Attachment_07e_4855.2T.pdf

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER EAST

PSCBOX8021

CHERRY POINT NC 28533-0021

FRC EAST INSTRUCTION 4855.2T

FRCEASTINST 4855.2T

Code 6.4.2.1-RRC

AUG 0 4 2014

From: Commanding Officer, Fleet Readiness Center East

Subj: REMOVAL AND REINSTALLATION MAINTENANCE ACTIONS

Ref: (a) COMNAVAIRFORINST 4790.2B

(b) FRCEASTINST 4855.8C

(c) FRCEASTINST 4710.1V

1. Purpose. To establish procedures and responsibilities for processing parts removed for access.

2. Cancellation. FRCEASTINST 4855.2S

3. Summary of Changes. This revision has updated requirements.

4. Background. The FRC East 4855/41, "Removal and Reinstallation List," provides necessary traceable documentation for work that is not otherwise tracked by work documents. The FRC East 4855/41 is not intended to be used for components requiring a Quality Characteristic List (QCL) for installation.

5. Action

a. Aircraft Repair Shop Personnel within the Workload Scope Determination Division (Code 6.2.2)

(1) Maintain the FRC East 4855/41 with the Aircraft Rework Control Listing (301) near the applicable aircraft on a normally scheduled aircraft. On nonscheduled aircraft or on aircraft awaiting induction, the cognizant Quality Assurance Specialist (QAS) will initiate a FRC East 4855/41. The planner will maintain the completed FRC East 4855/41s for historical purposes.

(2) Without exception, record on the appropriate FRC East 4855/41 at the time of occurrence:

"UNSURPASSED SERVICE TO THE FLEET AND RELENTLESS FOCUS ON QUALITY, ENVIRONMENT

AND OCCUPATIONAL HEALTH AND SAFETY"

FRCEASTINST 4855.2T

AUG 0 4 2014

(a) All undocumented removals and reinstallations to include, but not limited to, components, assemblies, and subassemblies, removed for access that will not be removed for a period of time not to exceed twenty-four hours;

(b) All work previously certified that has been compromised;

(c) Maintenance tasks that are not covered by a work document; and

(d) If a system or component fails that is not work specification driven or after the task has been sold, it becomes unscheduled maintenance. The Examination and Evaluation Branch (Code 6.2.2.1) will issue a work order to fix the failure, but the FRC East 4855/41 will be used to gain access.

(3) Without exception, provide the QAS the opportunity to perform the appropriate verification during the actual maintenance action. The percent sign in block 16 of the FRC East 4855/41 indicates the QAS must be notified.

(4) Annotate the part number in Block 7, the serial number of the removed component in block 8, and the serial number of the installed component in block 13. Ensure all serialized components removed and/or installed are documented on the FRC East 4855/41.

(5) Reconstruct the FRC East 4855/41 if it is lost during the production cycle. Every attempt should be made to locate the original prior to reconstruction.

(a) Review maintenance actions and interview all employees who performed work since the latest date on the previous FRC East 4855/41.

(b) Review the FRC East 3710/1, "Flight Test Discrepancies," and the FRC East 4855/24, "HWSO/DWO/Add-A Line/Late Load," in order to identify components that may have been removed.

(6) Submit reconstructed FRC East 4855/41 to the cognizant QAS for review.

NOTE: All mandatory verifications shall be reinspected if not properly documented. This may include disassembly of previously completed task.

(7) Maintain the completed, certified, and verified FRC East 4855/41 in the Aircraft Control Listing (301).

(8} Forward the completed FRC East 4855/41 for each scheduled aircraft along with the aircraft maintenance records to the Planning and Estimation Branch (Code 6.2.2.2).

b. Field Team Modification/Repair Team Services Leader/Artisan (Code 6.2.2.3). Initiate a FRC East 4855/41 to record appropriate information for each aircraft when an item, component, assembly, subassembly, or system is altered, adjusted, disturbed, or modified by the field team.

