Attachment_07m_10290.1P.pdf

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER EAST

P50 BOX 8021

CHERRY POINT NC 28533-0021

FRCEASTINST 10290. lP Code 6.3.2-SAA

JUL 282015

FRC EAST INSTRUCTION 10290.1P

From: Commanding Officer, Fleet Readiness Center East

Subj: TOOL CONTROL PROGRAM

Ref: (a) COMNAVFORINST 4790.2B CH-l

(b) FRCEASTINST 4355.lV

(c) FRCEASTINST 11016.15

(d) 29 CFR 1910.242

(e) FRCEASTINST 52l3.2V

(f) FRCEASTINST 4855.80

(g) FRCEASTINST 10290.2B

(h) COMNAVAIRPAC/COMNAVAIRLANTINST 4790 .21B

End: (1) Tool Control Program

1. Purpose. To establish policies and procedures for the control, accountability, issuance, replacement, maintenance, and disposal of tools in accordance with references (a) through (h) -

2. Cancellation. FRCEASTINST 10290.1N.

3. Summary of Changes. Recipients should review this instruction in its entirety.

4. Program Responsibility

a. The Commanding Off icer shall designate, in writing, the Tool Control Program Manager (TCPM)

b. The Production Activity Control Division (Code 6.3.2) is responsible for administering the Tool Control Program (TCP)

c. Code 6.3.2/Shop 32300 is responsible for managing all aspects of the TCP in all areas under tool control and for designating a Tool Control Program Coordinator (TCPC)

d. The TCPC shall be directly responsible to the TCPM for all TCP matters delegated to him or her. The TCPC shall implement and maintain tool control procedures according to reference (a) and this instruction.

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

AND OCCUPATIONAL HEALTH AND SAFETY’

FRCEASTINST 10290 . 1P

JDL 282015

The TCPC shall maintain all aspects of the tooling from acquisition to disposal controlled by Code 6.3.2/Shop 32310.

e. The Information Technology/Information Management Department (Code 7.2) is responsible for the computer system and software administration, maintenance, and report creation.

5. Action. All FRC East personnel, including military and contract personnel, will comply with the applicable requirements of this instruction.

6. Records Management. Records created as a result of this instruction, regardless of media and format, will be managed per SECNAV Manual 5210.1, Department of the Navy Records Management Manual.

7. Instruction Responsibility

a. Production Activity Control Division Tool Rooms/HDSC’s (Code 6.3.2/Shop 32300) will maintainthis instruction in a current status.

b. The TCPC shall implement and maintain tool control procedures in this instruction in a current status under the direction.of the TCPM.

8. Required Forms. Required forms are listed in Appendix A.

EANNA B. RADFORD

By direction

Distribution: II

FRCEASTINST 10290. 1P

JUL 282015

TOOL CONTROL PROGRAM

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RECORD OF CHANGES

JUL 282015

IDENTIFICATION DATE OF DATE OF ENTERED BY

OF CORRECTION OR CHANGE ENTRY

CHANGE

CHAPTER

TABLE OF CONTENTS

TITLE

FRCEASTINST 10290. 1P

JUL 282015

PAGE

General Information Principle Authority Definitions Policy Figure 1-1 Critical and Non- Work Areas Obj ective Functional Responsibilities.

Tool Control Procedures Tool Containers Tool Container Care and Maintenance.

Tool Container Inventories Tool Container Key/Combination Types of Issue Test Tools Worn, Broken, or Damaged Tools Defective Tool Missing Tool or Part of a Tool Locally Manufactured Tools Locally Modified Tools Calibrated Tools In All Areas.

Power Tools/Electrical Tools.

Hexavalent Chromium/Cadmium Plating.

Inventory and Inspection of Tools Responsibilities Shop Supervisors or Designated Representative Employees in Critical Work Areas Supervisors of Non-Critical Work Areas Employees of Non-Critical Work Areas..

4 Lost or Missing Tools General Requirements Report and Investigation Procedure.

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Critical

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TABLE OF CONTENTS (CONT’D

JUL 282015

5 Field Team and Commercial Contractor Tool Control Requirements Field Teams 5-1 Commercial Contractors 5-3

Personnel Transfers, Reassignments, Separations, or Extended Absences Transfers and Reassignments 6-1 Separations 6-1 Extended Absences 6-2

Tool Control Procedures for the F-35 Tool Containers Lost Tools Broken and Worn Tools Consumable Tooling

7-1 7-1 7-2 7-2

Appendix A Tool Control Forms A-l

FRCEASTINST l0290.1P

JULZ8ZOI5

CHAPTER 1

General Information

1. Principle. The Tool Control Program (TCP) provides the framework for authorities, responsibilities, functions, and relationships to achieve improvements, economy of operations, and quality of end product. The TCP embraces commonly accepted principles as the first step in a complete TCP.

2. Authority. Reference (a) requires a comprehensive, integrated, and monitored TCP in all areas where tooling is required for either repair or installation of aircraft, engine, components, and related equipment. This instruction shall also be followed by all Fleet Readiness Center East (FRC East) employees regardless of where they work. The objective of this program is the elimination of Foreign Object Damage (FOD) potential in all aircraft rework and related programs. Levels of tool control are determined by FOD potential. When the potential for FOD is less likely, a less stringent level of control may be used in specified areas as noted within this instruction.

3. Definitions. Some of the terms have various connotations and inferences depending upon the conditions under which they are used. The following definitions are provided to explain their use in this instruction:

a. Unique Hand Tools. Unique hand tools are common tools normally held and propelled by hand, such as screwdrivers, wrenches, hammers, pliers, tool kit containers, measuring instruments, such as tapes, protractors, rulers, and levels. It also includes “Special Tools” as defined in reference (a) These tools are marked with an organization code and an identifying kit number or drawing number. Tools not assigned to a kit are marked with the organization code and letters/numbers tracing it to a tool room. In addition, some have Tool Control Numbers (TCN) on them; however, the TCN is being phased out.

Note: A certification stamp and tool box key are not “common” hand tools as defined by this instruction. However, if lost or missing, those items must be reported lost or missing in accordance with Chapter 4 of this instruction.

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FRCEASTINST 10290 1P

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b. Unique Calibrated Tools. Unique calibrated tools are tools used for precise or quantitative measurements such as micrometers, calipers, and torque wrenches, which are marked with an organization code and a unique series of numbers.

c.. Expendable Hand Tools. Expendable hand tools are common tools held by hand, holders, or other tooling such as drills or grinders. These may include, but are not limited to, drill bits, screwdriver bits, files, end mills, rivet sets, scribes, and countersinks. An organization code and kit number will be laser marked, if feasible.

Note: Expendable tooling belonging to a kit that is not marked with a kit number can be taken to the nearest distribution site and exchanged one-for-one, size-for-size.

d. Consumable Tools. Consumable tools are tools issued and expected to be used until they reach “beyond economical use” status. Such tools are not returned to a distribution site.

Some examples are: carbide inserts, welding cups, accessories, and replacement parts for original tools. There are no markings on Consumable tools.

e. Portable Power Tools. Portable power todls may include, but are not limited to tools powered by electricity, air-driven drills, grinders, pneumatic nut runners, chipping hammers, planers, saws, routers, sanders, and battery operated tools.

The primary determinant is that they are both portable and propelled by power. These items are marked with an organization code and kit number. If the item is not part of a kit, the serial number will be marked on the tool, in addition to the organization code and letters/numbers tracing it to a specific tool room.

Note: The Production Activity Control Division Tool Rooms/Hazardous Distribution Service Center (HDSC) (Code 6.3.2/shop 32310) will maintain stock for issue and replacements of common tooling. Shops must budget and pay for “first-time” purchases and for any items that are peculiar to a shop or machine, i.e., tools that. are not for production-wide use/distribution.

f. Local Manufactured Tools. Tools received from tool manufacturing or a shop with a part number or drawing number

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FRCEASTINST 10290.1P

assigned by the Plant Process Engineering Branch (Code 6.3.1/Shop 31200) and/or from the Research and Engineering Department (AIR-4.0) at FRC East. These tools are locally designed and manufactured due to the unavailability of an original tool for purchase or because of unique use requirements that cannot be fulfilled through purchasing resources. These items must be marked with the organizational code, respective drawing number, and kit number, where feasible.

g. Local Modified Tools. Tools modified from their original shape or size in order to perform a specific task called for in the manual, and where an existing tool does not exist to perform that task. See refetence (f)

Note: It is the responsibility of the employee using the manufactured or modified tool(s), i.e., the end user, to ensure the tooling has been authorized for use in repair and/or manufacturing tasks. Tools that have NOT been authorized for use by the appropriate authority are strictly prohibited.

h. Critical Work Areas. Critical work areas are those areas of aircraft maintenance and related work sites that pose a high potential for foreign object damage (FOD) contamination in aircraft, engines, components, and/or related equipment. These areas include, but are not limited to, aircraft rework and assembly, engine rework and assembly, test cells, and flight lines.

3.. Non-Critical Work Areas. Non-critical work areas are those areas with a remote possibility of FOD contamination in aircraft, engines, components, and/or related equipment. These areas include, but are not limited to, component buildup and repair, and electric and electronic shop areas.

Note: Figure 1-1 of this Chapter identifies the designated critical and non-critical areas~within the FRC East.

j. Tool Containers. Tool containers are receptacles used for storing, holding, securing, carrying, or displaying tools and tooling. They may include, but are not limited to, toolboxes, viewing boards, rollaway boxes, or rolled up canvas carriers, desk drawers, etc. Tool containers will not be painted or modified in any manner. They will not be defaced with unauthorized stickers, appliques, or other decorative or

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FRCEASTINST 10290 1P

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distinguishing items of any kind on the outside of the container after issue from Code 6.3.2/Shop 32310. Instructions and further guidance for modifications are provided in Chapter 3 of this instruction.

Note: Tool tote trays and temporary tool carrying containers may only be used on a daily basis to TRANSFER tools to and from an aircraft or temporary work area.

k. Point of Use Tool Box (POU) . The P013 boxes, otherwise referred to as shop boxes, are tool containers issued to and maintained by individual shops. Artisans are to check out tooling using either the FRC East 10290/lA, “Shop Tool Container Sign Out Sheet,” for aircraft containers or FRC East l0290/lC, “Shop Tool Sign Out Sheet,” for component boxes.

1. Tool Control Numbers. The TCNs are multi-digit numbers.

They are being phased out of use and will be eliminated over time. New tools will not be assigned a TCN.

m. Tool Control Personnel. Includes the TCPM, TCPC and personnel assigned to Code 6.3.2/Shop 32310.

n. Visual Inventory. A visual inventory is when an employee opens all drawers, slots, receptacle’s etc. of a tool container and performs a visual inspection/check to verify whether all tools are present or not present. This inspection process also includes a visual inspection of the condition of the tools in inventory.

o. Physical Inventory. A physical inventory is when an employee physically verifies the kit number, tool crib number or serial number on all individual tools and verifies the organizational code. If the tool has all three identification numbers, the numbers must be verified. Other tools in the kit will be verified for correct description and quantity. The container will also be thoroughly looked at to ensure calibrated tools are in compliance with calibration schedules, and that there is no presence of micro-FOD, damage, breakage or unauthorized modified tools.

p. Prohibited/Unauthorized Tools. Prohibited/Unauthorized tools include, but are not limited to: personal hand tools, shop produced and modified tools, personal knives, pocket

1-4 flashlights, multi-purpose tools, or any other tool not issued/authorized in accordance with the TCP.

4. Policy. The policy of Code 6.3.2/Shop 32310 is to:

a. Provide ou~ customers quality products and services on time and at the lowest possible cost.

b. Use tool silhouettes in tool containers with a contrasting background that provides a place for each tool to enhance the effectiveness of visual inspections in detecting missing tools. Silhouetted tool containers are mandatory in all work areas.

c. Establish a permanent tool marking system. Tools used within the confines of the facility or taken on field team trips that are unique hand tools, unique calibrated tools, and some expendable hand tools will be laser etched (if feasible) so they can be readily identified to a specific source (see warning below) . Portable power tools will be laser etched. Exception to marking will be made by the TCPC. They shall be etched with the organization code, tool crib number and/or a kit number when feasible. Power tools are marked with an organization code, tool crib number, and kit number, if required. All tools will be kept in silhouetted containers when possible with an inventory list for identity, even if the tool is too small to be etched. Replacement tools will have the same kit markings as the original tool, including a method to distinguish second and subsequent replacements [which is maintained in the Maximo Tool ContrQl Module) and history files maintained in the Central Distribution Center.

WARNING

DO NOT ETCH NONSPARKING, NONMAGNETIC BERYLLIUM HAND TOOLS.

THE ETCHING PROCESS OF BERYLLIUM HAND TOOLS GENERATES A FINE

DUST OF BERYLLIUM, A KNOWN HEALTH HAZARD.

AT NO TIME SHALL THESE TOOLS BE CUT, MELTED, WELDED, GROUND, OR

OTHERWISE MODIFIED.

d. Issue required tools on a temporary basis from distribution sites to all FRC East employees as requested. Use the FRC East 10290/3, “Tool/SSE/Hazmat Issue Receipt,” when the computer generated issue receipt is unavailable. The distribution sites will ensure that each tool issued is

1-5 traceable to the recipient. These tools must be returned to the distribution site at the end of the shift, unless the tool is authorized to be kept for longer periods. Tools checked out of the distribution sites for one day or longer may be stored inside the tool container with the tool issue receipt. Tools needed for more than one day must be approved by tool room supervisors or work leaders.

Note: Examples of situations that would qualify for an extension: machinist’s working on a project that will not be completed in a shift or two, tools/equipment being mounted on an aircraft, a one time job where time for set up and tear down would necessitate more than one day, an engineering investigation, and maintenance mechanics repairing, plant equipment. This list is not conclusive. All requests other than a machinist, maintenance mechanic or a tool/equipment being mounted on an aircraft shall be approved by Code 6.3.2/Shop 32310 tool room supervisors or work leaders.

CRITICAL AND NON-CRITICAL WORK AREAS

Ron-C~&tiaa1 (t’,,*-ifl~1 ~t~r1~ ttra~l Wnrir Am,.

~j~r~r ~ 4W4~t~4~

6.6, 6.7, 6.8, 6.9 None All Logistics Group

4.0 Research and Building 4841 High Bay Areas within

Engineering Group’ Area and flight deck in FRC East

Front of high bay. fenced areas and Building

4841 CASS

‘ Lab.

6.0DB Director of Flight Check Program All work Operations/Flight Office. All work areas not Check Program areas directly involved listed as Office with flight check of critical work aircraft, testing areas.

engines, or critical components.

6.2.2.1 Examination E&E - All work areas All shops not

and Evaluation directly involved with listed as Branch flight check of critical work aircraft, testing areas.

engines, or critical components.

1-6

6.2 Industrial Building/Shop All shops not

Execution 137- Aircraft Clean listed as Department Shop critical work

245 - Aircraft Paint areas.

Shop

129 -

Ordnance/Survival Equipment Shop 133/4188 - F402/J79 Engine Repair and Test Shop 133 - T58/T400 Engine Repair and Test Shop 137- Auxiliary Power Units/Fuel Accessories Shop —All aircraft shops are considered critical.

This includes all personnel from outside shops performing work in an aircraft work area.

6.3 Industrial Ops 6.3 personnel working All shops not

Management in an established listed to the Department critical area. left.

6.4 Industrial Code 6.4.2 QAS’s - All All shops not

Quality Department work areas directly listed as involved with flight critical work check of aircraft, areas.

testing engines, or critical components.

Enclosure (1)

Figure 1-1

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JUL28 2815

e. Assign long-term custody of tool containers required by each shop to each individual artisan or supervisor as requested by the supervisor.

f. Delegate (or Transfer) responsibility for tool inventory and accountability to the individual worker while the container(s) and tools ar.e in the individual’s custody/control or once the container and tools have been signed over into the individual’s custody. This includes the responsibility for verifying calibration due dates on all calibrated measuring instruments; verifying preventative maintenance dates; checking electrical tooling for frayed cords, broken plugs, and/or other damage; and ensuring all organizational and kit numbers are legible at all times.

g. Evaluate each production shop for its FOD potential.

Each shop is categorize.d as either a critical or non-critical work area. Tool control procedures in critical work areas are more stringent than in non-critical areas. Supervisors will ensure artisans follow the tool control guidelines in this instruction and any specific requirements of the shop to which they are assigned, i.e., when moving from a non-critical area to a critical area would mean working under the guidelines of the critical area.

h. Steps to be taken by an artisan to order a tool not already carried and to ensure a complete audit trail on ordering of tools: FRC East artisans will submit a Work Order Request in MAXIMO through their appropriate chain of command to the Central Tool Room with the following information specified on the work order:

(1) Platform Specific or NAVAIR Approved Manual, or

(2) NAVAIR Approved Drawing; or,

(3) Depot Tooling Manual SE-17-l-SE-CP. (Example:

NAVAIR Ol-1A-505-1, 0 13 00, paragraph 162)

(4) If paragraphs 4h(1) through 4h(3) above do not apply, then the artisan will: request assistance from the production support engineer (PSE) or support equipment technical team engineer. The PSE or the support equipment technical team engineer will determine the tool utilizing the appropriate policy/procedures and annotate on the FRC East Work Order the

Enclos~ure (1)

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JUL 28 2Q15

proper tool with applicable title, chapter, and paragraph number. Additionally they will ensure appropriate technical data update is performed and reference the number on the FRC East Work Order. Once completed, the FRC East Work Order will be maintained by Code 6.3.2/Shop 32310.

5. Objective. The primary objective of the TCP is to enhance flight safety by preventing aircraft accidents attributable to missing tools or other tool-related FOD during and following maintenance or repairs. Secondary objectives include reduction of expenditures through accountability, improved inventory control, and improved quality of aircraft maintenance by ensuring tool quality is commensurate with the task.

6. Functional Responsibilities

a. Aviation Safety Off icer (Code 6.OD) . Monitor the TCP to ensure FOD prevention.

b. Director of Operations (Code 6.0DB) . Ensure compliance with this instruction.

c. Group/Department Heads. Ensure the success of the TCP within the respective groups/departments.

d. Workload Planning Branch (Code 6.3.2/Shop 32100). Work closely with the field team shop (artisans performing aircraft rework outside the confines of the FRC East) to determine tooling needs of field team members to avoid delays in notifying the Code 6.3.2/Shop 32310 of tooling requirements.

e. Information Technology/Information Management Department (Code 7.2) . Perform system administration, maintenance, and report creation. Responsible for maintenance forecasting budget requirements concerning server hardware, operating systems, databases, and technical contractor support.

f. Industrial Quality Department (Code 6.4)

(1) Audit program as required by reference (a).

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JuL 282015

(2) Assist/conduct missing tool investigations as required by reference (a) -

(3) Monitor program as required by reference (a) -

(4) Ensure cognizant QAS verifies that a visual inventory of all tool containers not included in the FRC East TCP used by non-FRC East personnel prior to entry and departure of their area of responsibility for performance of any maintenance on aircraft, engines, components, or related equipment in the custody of FRC East. The inventory will be conducted in the central room prior to going to work.

(5) Responsible for maintaining custody of any tooling issued to them on a permanent basis by using the FRC East 10290/5, “Permanent Tool Custody Receipt.” Secure tools when not in use.

g. Mission Workforce and Safety Division (Code 7.10.1) Inspect tools to determine any noticeable safety defects, perform initial testing, if deemed necessary, and provide initial safety operation recommendations for use of the tool in production operations.

h. TCP Manager (TCPM) . Code 6.3.2/Shop 32300:

(1) plan, organize, coordinate, and provide administrative and technical support for the FRC East TCP as defined by this instruction and reference (a).

(2) Develop and maintain specific indices of effectiveness in the TCP for command level review on a periodic basis.

(3) Develop operating procedures and provide technical support for the TCP.

(4) Oversee Code 6.3.2/Shop 32310 for compliance with the TCP and reference (a) . Report findings and program deficiencies to Code 6.3.2.

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• FRCEASTINST 10290.1P

(5) Coordinate the TCP inquiries/requests of the division directors/branch heads/shop supervisors to ensure action is taken.

(6) Represent the Department/FRC East as directed at conferences/workshops associated with the TCP.

(7) Ensure the FRC East 10290/1, “Missing Tool Report,” located in the Electronic Continual Analysis Metrics (eCAM) System is filled out properly and verify that every effort has been made to locate missing tool(s).

(8) Plan and allocate funds for the procurement of tool containers, special tool kits, hand tools, and portable power tools. Allocated funds are not appropriate for use in first time requests, one time buys, or tooling peculiar to a machine or shop. As noted in section 3e above, such items will be funded by the ordering/requesting shop.

(9) Ensure all MAXIMO work orders are filled out and submitted electronically for the purchase of tools. All Work Orders go through the TCPM, who will process. All orders for new calibrated tooling/equipment will be approved for purchase by Workload Scope Determination Division, Calibration Branch (Code 6.2.2.4/Shop 91302), prior to purchase to ensure the item can be supported. Once approved, the work order will be given to the tools and tooling technician (Code 6.3.2) for procurement. The tools and tooling technician is the only individual in FRC East who is authorized to purchase common hand tools, tool containers, and government locking systems used to secure tool containers.

(10) Investigate and approve or disapprove all requests to modify, add, or delete tools to/from existing tool containers.

(11) Forward delinquent tool listings to the Master Supervisors email distribution list on a weekly basis. The supervisors are responsible for taking any necessary follow up action. Listings to be submitted include calibration tooling due/overdue, temporary tool issues, tooling due for preventative maintenance, and replacement tools that are ready for pickup.

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1. TCP Coordinator Code 6.3.2/Shop 32310

(1) Manages all aspects of the request, receipt, issue, return, maintenance, stocking levels, calibration, and disposal of the FRC East tooling. This responsibility will also include prompt exchange of worn or broken tools, replacement of missing tooling, reporting functions, monitor and process for re calibration of all measuring instruments controlled by Code 6.3.2/Shop 32310.

(2) Procure, receive, mark, issue, and maintain stock levels of all tooling. Do not procure first time requests, one time buys, or tooling peculiar to a machine or shop (i.e.

carbide inserts, collets for machinery)

(3) Functionally maintain the data for tooling in Maximo.

(4) Review the tool-related records of all employees (both FRC East and Defense Logistics Agency Aviation at Cherry Point), military, contractor, and civilian prior to their retirement, separation, or transfer to ensure all tools have been returned and are accounted for. Annotate any discrepancy on the FRC East 10290/9, “Government Owned Tools Inventory Statement.”

(5) Assign kit numbers, category numbers, or tool crib numbers as required for inventory tracking purposes in accordance with reference (a) on common/unique hand tools, power tools, expendable tools (if feasible), and calibrated tools.

(6) Assign shop tool containers to the shop supervisor.

Ensure routing of all shop tools to the appropriate shop, to include any requirements for calibration.

(7) Monitor tools requiring calibration for up-to-date calibration due dates, ensuring requirements are met in a timely manner.

(8) Monitor the monthly Calibration Overdue Report to ensure compliance and take appropriate action, when necessary, to preclude recurrence of overdue calibrated tooling.

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~JUL 28 2015

(9) Support all field team operations in accordance with this instruction. Conduct evaluations of the field team tool control effort to verify accurate inventories are conducted and toolboxes are locked prior to team departure from FRC East.

(10) Coordinate inquiries/requests of the division directors, branch heads, supervisors, and artisans.

(11) Design and manufacture rapid inventory tool containers. Procure or modify existing containers to provide control, and mark for identification. Issue, maintain, and replace all authorized tool containers. This includes all tool containers needed to process aircraft, engines, components, and related equipment.

(12) Maintain tool custody inventory records of all permanent issued tools and a master inventory listing of tools contained in all tool containers.

(13) Establish and maintain custodial control of tools.

Perform visual inventory of special tool kits checked out from and returned to a distribution site.

(14) Issue replacement tools on a one-for-one exchange basis and only for properly marked tools unless deemed expendable/consumable unmarked tooling. Use the FRC East 10920/20, “Tool Exchange,” when a computer generated exchange receipt is unavailable or the replacement tool is a substitute and not the same category as the original. Remove and destroy all irreparably damaged or worn tools from inventory.

(15) Ensure all sites are secured at all times and no one enters a site unescorted unless authorized.

(a) Temporary tools not returned at the end of each shift are delinquent.

(b) If temporary tools are not returned (are unaccounted for) at the end of the shift, the artisan will be locked out of Maximo and will not be able to check out any other tooling until he/she returns the unaccounted for items.

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FRCEASTINST 10290.lP

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j. Industrial Execution Department (Code 6.2) and the

Industrial Operations Management Department (Code 6.3) Delegate the responsibility for the implementation and operation of the TCP within their work areas.

k. Field Team Coordination Branch (Code 6.2.2.3/Shop 91500)

(1) