afrli21-101.pdf

BY ORDER OF THE COMMANDER

AIR FORCE RESEARCH LABORATORY

AIR FORCE RESEARCH LABORATORY

INSTRUCTION 21-101

19 FEBRUARY 2015

Maintenance

LOGISTICS MAINTENANCE

MANAGEMENT

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

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

RELEASABILITY: There are no restrictions on this publication

OPR: AFRL/DSO

Supersedes: AFRLI 21-101, 7 July 2010;

AFRLI 21-102, 1 June 2010;

AFRLI 21-103, 3 May 2010;

AFRLI 21-104, 1 December 2009;

AFRLI 21-105, 2 June 2010;

AFRLI 21-107, 9 April 2010

Certified by: AFRL/DS

(Colonel Jon Yost)

Pages: 66

This instruction implements AFI 21-101, Aircraft and Equipment Maintenance Management, Technical Order (TO) 00-5-1, AF Technical Order System, TO 00-20-1, Aerospace Equipment

Maintenance Inspection, Documentation, Policy and Procedures, TO 00-20-14, Air Force

Metrology and Calibration Program, TO 00-25-234, General Shop Practice Requirements for the Repair, Maintenance, and Test of Electrical Equipment, Section VII, Electrostatic Discharge

Control and American National Standards Institute/Electrostatic Discharge (ANSI/ESD) S20.20, Protection of Electrical and Electronic Parts, Assemblies and Electronic Parts, Assemblies and

Equipment (excluding electrically initiated explosive device). This instruction is the basic Air

Force directive for maintenance management in the Air Force Research Laboratory (AFRL) and it provides the minimum basic maintenance-related concepts and programs for all levels within

AFRL. It applies to all AFRL personnel working in research, manufacturing, test, development, and integration laboratories including work centers used by Research, Development, Test, and

Evaluation (RDT&E)-funded portions of AFRL organizations and their contractors on AF property and by RDT&E-funded AFRL personnel off AF property. Any person or function that does not perform work in research, manufacturing, test, development, and integration laboratories and work centers is not bound by this instruction. This publication may be supplemented at any level, but all direct supplements must be routed to the office of primary http://www.e-/

2 AFRLI21-101 19 FEBRUARY 2015

responsibility (OPR) of this publication for coordination prior to certification and approval.

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. Requests for waivers must be processed through command channels to the publication OPR for consideration.

Ensure that all records created as a result of processes prescribed in this publication are maintained IAW Air Force Manual (AFMAN) 33-363, Management of Records, and disposed of

IAW Air Force Records Information Management System (AFRIMS) Records Disposition

Schedule.

SUMMARY OF CHANGES

This document is substantially revised and must be completely reviewed. AFRLI instructions

21-101, Tools and Equipment, 21-102, General Logistics Responsibilities, 21-103, Quality

Assurance, 21-104, Technical Data Management, 21-105, Foreign Object Damage (FOD) and

21-107, Electrostatic Discharge (ESD) have been combined into AFRLI 21-101. AFRLI 21-101 has been renamed to Logistics Maintenance Management. Chapter 2, paragraph 2.2, Center certification official for logistics policy changed from the AFRL Vice Commander to the Chief of Staff. Chapter 2, paragraph 2.3, Senior Logistic Manager (SLM) changed to Center

Logistics Manager (CLM), SLM responsibilities rolled into Quality Assurance (QA)

Superintendent responsibilities, and requirement to update Logistics Standardization and

Evaluation Program (LSEP) changed from semi-annual to annual. Chapter 2, paragraph 2.4, Detachment Commander responsibilities reduced significantly. Detachment Commanders only responsible for establishing policy and procedures for the site and ensure a quality assurance superintendent is appointed. Chapter 2, paragraph 2.6, logistics manager changed to technology directorate/711th Human Performance Wing (HPW) level position. This position will work closely with the QA Superintendent instead of the SLM, this position also responsible for tool control oversight. Chapter 2, paragraph 2.8, added specific responsibilities for branch chiefs. Chapter 3, paragraph 3.2, previous QA Chief Inspector and SLM responsibilities rolled into Quality Assurance Superintendent responsibilities. Chapter 4, includes new procedure for handling proprietary data. Chapter 5, composite tool kit (CTK) custodian signs the master inventory lists , not the branch chief. Chapter 6, Detachment foreign object damage (FOD) monitor position removed, the TD/711 HPW FOD monitor now reporting to HQ AFMC

Maintenance Division (AFMC/A4). Wright Research Site (WRS) was replaced with Wright

Patterson AFB (WPAFB).

Chapter 1—MANAGEMENT PHILOSOPHY AND POLICIES 6

1.1. This instruction prescribes the basic programs and responsibilities to be used in

AFRL and provides government employees on/off AF property and contract employees on AF property with direction for accomplishment of logistics/maintenance management