NOTE: Only a D-level QAS shall accomplish Type I verifications of Safety of Flight/Critical Item Characteristics. Maintenance action forms with D-level QAS verification requirements shall be checked ~QAS REQUIRED."

(1) Assume the QAS responsibilities when a QAS is not assigned to the field team in accordance with references (a) through (c) for non Type I verifications.

(2) Maintain the FRC East 4855/41 with the applicable quality field team package.

(3) The blank FRC East 4855/41 shall be dated and stamped by the originating QAS. Any FRC East 4855/41 not properly numbered, dated, and stamped by the QAS will be considered invalid. Under no circumstances will an FRC East 4855/41 be inserted for an aircraft unless it has been dated and stamped by a QAS. Forward the completed FRC East 4855/41 for each field team aircraft along with the quality field team package to the field team supervisor for review. After review, the field team supervisor will forward with the field team package to Code 6.2.2.2 to be filed.

c. Code 6.2.2.2

(1) Initiate repair identification for all aircraft, both scheduled and nonscheduled, and field modification /repair/calibration team services.

(2) Retain FRC East 4855/41 as part of the aircraft historical records as required by reference (b) .

(3) Store and provide easy access and retrieval of retained FRC East 4855/41.

d. Code 6.2.2

(1) Initiate a FRC East 4855/24 for annotating work orders or added operations initiated during the production process to document additional work required. Annotate added operations on the Aircraft Rework Control Listing (301).

(2) Initiate a FRC East 4855/24 for all flight critical components that require removal/reinstallation/rework to ensure traceability and quality assurance review.

(3) Provide the Aircraft Rework Control Listing (301) to the Aircraft Quality Assurance Branch (Code 6.4.2.1) at time of induction for insertions of FRC East 4855/4ls and quality review.

e. Aircraft Quality Assurance Branch (Code 6.4.2.1)

(1) Initiate a FRC East 4855/41, as needed, for nonscheduled aircraft and/or aircraft awaiting induction.

(2) Insert, at time of induction, six blank FRC East 4855/41s, sequentially numbered, with the Aircraft Rework Control Listing (301). The blank lists shall be dated and stamped by the originating QAS. Upon request from production, insert additional sequentially numbered FRC East 4855/41s. Upon completion of all blank FRC East 4855/418, notify the QAS for additional lists to be inserted. Any FRC East 4855/41 not properly numbered, dated, and stamped by the QAS will be considered invalid. Under no circumstances will an FRC East 4855/41 be inserted for an aircraft unless it has been dated and stamped by a QAS.

(3) Ensure any FRC East 4855/41 that is included with a

Field Team Package is dated and stamped during review upon the check-in and check-out process

(4) Document on the front cover of the aircraft quality assurance folder the number of FRC East 4855/41s inserted during the production effort. Date and stamp this entry. This will facilitate the final documentation review process prior to first flight, and will prevent insertion of an uncontrolled FRC East 4855/41.

(5) Determine if verification is to be performed when the completed/certified FRC East 4855/41 is presented by the certifier. Perform the appropriate type of verification

I required.

(6) Document quality reject observations in the Internal Defect Reporting System section of MRP II.

(7) Initiate a discrepancy work order to document discrepancies identified.

(8) Review any reconstructed FRC East 4855/41 for scope of work performed and required verifications.

(9) When the aircraft is certified "Safe For Flight," the pilot shall be briefed by the QAS as to actions taken.

(10) Ensure a FRC East 4855/41 is forwarded to the Flight Check Office (Code 6.0DB) and included in the aircraft flight folder.

6. Instruction Responsibility. The Policy and Quality Department (Code 6.4) will review this instruction annually.

7. Forms Required. Forms required by this instruction are located on Naval Forms Online and shall be maintained per the requirements of paragraph Sa of this instruction.

a. FRC East 4855/41, "Removal and Reinstallation List,"

b. FRC East 3710/1, "Flight Test Discrepancies,"

c. FRC East 4855/24, "HWSO/DWO/Add-A-Line/Late Load"

Distribution: II