of people, facilities, and equipment, reduces unscheduled maintenance, and allows for progressive actions toward maintaining and returning aircraft and equipment to safe operating condition. Conducting a bench check of components and proper control of repair cycle assets throughout the maintenance cycle are also critical elements of the equipment maintenance program. AF units must implement and manage the tasks specified in the scheduled program for their assigned aircraft and associated support equipment (SE). Preventive maintenance concepts are described in

Technical Order (TO) 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures, and TO 00-25-108, Communications-Electronics Depot Support.

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

1.4. Technical Orders (TOs). AF TOs are published under the authority of the Secretary of the

Air Force (SECAF). Compliance with TOs is mandatory, except as explained in TO 00-5-1, AF

Technical Order System.

1.5. Modification Management. A modification proposal is a recommendation to alter the form, fit, function, or interface of an item, subsystem, or system. Refer to AFI 63-131, Modification Program Management, for modification management procedures.

AFI21-102_AFMCSUP_I 19 DECEMBER 2014 9

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

MIS will be accomplished IAW TO 00-20-2, Maintenance Data Documentation. MIS systems are clearly defined in TOs 00-20-1, 00-20-2, and 00-20-3, Maintenance Processing of Reparable

Property and the Repair Cycle Asset Control System. Non-maintenance systems are considered management information systems which follow guidelines under separate AFIs.

1.7. Nuclear Weapons Related Materiel (NWRM). The accomplishment of depot maintenance on NWRM items, whether at organic or contract (commercial) sites, shall comply with AFI 20-110, Nuclear Weapons-Related Materiel Management.

1.8. Duty Shifts and Rest Periods. Depot maintenance personnel shall have their duty hours aligned to provide the best mission support. Civil service employee work hours are governed by the collective bargaining agreement and its local supplement and federal and state laws.

Contracted civilian employee work hours are governed by the contract, federal, and state laws.

Consider union requirements and climatic conditions when determining work schedules; local work/rest schedules for extreme temperatures are recommended by the Medical Group commander.

1.9. Civilian Visitors. Units shall not permit civilian visitors to operate any AF equipment or specialized vehicles. Civilian employees, contractor employees, and other civilian personnel who must operate AF equipment as part of their assigned duties are not considered civilian visitors.

1.10. Statutory Framework. Title 10 of the United States Code contains a number of sections addressing depot maintenance. The paragraphs below identify selected applicable code sections.

NOTE: When necessary, authoritative interpretations or explanations of Title 10 provisions should be requested from the appropriate functional legal office.

1.10.1. Depot maintenance and repair is defined in Title 10, United States Code (USC) §

2460, Definition of depot-level maintenance and repair. It is defined as any action performed on materiel or software in the conduct of inspection, repair, overhaul, or the modification or rebuild of end-items, assemblies, subassemblies, and parts that requires extensive industrial facilities, specialized tools and equipment, or uniquely experienced and trained personnel that are not available in lower echelon-level maintenance activities, and is a function and, as such, is independent of any location or funding source and may be performed in the public or private sectors (including the performance of interim contract support or contract logistic support arrangements). Depot-level maintenance and repair also includes the fabrication of parts, testing, and reclamation, as necessary; the repair, adaptive modifications or upgrades, changes events made to operational software, integration and testing; and in the case of either hardware or software modifications or upgrades, the labor associated with the application of the modification.

1.10.2. Title 10, USC § 2464, Core depot-level maintenance and repair capabilities, defines the requirements for organic depot maintenance capabilities. Core depot maintenance are those which are necessary to maintain and repair the weapon systems and other military equipment (including mission-essential weapon systems or materiel), not later than four years after achieving initial operational capability, but excluding systems and equipment under special access programs, nuclear aircraft carriers, and commercial items. These capabilities

10 AFI21-102_AFMCSUP_I 19 DECEMBER 2014

are identified by the Secretary of Defense, in consultation with the Chairman of the Joint

Chiefs of Staff, as necessary to enable the armed forces to fulfill the strategic and contingency plans prepared by the Chairman of the Joint Chiefs of Staff. Core depot maintenance capabilities are discussed in detail in Department of Defense (DoD) Instruction

4151.20, Depot Maintenance Core Capabilities Determination Process.