1.2. Compliance Terminology

1.3. Waiver Request

AFRLI21-101 19 FEBRUARY 2015 3

Chapter 2—GENERAL RESPONSIBILITIES 7

2.1. This chapter outlines responsibilities for key leaders and personnel involved in maintenance activities

2.2. AFRL Director of Staff (AFRL/DS)

2.3. AFRL Center Logistics Manager (CLM) (AFRL/DSO)

2.4. Detachment Commander (DET CC)

2.5. 711th Human Performance Wing Commander (711 HPW/CC) and Technology

Director

2.6. TD/711 HPW Logistics Manager (LOG MGR)

2.7. Division Chief

2.8. Branch Chief

2.9. Logistics Operations (LOG OPS) Personnel

2.10. Operator or User

Chapter 3—QUALITY ASSURANCE (QA) 14

3.1. General

3.2. Quality Assurance Superintendent (QA Supt) Responsibilities

3.3. Quality Assurance Inspector Responsibilities

3.4. Logistics Standardization and Evaluation Program (LSEP)

3.5. Evaluation and Inspection (E&I) Plan

3.6. QA Training

3.7. Conducting Evaluations

3.8. AFRL-Approved QA Database

3.9. QA Monthly Summary

Chapter 4—TECHNICAL DATA MANAGEMENT 18

4.1. General

4.2. Center TODO (CTODO)

4.3. TODO

4.4. TDS Users

4.5. Technical Data System (TDS)

4.6. Time Compliance Technical Order (TCTO) Process

Chapter 5—TOOL AND EQUIPMENT MANAGEMENT 22

5.1. Overview

5.2. CTK Custodian

4 AFRLI21-101 19 FEBRUARY 2015

5.3. CTK/Tool User

5.4. General Program Requirements

5.5. CTK Construction, Organization and Contents

5.6. CTK Security

5.7. CTK Documentation

5.8. Laboratory/Shop Equipment and Accessories

5.9. Marking of Tools and Equipment

5.10. Tool Accountability and Control

5.11. Annual Tool Inventories

5.12. Tool Replacement Procedures

5.13. Spare Tool Management

5.14. Lost/Missing Tool/Item Procedures

5.15. Training

5.16. Locally Manufactured, Developed, or Modified Tools and Equipment

Chapter 6—FOREIGN OBJECT DAMAGE (FOD) PREVENTION 32

6.1. To prevent FOD to research/test articles/equipment

6.2. TD/711 HPW FOD Monitor

6.3. Personnel in FOD-Critical Areas

6.4. CTKs Supporting FOD-Critical Areas

6.5. Lost/Missing Tool/Item Procedures for FOD-Critical Areas

6.6. FOD-Related Incident Reporting Procedures

Chapter 7—ELECTROSTATIC DISCHARGE (ESD) CONTROL PROGRAM 34

7.1. This chapter defines the ESD control program and processes applicable in all research and laboratory areas; to prevent damage to ESDS items, equipment, and operational assets

7.2. ESD POC

7.3. ESD User

7.4. ESD Training

7.5. ESD Control Surveys

7.6. Periodic ESD Testing

Chapter 8—ADDITIONAL REQUIREMENTS AND PROGRAMS 37

8.1. 6S Process

8.2. Special Certification Roster (SCR) Memorandum

AFRLI21-101 19 FEBRUARY 2015 5

Table 8.1. Mandatory Special Certification Requirements and Prerequisites

8.3. Explosive Safety and Security of Explosives

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 39

Attachment 2—WAIVER/CHANGE REQUEST FORMAT 45

Attachment 3—AFSO 21 6S PRIMER 46

Attachment 4—QA SAMPLING PLAN 48

Attachment 5—COMPLETION INSTRUCTIONS FOR AFMC FORM 61 50

Attachment 6—COMPLETION INSTRUCTIONS FOR AFMC FORM 62 51

Attachment 7—COMPLETION INSTRUCTIONS FOR AF FORM 3126 52

Attachment 8—STANDARD MIL FORMAT 53

Attachment 9—INDEXED MIL FORMAT 56

Attachment 10—COMPLETION INSTRUCTIONS FOR NON-CTK EQUIPMENT SIGN

OUT SHEET 59

Attachment 11—AFRL EID CONVENTION 60

Attachment 12—COMPLETION INSTRUCTIONS FOR DISTRIBUTED CTK

INDIVIDUAL ITEM TRACKING LOG 61

Attachment 13—LOCALLY MANUFACTURED/MODIFIED TOOLS (LMT)

MEMORANDUM FORMAT 62

Attachment 14—COMPLETION INSTRUCTIONS FOR AFMC FORM 310 (FOR FOD

CRITICAL AREAS ONLY) 63

Attachment 15—AFRL FORM 30, ESD CONTROL SURVEY/ CERTIFICATION 66

6 AFRLI21-101 19 FEBRUARY 2015

Chapter 1

MANAGEMENT PHILOSOPHY AND POLICIES

1.1. This instruction prescribes the basic programs and responsibilities to be used in AFRL and provides government employees on/off AF property and contract employees on AF property with direction for accomplishment of logistics/maintenance management. It applies to all laboratories and work centers involved in manufacturing, maintenance, integration and RDT&E.

1.2. Compliance Terminology. For the purposes of this instruction, the following definitions apply:

1.2.1. Shall, Must, Will. Indicate mandatory requirements (“will” is also used to express a declaration of purpose for a future event.).

1.2.2. Should. Indicates a preferred method of accomplishment.

1.2.3. May. Indicates an acceptable or suggested means of accomplishment.

1.3. Waiver Request. Any waivers to this or higher headquarters’ directives shall be processed

IAW the specific policy directive. If no specific form or format is specified, submit waiver requests through the 711th Human Performance Wing Commander (711 HPW/CC) or

Technology Director for staffing to the Quality Assurance Superintendent (QA Supt) using the template in Attachment 2. The QA Supt will submit the waiver request to AFRL Center

Logistics Manager (CLM), AFRL/DSO for staffing to the AFRL Chief of Staff (AFRL/DS) and staffing to higher headquarters, as applicable.

AFRLI21-101 19 FEBRUARY 2015 7

Chapter 2

GENERAL RESPONSIBILITIES

2.1. This chapter outlines responsibilities for key leaders and personnel involved in maintenance activities.

2.2. AFRL Director of Staff (AFRL/DS). The AFRL/DS is responsible to ensure policy and procedures are established for AFRL. The AFRL/DS will:

2.2.1. Approve the annual Logistics Standardization and Evaluation Program (LSEP).

2.3. AFRL Center Logistics Manager (CLM) (AFRL/DSO). The AFRL/DSO CLM will:

2.3.1. Make recommendations to AFRL/DS to enhance the effectiveness of logistics operations.

2.3.2. Update the LSEP annually in conjunction with the QA offices. Ensure the LSEP is posted in the AFRL Enterprise Business System (EBS).

2.4. Detachment Commander (DET CC). The DET CC is responsible to ensure policy and procedures are established for the site. The DET CC will appoint the site QA Supt in writing.

2.4.1. The DET CC at Maui and Ft. Sam will not appoint a QA Supt. These geographically separated units (GSUs) will be supported by the QA Supt at the parent unit’s location.

2.4.2. The QA Supt will not serve as a TD LOG MGR.

2.5. 711th Human Performance Wing Commander (711 HPW/CC) and Technology

Director. The 711 HPW/CC is responsible for the logistics process in the 711 HPW and the

Director is responsible for the logistics process in the TD. The 711 HPW/CC/Director may delegate responsibilities involving day to day functioning of work centers or laboratories. When a 711 HPW/CC/Director is not located on site, these responsibilities will be delegated to the site leadership. The 711 HPW/CC/Director will:

2.5.1. Establish a close working relationship with division chiefs to ensure an understanding of the requirements and capabilities of logistics actions.