1.10.3. Title 10, USC § 2466, Limitations on the performance of depot-level maintenance of materiel, (the 50/50 rule) requires not more than 50 percent of the funds made available in a fiscal year (FY) to a military department or a Defense Agency for depot-level maintenance and repair workload may be used to contract for the performance by non-Federal

Government personnel of such workload for the military department or the Defense Agency.

Any such funds that are not used for such a contract shall be used for the performance of depot-level maintenance and repair workload by employees of the DoD.

1.10.4. Title 10, USC §2469, Contracts to perform workloads previously performed by depot-level activities of the Department of Defense: requirement of competition, (the $3

Million Rule) requires that depot-level maintenance and repair workloads that have a value of not less than $3,000,000 (including the cost of labor and materials), that is being performed by a depot-level activity of the DoD, may not be changed to performance by a contractor or by another depot-level activity of the DoD, unless the change is made using merit-based selection procedures (for competitions among all depot-level activities of the

DoD) or competitive procedures (for competitions among private and public sector entities.)

Office of Management and Budget Circular A-76 does not apply to performance changes under this section.

1.10.5. Title 10, USC §2472, Prohibition on management of depot employees by end strength, requires that civilian DoD employees (including AF personnel) who perform, or are involved in the performance of depot-level maintenance and repair workloads, may not be managed on the basis of any constraint or limitation in terms of man-years, end strength, full-time equivalent positions, or maximum number of employees. These employees shall be managed solely on the basis of the available workload and the funds made available for such depot-level maintenance and repair.

1.10.6. Centers of industrial and technical excellence (CITEs) are addressed in Title 10, USC

§ 2474, Centers of Industrial and Technical Excellence: designation; public-private partnerships. Within the AF, the SECAF has designated three depot maintenance activities as CITEs: Oklahoma City Air Logistics Center (ALC), Ogden ALC, and Warner Robins

ALC. CITEs shall engineer industrial processes and adopt best-business practices in connection with their core competency requirements in order to serve as leaders in their core competencies throughout the DoD and in the national technology and industrial base. CITEs are also permitted to enter into public-private partnerships (PPPs) with private industry or other entities outside the DoD. PPPs are discussed in detail in DoDI 4151.21, Public-Private

Partnerships for Depot-Level Maintenance.

1.10.7. Title 10, USC § 2476, Minimum capital investments for certain depots, (the 6%

Rule) discusses the minimum capital investment requirements for certain depots. It requires that each FY, the Secretary of a military department shall invest in the capital budgets of the covered depots of that military department a total amount equal to, but not less than, six percent of the average total combined workload funded at all the depots of that military

AFI21-102_AFMCSUP_I 19 DECEMBER 2014 11

department for the preceding three FYs. The capital budget of a depot is defined as including

“investment funds spent on depot infrastructure, equipment, and process improvement in direct support of depot operations.”

1.11. (Added-AFMC) Metrics and Reporting. AFSC will develop and provide metrics and reports to higher headquarters as requested. The broad metrics areas include, but are not limited to, Functional Check Flight (FCF) performance, financial, production, quality, manpower, training, capacity, capability, and infrastructure. Each of these broad categories may contain significant numbers of sub-metrics that are useful for depot operations. Standard metrics will be directed as needed in specific data calls and guidance from higher headquarters.

12 AFI21-102_AFMCSUP_I 19 DECEMBER 2014

Chapter 2

ROLES AND RESPONSIBILITIES

2.1. Assistant Secretary of the Air Force for Financial Management and Comptroller

(SAF/FM) shall:

2.1.1. Establish AF budget policies and procedures, to include budget formulation, justification, and execution of Depot Purchased Equipment Maintenance (DPEM).

2.1.2. Establish and maintain financial management structures to determine funding priorities, to approve financial plans, and to ensure that funding resources are allocated and executed legally, effectively, and efficiently.

2.1.3. Issue operation and maintenance (O&M) direct funding/budget authority when

Congress enacts the DoD appropriations.

2.1.4. Ensure obligations recorded by 30 September are valid and efficiently used to meet the AF's operational requirements.

2.2. Assistant Secretary of the Air Force for Installations, Environment and Logistics

(SAF/IE) shall:

2.2.1. Provide policy for depot maintenance and for depot reporting requirements.

2.2.2. Collaborate with SAF/FM in developing appropriate budget exhibits and documentation to support the Planning, Programming, Budgeting and Execution (PPBE) process.

2.2.3. Coordinate financial planning, requirements, and budget estimates (including changes in the DPEM funding positions) with associated mission panels.

2.2.4. Validate/defend justification of maintenance requirements and budget estimates.

2.2.5. Report depot figures for DoD reporting requirements.

2.2.6. Develop an AF Depot Maintenance Strategy IAW Chapter 3 of this Instruction.

2.3. Deputy Chief of Staff for Logistics, Installations, and Mission Support (AF/A4/7) shall:

2.3.1. Assist SAF/IE in providing guidance on the requirements generation process for financial planning and budget estimates.

2.3.2. Assist SAF/IE in coordinating financial planning, requirements, and budget estimates.

2.3.3. Assist SAF/IE in validating/defending justification of maintenance requirements and budget estimates.

2.3.4. Develop guidance for the management of depot maintenance.

2.3.5. Support SAF/IE in development of the AF Depot Maintenance Strategy IAW Chapter

3 of this Instruction.

2.4. Deputy Chief of Staff for Operations, Plans and Requirements (AF/A3/5) shall:

2.4.1. Provide the force structure contingency scenarios in an unclassified electronic media to SAF/IE, AF/A4/7 and AFMC/CC.

AFI21-102_AFMCSUP_I 19 DECEMBER 2014 13

2.5. Commander, AF Materiel Command (AFMC/CC) shall:

2.5.1. Ensure development, implementation, and sustainment of the capability necessary to satisfy depot maintenance requirements for AF managed equipment.

2.5.1.1. Develop a logistics requirements determination process for determining and prioritizing requirements. Ensure the process is integrated, standardized, and repeatable, and that it allows trade-offs for optimization at the AF enterprise level.

2.5.2. Develop and implement depot maintenance strategies, plans, and procedures, and collect and report data to satisfy statutory requirements, including:

2.5.2.1. Core logistics capability IAW Title 10, USC § 2464, Core logistics capabilities.

2.5.2.2. 50/50 stipulations and data reporting IAW Title 10, USC § 2466, Limitations on the performance of depot-level maintenance of materiel.

2.5.2.3. CITEs and PPPs IAW Title 10, USC § 2474, Centers of Industrial and Technical

Excellence: designation; public-private partnership.

2.5.3. Develop and implement a process for assessing organic depot maintenance workload requirements and for making depot maintenance source of repair (DSOR) recommendations for non-Core workloads and source of repair decisions IAW AFI 63-101.

2.5.3.1. Assess availability of existing DoD depot capabilities that will satisfy additional

AF requirements versus establishing new organic ALC capability or contract support.

2.5.3.2. Ensure development of dual DoD depot sources of repair within an area of responsibility and/or the need for multiple repair sources are justified and documented.

2.5.3.3. Ensure establishment or major expansion of overseas Government depot maintenance facilities is justified and documented. Ensure a continental United States

(CONUS) repair source for each item is supported. (NOTE: The backup DSOR for all overseas workload programs is the CONUS DSOR.)

2.5.4. Develop financial planning and prepare budgets for depot maintenance requirements.

2.5.4.1. Provide funding for depot maintenance requirements through the PPBE including the program objectives memorandum (POM) and the annual planning and programming guidance (APPG) processes.

2.5.4.2. Develop and implement a productivity and work specification procedure to ensure performance to budget.

2.5.5. Provide processes to determine and substantiate depot maintenance workload.

2.5.6. Modernize depot facilities, processes, and equipment through the use of new technologies, production enhancements, and development of consolidated support facilities.

2.5.6.1. Review existing depot capabilities for capital equipment investments to modernize, replace, or update.

2.5.6.2. In collaboration with Program Managers (PMs)/Product Support Managers

(PSMs)/Product Group Managers (PGMs), ensure capital investment actions are accomplished to provide for depot maintenance activities.

14 AFI21-102_AFMCSUP_I 19 DECEMBER 2014

2.5.7. Implement procedures to assess processes for improvement and to ensure technical orders contain all data required to execute depot maintenance and demilitarization requirements.

2.5.8. Have a surge contingency plan that provides:

2.5.8.1. Guidance and procedures for a responsive capability to accelerate, surge, or compress depot maintenance or modifications.

2.5.8.2. Procedures for approval or disapproval from the requesting PM of AFMC’s projection of cost/impacts.

2.5.9. Ensure robust corrosion prevention and control execution for fielded assets.

2.5.9.1. Collect and report corrosion related cost data as required by the AF Corrosion

Control and Prevention Executive.

2.5.9.2. Develop funding forecasts to mitigate newly discovered corrosion problem areas.

2.5.9.3. Support PM/PSM/PGM and cognizant engineering authority in developing substitution strategies for hazardous and expanded standards chemicals (to include Cd, Cr

6+, strontium chromate, lead, etc.).

2.5.10. Employ serialized item management (SIM) techniques. SIM is enabled through Item

Unique Identification (IUID), automatic identification technology (AIT), automated information systems (AIS), and radio frequency identification (RFID).

2.5.11. Implement a process to control and document cannibalizations (CANN). Establish written guidance on individual responsibilities and specific procedures for cannibalization actions IAW Chapter 13 of this Instruction.

2.5.12. Establish and sustain calibration capability to support maintenance requirements for depot maintenance activities.

2.5.13. Ensure depot activities document and report: flying hours; equipment inventory, status, and utilization; and equipment reliability and maintainability deficiencies and/or improvements. (Refs: AFI 21-103, Equipment Inventory, Status, and Utilization Reporting;

AFI 21-118, Improving Air and Space Equipment Reliability and Maintainability; and TO

00-20-2.)

2.5.14. Ensure a Maintenance Standardization and Evaluation Program (MSEP) is established IAW Chapter 8 of this Instruction.

2.5.15. Allocate resources to meet all mission requirements. Ensure the maintenance organizations are not overly tasked with augmentation duties outside maintenance functional areas.

2.5.16. Accomplish depot maintenance activation and business planning. Support development of depot maintenance requirements and planning for new system acquisitions.

2.5.17. Implement AF depot maintenance transition plans and manufacturing process procedures.

AFI21-102_AFMCSUP_I 19 DECEMBER 2014 15

2.5.18. Maintain accurate data on Core, 50/50, and PPP for data call reporting from

Headquarters Air Force (HAF).

2.5.19. Identify contract partnership workload that is CITE-related and validate the DSOR decision for contract versus organic CITE support.

2.5.20. Implement a process through which depot maintenance activities can request and receive engineering disposition for nonconforming technical problems that are outside published authority and new/revised procedures to facilitate equipment troubleshooting and repair procedures under work stoppage or anticipated work stoppage conditions.

2.5.21. Implement procedures and training for successful execution of DPEM.

2.5.21.1. Schedule and distribute annual memorandums announcing the DPEM process meeting.

2.5.21.2. Publish an annual timeline and calendar of DPEM events that will ensure timely identification, validation, consolidation, and review of requirements in order to satisfy the timetable of HAF PPBE events.

2.5.21.3. Establish processes and lead development and management of maintenance requirements work packages (MRWP) in collaboration with PMs and using commands.

2.5.21.4. Provide guidance on the requirements generation process for DPEM across all the categories of commodities. Articulate the relationship between DPEM requirement and levels of funding and the impact of the unfunded requirement on work deferred and operational readiness.

2.5.21.5. Ensure timely execution and tracking of obligations of DPEM funding.

2.5.22. Establish an Aircraft and Equipment Decontamination Program IAW Chapter 13 of this Instruction.

2.5.23. Establish Foreign Object Damage (FOD) and Dropped Object Prevention (DOP)

Programs IAW Chapter 13 of this Instruction.

2.5.24. Establish a radiation protection program IAW Air Force Occupational Safety and

Hea…