2.5.2. Provide the necessary resources to support the logistics programs within their TD/711

HPW.

2.5.3. Appoint a LOG MGR in writing.

2.5.3.1. The LOG MGR will not also serve as a QA Supt or QA Inspector.

2.5.4. Appoint a foreign object damage (FOD) monitor in writing, which should be the LOG

MGR.

2.5.5. Ensure the TD/711 HPW System Safety Engineer (SSE) and the FOD monitor assess all work centers to identify potential FOD critical areas. The following areas are, by their nature, FOD-critical areas:

2.5.5.1. Work on or near the flight line.

2.5.5.2. Work on or near aircraft/engines.

8 AFRLI21-101 19 FEBRUARY 2015

2.5.5.3. Work on equipment designated to be installed on an aerospace vehicle.

2.5.6. Ensure Division Chiefs perform foreign object (FO) operational risk management

(ORM) assessments on any work center identified as a potential FOD critical area.

2.5.6.1. The 711 HPW/CC/Director is not restricted by FO ORM assessments from designating a work center as a FOD-critical area at their discretion.

2.5.6.2. The 711 HPW/CC/Director signs the FO ORM assessments and provides copies to the FOD monitor.

2.5.7. Ensure Test, Measurement and Diagnostic Equipment (TMDE) is maintained and managed IAW TO 00-20-14, Air Force Metrology and Calibration Program.

2.5.8. Ensure a tool control program is established IAW this instruction.

2.5.9. Ensure an Electrostatic Discharge (ESD) program is established IAW TO 00-25-234, General Shop Practice Requirements for the Repair, Maintenance, and Test of Electrical

Equipment, and this instruction.

2.5.9.1. Appoint an ESD point of contact (POC) in writing.

2.5.10. Ensure necessary technical data is available to TD/711 HPW personnel.

2.5.11. Ensure site QA Inspectors have as much unrestricted access as possible to all TD/711

HPW areas.

2.5.12. Ensure support equipment (SE) is maintained and managed IAW TO 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policy and Procedures.

2.5.13. Ensure the 6S process is implemented within their TD/711 HPW; ensure personnel implement and support the 6S Process (Attachment 3).

2.5.14. Ensure general housekeeping, safety, security, equipment accountability, vehicle management, environmental control and Air Force Occupational Safety and Health Standards

(AFOSHSTDS) are followed.

2.5.15. (Wright-Patterson AFB only) The RQ Director will appoint the WPAFB QA Supt in writing on behalf of the AFRL/CC.

2.5.15.1. The WPAFB QA Supt will support the 711 HPW and WPAFB TDs.

2.5.15.2. The WPAFB QA Supt will not serve as a TD LOG MGR.

2.6. TD/711 HPW Logistics Manager (LOG MGR). The LOG MGR is the primary logistics advisor to the 711 HPW/CC/Director, Division Chiefs, Branch Chiefs and TD/711 HPW personnel. Due to his role in policy implementation, the LOG MGR will not serve as a QA Supt or QA inspector. The LOG MGR will:

2.6.1. Be responsible for parent TD and GSU location logistics policy and procedures.

2.6.2. Work closely with the QA Supt to develop site policies and identify issues to resolve.

2.6.3. Oversee the TD/711 HPW logistics programs and provide direction to Logistics

Operations (LOG OPS) personnel who will:

2.6.3.1. Coordinate with the applicable division chiefs to ensure logistics processes and procedures are supportable within the TD/711 HPW.

AFRLI21-101 19 FEBRUARY 2015 9

2.6.3.2. Develop TD/711 HPW-specific policies and procedures to support AFRL/site policies, as needed.

2.6.3.3. Determine initial/recurring TD/711 HPW logistics training requirements.

2.6.4. Perform the following responsibilities at the TD/711 HPW level. These responsibilities may be delegated to the division-level Tool Control Manager (TCM), when assigned.

2.6.4.1. Oversee design of all composite tool kits (CTKs).

2.6.4.2. Develop procedures to assign the complete equipment identification designator

(EID) to the CTKs in the TD/711 HPW/Division.

2.6.4.3. Maintain copies of the following records (hard copy or electronic):

2.6.4.3.1. A current list of all CTK Custodians with appointment letters.

2.6.4.3.2. A current list of all TD/711 HPW CTK numbers.

2.6.4.3.3. A documented branch process for control of individually issued tools.

2.6.5. Ensure an effective technical data management process is established.

2.6.5.1. Assist users to determine if equipment items will require either TOs or commercial-off- the-shelf (COTS) manuals as tech data.

2.6.5.2. Develop specific procedures for personnel to notify the responsible Technical

Order Distribution Office (TODO) when new RDT&E/support equipment is brought into the laboratory or research areas.

2.6.6. Work with ESD POCs to interpret ESD policies and procedures. The Air Force ESD

Control Technology Center, Materials and Manufacturing Directorate, Materials Integrity

Branch (AFRL/RXSA) will be the final arbiter on questions relating to interpreting TO 00-

25-234.

2.6.7. Monitor and report status of logistics programs, as required.

2.6.8. Review QA and other management reports and assist TD/Wing leadership in determining the appropriate management actions to meet new workloads, target deficiencies and identify and correct root causes.

2.7. Division Chief. The Division Chief is responsible for the logistics process in the division.

Division Chiefs may delegate responsibilities involving day to day functioning of work centers or laboratories. The Division Chief will:

2.7.1. Appoint LOG OPS personnel, in writing, to effectively manage their responsible programs and areas. A copy of this appointment letter will be forwarded to the LOG MGR.

2.7.2. Manage special certification roster as outlined in this instruction.

2.7.3. Ensure an initial FOD awareness training and responsibilities briefing is given to all newly assigned personnel that work in or regularly traverse work centers conducting research, test, development, integration, or manufacturing.

2.7.4. Perform an FO ORM risk assessment in conjunction with the SSE, FOD monitor and

Branch Chief on any work center identified as a potential FOD critical area/process. The

10 AFRLI21-101 19 FEBRUARY 2015

assessment will be written, with supporting rationale, and submitted to the 711

HPW/CC/Director.

2.7.4.1. The risk assessment matrix in AFRLI 61-103, AFRL Research Test

Management, will be used for the FO ORM assessment.

2.7.4.2. Assess the FOD hazard probability category to the appropriate level.

2.7.4.3. A risk number of nine (9) or lower requires the area/process to be classified as

FOD critical and to implement FOD prevention controls.

2.7.4.4. The opinion of the Detachment Safety Chief will be the deciding factor when the assessment team members are divided on the risk number.

2.7.5. Ensure all FOD critical areas are identified during the safety review process at the beginning of a new program, research, experiment, etc.

2.7.5.1. At any time, a process or area can be declared FOD critical by the program’s senior researcher while the proper paperwork is processed.

2.7.5.2. Work centers shall not switch between FOD critical and non-FOD critical unless the mission changes and only with the written approval of the 711 HPW/CC/Director.

2.7.6. Ensure FOD critical areas are clearly marked with prominent signs.

2.7.7. Manage tool control program; ensure required CTKs, special tools and SE are available.

2.7.7.1. May appoint a division TCM in writing; forward a copy to the LOG MGR.

2.7.7.2. Appoint CTK Custodians in writing and forward a copy to the LOG MGR.

2.7.8. Implement the division’s ESD program IAW TO 00-25-234 and this instruction.

2.7.8.1. Appoint ESD POCs at the division, branch, work center, and laboratory area level where required to effectively manage the ESD program.

2.7.8.2. Ensure that all applicable support services contracts will include the requirement for in- house contractors to receive Government ESD training.

2.7.9. Enforce strict adherence to the use of current technical data and management procedures.

2.7.9.1. Ensure personnel have access to the Technical Data System (TDS) and the

Enhanced Technical Information Management System (ETIMS) as required.

2.7.9.2. Designate in writing government supervisors/managers authorized to grant access to restricted-access technical documents in TDS/ETIMS. Forward a copy of the approval letter to the LOG MGR and TODO. To add or delete government supervisors/managers, a new letter will be published.

2.7.9.3. Approve and sign the title page of locally developed procedures (LDPs) and calibration work instructions (CWIs). Prior to signing, ensure the LDP/CWI has been routed through any relevant offices for their coordination/approval: Safety, QA, Security, Scientific and Technical Information (STINFO), etc.

AFRLI21-101 19 FEBRUARY 2015 11

2.7.9.4. If the division includes a TODO, ensure the TODO is assigned in writing and has necessary training to perform all applicable TODO responsibilities.

2.7.9.5. Establish procedures for notifying the TODO to change TDS permissions and

ETIMS library access when personnel in-process, out-process or change positions within the organization.

2.7.10. Ensure personnel implement and support the 6S Process as implemented within their division.

2.7.11. Ensure general housekeeping, safety, security equipment accountability, vehicle management, environmental control and AFOSHSTDS are followed.

2.8. Branch Chief. The Branch Chief is responsible to the Division Chief for all logistics matters. Branch Chiefs may delegate responsibilities involving day to day functioning of work centers or laboratories. The Branch Chief will:

2.8.1. Enforce adherence to using current technical data and management procedures.

2.8.2. Ensure SE is maintained/managed IAW TO 00-20-1.

2.8.3. Review QA and other management reports to determine appropriate management actions to meet new workloads, target deficiencies and identify and correct root causes.

2.8.3.1. Review LSEP results and trends to target areas for improvement.

2.8.4. Establish and review requirements for vehicles, and ensure compliance with operation and maintenance procedures, as applicable.

2.8.5. Manage the branch’s responsibilities in the FOD Prevention Program.

2.8.5.1. Ensure FOD preventative measures are considered during the AFRL Safety

Permit process.

2.8.5.2. Participate in FO ORM assessments.

2.8.5.3. Ensure FOD prevention measures are implemented in all applicable branch work centers.

2.8.6. Ensure CTK management processes are followed.

2.8.6.1. All non-FOD critical CTKs will be signed open/close on a weekly interval. All

CTKs supporting FOD critical areas will be on a daily interval.

2.8.6.2. Ensure positive control and accountability is enforced for all assigned

CTKs/tools.

2.8.6.3. Determine the type, size, and numbers of CTKs for each work center.

2.8.6.4. Ensure personnel using CTKs receive initial tool control training. Verify that one-time training is documented.

2.8.6.5. Ensure CTKs are secured when not in use.

2.8.6.6. Ensure CTKs/equipment is stored in their assigned location.

2.8.6.7. Notify the LOG MGR/TCM when new/additional CTKs are required.

2.8.6.8. Manage a tool procurement process.

12 AFRLI21-101 19 FEBRUARY 2015

2.8.6.9. Ensure that appropriate personal protective equipment (PPE) is available and ready for use.

2.8.6.10. Approve all individually issued tools within the branch. Coordinate with the

LOG MGR and logistics operations personnel to develop a process to number, approve, and control individually issued tools.

2.8.7. If applicable, ensure the branch’s ESD program is implemented.

2.8.7.1. Ensure any area used to work on electrostatic discharge sensitive (ESDS) electrical items receives an ESD control survey and appropriate ESD measures are implemented.

2.8.7.2. Provide team members to assist the TD/711 HPW/Division ESD POC with ESD control surveys as required.

2.8.7.3. Notify TD/711 HPW/Division ESD POC when additional work areas are required or changes are made to existing areas.

2.8.7.4. Ensure all personnel involved with handling, repair, or storage of ESDS items receive initial and annual ESD awareness training.

2.9. Logistics Operations (LOG OPS) Personnel. LOG OPS personnel are located throughout the TD/711 HPW at the discretion of the Division Chiefs and/or Branch Chiefs. LOG OPS personnel will:

2.9.1. Be assigned as the program managers for one or more logistics programs.

2.9.2. Manage assigned programs as specified by policy directives.

2.9.3. Function as the logistics focal point for their assigned area.

2.9.4. Assist personnel with logistics processes and procedures.

2.9.5. Work closely with the LOG MGR to ensure logistics requirements are met.

2.9.6. Assist TD/Wing leadership in implementing management actions to meet new workloads, target deficiencies and identify and correct root causes.

2.9.7. Coordinate equipment purchases with the proper personnel (TMDE Coordinator, Equipment Custodian, Log Manager, Safety, etc.) prior to making any purchases.

2.10. Operator or User. An Operator or User is anyone that uses RDT&E equipment and logistics processes. Operators or Users will:

2.10.1. Work with LOG MGR/Log Ops Personnel to identify logistics requirements for their work area/lab.

2.10.2. Coordinate equipment purchases with the proper personnel (TMDE Coordinator, Equipment Custodian, Log Manager, Safety, etc.) prior to making any purchases.

2.10.3. Use only TMDE calibrated through a AFLCMC/WNM previously WR-ALC/ENH

[Air Force Metrology and Calibration (AFMETCAL)] approved source to collect quantitative measurements.

2.10.4. Prior to use, ensure the status of the TMDE item is appropriate for the application.

AFRLI21-101 19 FEBRUARY 2015 13

2.10.5. Notify the TMDE coordinator if the TMDE item is overdue for calibration or is labeled No Periodic Calibration (NPC) and requires calibration.

2.10.6. Follow logistics programs IAW this instruction and TD/711 HPW direction.

14 AFRLI21-101 19 FEBRUARY 2015

Chapter 3

QUALITY ASSURANCE (QA)

3.1. General. The QA office evaluates the quality of the TD/711 HPW logistics activities and manages the Evaluation and Inspection (E&I) Plan. The E&I plan provides an objective sampling of the logistics activities. QA personnel are not an extension of the logistics work force but serve primarily as technical advisors. Due to their policy and inspection responsibilities, QA personnel will not be responsible for the implementation of any logistics programs other than the

QA program.

3.1.1. The site QA will inspect the common logistics programs and processes used by munitions (MUNS) personnel: Tool Control, FOD, ESD, TMDE, etc. These results will be tracked and incorporated into the monthly QA summary like any other QA inspection.

3.1.2. MUNS QA: Due to the unique nature of RDT&E operations and that all munitions are required to be managed on a custody account, no formal MUNS QA is required and no PEs or QVIs will be performed. The weapons safety program requirements in AFI 91-202 provide adequate oversight of AFRL munitions related aspects.

3.2. Quality Assurance Superintendent (QA Supt) Responsibilities. The QA Supt uses QA inspection results to ensure consistent logistics practices according to technical data and management procedures. The QA Supt ensures QA and logistics programs meet the customer’s needs and the intent of higher headquarters instructions. The QA Supt shall:

3.2.1. Serve as a Logistics Technical Advisor to detachment leadership and LOG MGRs.

Make recommendations to the AFRL/DSO CLM to enhance the effectiveness of logistics operations.

3.2.2. Determine the duties and responsibilities of the QA Inspector.

3.2.3. Train QA Inspectors IAW practices specified in this chapter.

3.2.4. Develop site logistics policy and assist in developing any logistics training material as required.

3.2.5. Coordinate and provide oversight on all initiatives to change published logistics instructions or processes.

3.2.6. Implement and administer the LSEP.

3.2.6.1. Assist AFRL/DSO CLM in developing the LSEP.

3.2.6.2. Review inspection report summary inputs for accuracy and content.

3.2.6.3. Initiate actions when additional attention is required to resolve adverse trends.

3.2.6.4. Establish procedures for inspectors to document completed inspections.

3.2.6.5. Ensure a monthly LSEP summary is published. Forward a copy of the monthly

LSEP summary to leadership and to AFRL/DSO CLM for distribution to the AFRL/DS.

3.2.7. Conduct other management assessments and program evaluations of logistics and related programs as assigned.

AFRLI21-101 19 FEBRUARY 2015 15

3.2.8. Evaluate logistics management procedures, including locally developed forms, publications, operating instructions (OI), checklists, etc., for accuracy, intent, and necessity.

3.2.9. Coordinate with TD/711 HPW to ensure inspectors have unrestricted access to research labs and work centers.

3.2.10. Perform the responsibilities of the QA inspector.

3.3. Quality Assurance Inspector Responsibilities. QA inspectors will:

3.3.1. Evaluate the TD/711 HPW logistics activities.

3.3.2. Perform inspections and evaluations as outlined in the LSEP.

3.3.3. Include explanatory comments in reports to allow supervisors to assess the health of logistics programs.

3.3.4. Develop and ensure currency of assigned logistics self-inspection checklists.

3.3.5. Assist the TD/711 HPW logistics manager in performing logistics technical research, preparing accident/incident reports, and other tasks as necessary to ensure continuous process improvement.

3.3.6. Enter inspection and evaluation reports into the Quality Assurance Tracking and

Trend Analysis System (QANTTAS), the QA database.

3.3.7. Evaluate pertinent forms documentation.

3.4. Logistics Standardization and Evaluation Program (LSEP). The AFRL/DSO CLM will update/revise, publish and distribute an AFRL/DS approved annual LSEP plan which will include:

3.4.1. Methods for inspecting, evaluating, and rating technician proficiency, equipment condition, etc.

3.4.2. Establish acceptable quality levels (AQL) for tasks. An AQL denotes the maximum allowable number of minor findings that a task, process or product may be charged for the evaluation to be rated “Pass.” Failure to meet an AQL/standard results in the task being rated as “Fail.”

3.4.3. Key task listing.

3.4.4. Routine inspection listing.

3.5. Evaluation and Inspection (E&I) Plan. Each QA office will develop an E&I plan showing areas, types and numbers of inspections and evaluations that must be conducted based on the instructions in Attachment 4. QA will inspect all special inspection areas listed in the

LSEP if present. The E&I plan will be coordinated with the TD/711 HPW LOG MGRs. The

E&I plan will be posted in the Enterprise Business System (EBS). When developing the plan, the QA Supt will:

3.5.1. Address areas of concern identified by leadership or Higher Headquarters (HHQ) inspections.

3.5.2. Tailor the plan for each TD/711 HPW.

3.5.3. Review, update, formalize and distribute the E&I plan at least quarterly.

16 AFRLI21-101 19 FEBRUARY 2015

3.6. QA Training. The QA Supt will develop a training plan to train all QA personnel to ensure uniformity in application of E&I techniques and philosophy.

3.6.1. Training must cover E&I techniques, documenting inspection worksheets and actions to prevent personnel injury or equipment damage.

3.6.2. Personnel must be familiar with all tasks they evaluate/inspect.

3.6.3. Inspectors must be trained in procedures for evaluating work centers that may include contractor employees to be familiar with proper procedures for elevating issues.

3.6.4. Upon completion of training the QA Supt and trainee will sign and date the last page of the training plan indicating that training has been completed. The QA Supt will retain the signed training plan as long as the Inspector is assigned to QA. Training documentation does not apply to contractors.

3.7. Conducting Evaluations. QA inspectors must have access to all TD/711 HPW areas.

TD/Wing LOG MGR/Log Ops Personnel will facilitate no/short notice access to all areas, subject to active testing restrictions. When performing evaluations, the QA Inspector will:

3.7.1. Upon entering an area to perform an inspection, identify themselves to TD/711 HPW personnel and explain what will be inspected.

3.7.2. Perform the evaluation.

3.7.3. Out brief the results of the evaluation to the area supervisor. If the area supervisor is unavailable, brief the results to the TD/711 HPW LOG MGR.

3.7.4. Route the completed evaluation to the TD/711 HPW LOG MGR, who is responsible for engaging leadership and crafting/implementing a corrective action.

3.7.5. Munitions Workload Surveillance.. The following steps were developed in coordination with HQ AFMC A4MW and A4US and are being implemented in lieu of standing up a formal munitions QA program.

3.7.5.1. All sites except DET 7: implement the following:

3.7.5.1.1. Site QA will inspect the common logistics programs and processes (tool control, FOD, ESD, TMDE, etc.) used by munitions personnel. The results will be tracked and incorporated into the monthly QA summary like any other QA inspections. Incorporate Additional Duty Weapons Safety Manager (ADWSM) spot inspection results into the monthly QA summary.

3.7.5.1.2. ADWSM will perform spot inspections and forward the results to the site

QA.

3.7.5.2. DET 7 only: Due to DET 7 having stockpile and custody accounts, implement the following:

3.7.5.2.1. SI’s will be performed on items 10-17 of AFI 21-101 AFMC Sup, table

8.1. Incorporate the results into the monthly QA summary.

3.8. AFRL-Approved QA Database. Each QA office will use QANTTAS as the QA database to capture assessment and trend data. The AF Advanced Composites Office (AFRL/RXSSH) at

Hill AFB, Utah is exempt from using QANTTAS. QA evaluation data must be captured

AFRLI21-101 19 FEBRUARY 2015 17

manually and monthly summary data must be provided to the parent TD/711 HPW LOG MGR for inclusion in the monthly AFRL metric data.

3.9. QA Monthly Summary. The QA office will publish and distribute electronically a monthly LSEP summary of QA inspection data to the AFRL/DSO CLM, TD/711 HPW LOG

MGRs, Integration & Operations (I&O) Division Chiefs and TD/711 HPW leadership. The summary will include the following, when applicable:

3.9.1. Trend analysis.

3.9.2. Compliance with and currency of TOs, technical data, and directives.

3.9.3. Equipment forms documentation.

3.9.4. Compliance and management of safety, environmental and housekeeping programs.

3.9.5. Compliance with unit directed programs.

18 AFRLI21-101 19 FEBRUARY 2015

Chapter 4

TECHNICAL DATA MANAGEMENT

4.1. General. Technical data will be managed as required per TO 00-5-1, AF Technical Order

System. When a TO is not available, COTS manuals, LDPs or CWIs will be used to support and maintain AFRL equipment. The AFRL equipment owner will ensure required COTS manuals are available and scanned into TDS.

4.1.1. eTOs viewed via ETIMS will be centrally managed by WPAFB on one “AFRL

TODO” account for all AFRL units. The AFRL TODOs will also create and manage a

TODO account for each site in case they require physical media.

4.1.2. Organizations that require classified TOs must establish a TODO account IAW TO

00-5-1 and will order and manage the classified TOs themselves.

4.1.3. Organizations that require hard copy versions of TOs must contact the AFRL TODO to establish a (paper) sub-account. These TOs must be located in an operational library.

4.1.4. TDS training is available online for TODOs, supervisors and users at:

https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/fetch/2000/210703/210704/12357229/378

09116/10970363/16600933/16616482/16465167/TDS_Help.htm?nodeid=16468381&vern um=-2

4.2. Center TODO (CTODO). Responsible for AFRL technical data policy and management of TDS. Functions as Center contact for TO issues IAW AFMCI 21-301, Technical Order

System Implementation Policies. The CTODO will:

4.2.1. Represent AFRL at AF and Air Force Materiel Command (AFMC) Centralized

Technical Order Management (CTOM) committees.

4.2.2. Program Manager for TDS; test, validate and approve TDS system change requests.

4.3. TODO. A TODO and an alternate will be established in writing and be the main focal point to manage the technical data effort. TODOs will:

4.3.1. Use the ETIMS to establish an initial distribution (ID) and to maintain the currency of all TOs in-use.

4.3.2. Load and maintain technical data documents in TDS.

4.3.3. Grant access to specific personnel for required documents when approved by a government supervisor/manager. Verify approval authority using the TD/711

HPW/Detachment/Division (consolidated if possible) approval list, as applicable.

4.3.4. Assist in locating applicable technical data.

4.3.5. Assist in the development of LDPs and CWIs.

4.3.6. Manage TCTOs (see para 4.6).

4.4. TDS Users. Users will:

4.4.1. Ensure all equipment has a TO or COTS manual available for it in ETIMS or TDS.

When purchasing new equipment, verify there is technical data for it in ETIMS or TDS. If https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/fetch/2000/210703/210704/12357229/37809116/10970363/16600933/16616482/16465167/TDS_Help.htm?nodeid=16468381&vernum=-2 https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/fetch/2000/210703/210704/12357229/37809116/10970363/16600933/16616482/16465167/TDS_Help.htm?nodeid=16468381&vernum=-2 https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/fetch/2000/210703/210704/12357229/37809116/10970363/16600933/16616482/16465167/TDS_Help.htm?nodeid=16468381&vernum=-2

AFRLI21-101 19 FEBRUARY 2015 19

not, the purchaser will obtain the technical data, scan it and submit it to the TODO for upload into TDS.

4.4.2. TOs. Access TOs via ETIMS or TDS.

4.4.2.1. Access eTOs (TOs ending in WA-1) in ETIMS via the following AF Portal link https://www.my.af.mil/etims/ETIMS/index.jsp.

4.4.2.2. Access other TOs (paper, WA-2, etc.) via the following TDS link https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/2091845

4.4.2.3. Submit TO addition requests to the TODO via TDS.

4.4.3. COTS Manuals. If no TO is available, ensure a COTS manual is available for all equipment. If incomplete or out of date, the user will obtain a current version, scan it and submit it to the TODO for update in TDS.

4.4.3.1. If research needs require the use of older versions of COTS manuals, end-users may use the required older version(s). Users are responsible for obtaining the current or proper version to match equipment configuration.

4.4.3.2. Search TDS to ensure technical data is available for equipment being used.

4.4.3.2.1. If unable to open the document, request access via the automated TDS access/permission process.

4.4.3.2.2. If unavailable, submit addition requests to the TODO via TDS.

4.4.3.3. Scan the paper COTS manual or obtain an electronic COTS manual in pdf format. Send the electronic copy of the COTS manual to the TODO.

4.4.3.3.1. Attach any operational notes developed during setup or modification of equipment for tests at the end of the appropriate COTS manual as an addendum or working notes. Scan the notes and attach to the end of the document.

4.4.3.3.2. Scanned COTS manuals may be maintained in a COTS library at the discretion of the owning organization. The hard copy version of a COTS manual will be identical to the scanned version in TDS. Annotate on the COTS manual front cover that it has been entered into TDS.

4.4.4. LDPs and CWIs. Write LDPs for the use or maintenance of, and CWIs for the calibration of, research or test assets when a procedure does not exist.

4.4.4.1. Contact the TODO for assistance in formatting the LDP/CWI.

4.4.4.2. Route completed LDP/CWI for Division Chief approval and signature.

4.4.4.3. Forward signed LDP/CWI to TODO for upload into TDS.

4.4.5. Printing Technical Data Extracts. The user must ensure their technical data extracts are the most current available from the source document prior to use. Print TO extracts from

TDS or ETIMS if the following requirements are met.

4.4.5.1. When color is critical to understanding the TO data, local printing or reproduction must be in color.

https://www.my.af.mil/etims/ETIMS/index.jsp https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/2091845

20 AFRLI21-101 19 FEBRUARY 2015

4.4.5.2. The distribution markings and controls of the complete TO apply to any extracts.

Print the TO title page whenever printing or reproducing TO extracts. The TO title page must accompany the TO extracts at all times.

4.4.5.3. Users who print out the TO extract must include the following documentation on it: initials, date printed, and date verified current.

4.4.5.4. TOs or portions of TOs printed or reproduced from superseded versions or reproduced for non-operations & maintenance (O&M) use will be marked “FOR

REFERENCE ONLY”, and will not be used with operational equipment.

4.4.5.5. Destroy all TO extracts after use.

4.5. Technical Data System (TDS). The TODO loads and maintains unclassified technical data documents in TDS using the following procedures:

4.5.1. Order paper TOs if the user requires a paper TO or an eTO is unavailable.

4.5.1.1. Upon receipt, scan and upload an electronic, text-searchable copy of the document to TDS.

4.5.1.2. Post changes and supplements IAW TO 00-5-1 to scanned TOs and update the metadata fields in TDS to reflect currency.

4.5.2. Load COTS manuals (electronic copy from manufacturer or scanned, text-searchable copy of hard copy manual) into TDS.

4.5.2.1. Use the COTS manual naming convention located at:

https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/17746980. Note: The link is only accessible by AFRL personnel.

4.5.2.2. Enter a distribution code of “P” for proprietary data and “N” for non-proprietary data. The TDS TODO Reference Guide contains detailed information on this process/procedure and is located at:

https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/17742694 . Note: The link is only accessible by AFRL personnel.

4.5.2.3. For proprietary data, TODOs will obtain a “permission-to-host” document from the owner of the proprietary data prior to posting the document in TDS.

4.5.2.3.1. Upon receipt, upload the document in the applicable TDS Manufacturers

Consent to Host folder.

4.5.2.3.2. When contact cannot be established with the owner of proprietary data (i.e.

- no longer in business, etc.), the TODO will post a document within TDS that records the efforts to establish contact.

4.5.3. Assist in the development of LDPs and CWIs.

4.5.3.1. The LDP naming convention can be found at:

https://explorer.ebs.afrl.af.mil/livelink/llisapi.dll/open/17746980. NOTE: The link is only accessible by AFRL personnel.

4.5.3.2. The LDP templates can be found at

https://explorer.ebs.afrl.af.mil/livelink/llisapi.dll/open/LDP_Templates https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/17746980 https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/17742694 https://explorer.ebs.afrl.af.mil/livelink/llisapi.dll/open/17746980 https://explorer.ebs.afrl.af.mil/livelink/llisapi.dll/open/LDP_Templates

AFRLI21-101 19 FEBRUARY 2015 21

4.6. Time Compliance Technical Order (TCTO) Process. A TCTO is an AF mandated modification or improvement of an equipment item or system. Although TCTOs rarely apply to

AFRL work centers, TODOs and Work Center Leads will implement the following procedures when applicable.

4.6.1. TODOs will:

4.6.1.1. Establish a subscription to the applicable TCTO header in ETIMS.

4.6.1.2. When a TCTO is received, communicate with the QA office and the affected work center for a review of applicability.

4.6.1.2.1. If the TCTO does not apply, record non-applicability in the corresponding

ETIMS note block.

4.6.1.2.2. If the TCTO applies, record receipt on an AFTO Form 95, Significant

Historical Data, IAW TO 00-20-2, Maintenance Data Documentation, in lieu of

Reliability & Maintainability Information System (REMIS). To furnish a means of flagging the type of TCTO, the following codes will be entered at the end of the

TCTO title in the Remarks block: immediate action “I”, urgent action “U”, routine action “R” and safety “S”.

4.6.1.2.3. Update the AFTO Form 95 upon completion of the TCTO.

4.6.2. Work Center Leads will:

4.6.2.1. Order any parts/kits per the TCTO instructions and notify TODO when parts are received.

4.6.2.2. Notify the TODO upon completion of the TCTO.

4.6.2.3. Obtain the AFTO Form 95 from the TODO and attach it to the item upon return to the product center or supply system.

22 AFRLI21-101 19 FEBRUARY 2015

Chapter 5

TOOL AND EQUIPMENT MANAGEMENT

5.1. Overview. Tool control procedures prevent the duplication and proliferation of tools, ensure accountability, increase efficiency, and increase safety for personnel and equipment.

Additional tool and equipment rules for FOD critical areas are contained in Chapter 6.

5.2. CTK Custodian. The CTK Custodian is the focal point for tool control and accountability for their respective areas/CTKs. CTK Custodians will:

5.2.1. Determine the type, size, and quantities of CTKs required in each work center.

5.2.2. Ensure procedures are in place to secure CTKs when not in use.

5.2.3. Manage the loan of tools from CTKs.

5.2.4. Develop a Master Inventory List (MIL) for each CTK assigned and document CTK changes on the MIL.

5.2.5. Annotate missing/removed/broken/damaged CTK items on AFMC Form 61, Missing/Removed Tools and Equipment (see Attachment 5).

5.2.6. Ensure tools are stored in their assigned location and MIL is accurate.

5.2.7. Ensure all CTKs/tools are properly marked with EIDs.

5.2.8. Take corrective actions based on QA and other inspection reports.

5.2.9. Inspect CTKs when initially established and annually thereafter.

5.2.10. Manage the warranty replacement of tools.

5.2.11. Review and sign the MIL for each CTK.

5.2.12. Ensures only authorized personnel have access to tool rooms.

5.3. CTK/Tool User. CTK contents should be returned to CTK when no longer needed to maintain 6S and accountability of assets. CTK contents will be returned to the CTK at the end of the week. The CTK/Tool users will:

5.3.1. Open a CTK. Inventory its contents and document the AFMC Form 62, CTK

Inventory and Control Log (see Attachment 6).

5.3.1.1. A CTK without an individual lock in a secure work center must be signed open when the work center is entered.

5.3.1.2. Tool Room CTK. User will inventory and sign open when issued.

5.3.1.3. A CTK Individual Item Tracking Log may be used to track tools used by more than one individual.

5.3.1.4. Close a CTK.Will inventory contents and document the AFMC Form 62.

5.3.2. Tool Room CTK. CTK Custodian will inventory and sign closed on return.

5.3.2.1. A CTK must be signed closed on the last duty day of the week (typically

Friday).

AFRLI21-101 19 FEBRUARY 2015 23

5.3.2.2. CTKs supporting a FOD Critical area will be signed opened/closed on a daily interval.

5.3.3. Notify the CTK Custodian when any CTK discrepancies are discovered, a tool requires replacement or an additional tool is required. Users may replace consumed/expended items in CTKs up to the maximum quantity identified on the MIL.

5.3.4. Annotate AFMC Form 61 if CTK items are lost/broken/damaged/temporarily removed.

5.3.4.1. Briefly describe the reason the item was removed.

5.3.4.2. When full, create a new form and transfer open entries to the new form.

5.3.4.3. The AFMC Form 61 will not be used to track expendables in non-FOD critical areas.

5.3.5. Document the on-site loan of tools as follows:

5.3.5.1. On the losing CTK, annotate the AFMC Form 61 with who borrowed it, an estimated return date and the location where the tool is loaned in the “Reason” column.

5.3.5.2. Personnel borrowing the tool will add the item to the AF Form 3126, Supplemental Listing (see Attachment 7), and secure the item in the CTK when the CTK is closed.

5.3.5.3. Borrowing user must perform all inventory and user maintenance actions.

5.3.5.4. The loan duration will not exceed 90 days.

5.3.6. For the off-site loan of tools, contact the CTK custodian.

5.3.7. Prior to introducing any tools into a work area, the CTK Custodian must be notified to ensure the requirements of the tool control and management program are met.

5.3.8. If a tool/item is lost/missing in a non-FOD critical area, conduct a thorough search for the missing tool/item. If not found, notify the CTK Custodian, work center lead and Branch

Chief. See Chapter 6, Foreign Object Damage Prevention, for lost tool procedures for items in FOD critical area.

5.3.9. For CTKs supporting FOD critical areas, track the exact number of consumable/expendable items in the CTK, not the maximum quantity.

5.4. General Program Requirements.

5.4.1. CTK program templates can be found at the following location https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/15999551

5.4.2. Personally procured tools are not authorized in any laboratory or industrial area.

5.4.3. Individually Issued Tools. Tools owned by the work center but issued to individual personnel for the duration of their employment. Individually issued tools can be authorized by branch chief in non-FOD critical work centers and will not be managed through the CTK program. Individually issued tools are limited to Leatherman type multi-tools and mini-flashlights and will be marked per paragraph 5.9.14 https://livelink.ebs.afrl.af.mil/livelink/llisapi.dll/open/15999551

24 AFRLI21-101 19 FEBRUARY 2015

5.4.4. Work center tools and all equipment physically located within a CTK or tool room/crib will be incorporated into the CTK program.

5.4.5. Equipment items used outside of the contiguous TD/711 HPW complex or off site will be signed out.

5.5. CTK Construction, Organization and Contents. The CTK custodian will ensure:

5.5.1. All rollaway CTKs with attached or stack-on tool kits that have the same EID will be secured to each other to prevent separation.

5.5.2. CTKs will use a system of inlays, outlines, silhouettes, labels, or shadows in the shape of the tools for quick and easy visual inventories. No more than one item is stored in a cutout, outline, shadow, label, or silhouette except for tools issued in a set such as drill bits, Allen wrenches, apexes, or paired items (i.e., gloves and booties).

5.5.3. Hardware (screws, nuts, bolts, etc.) will not be stored in CTKs unless they are part of a tool in the CTK (i.e., rivets with a rivet gun) or required as tools.

5.5.4. If consumable/expendable items are added to a CTK, assign to a specific location, and identify them by nomenclature, size (if applicable), an asterisk (*) and maximum quantity on the MIL.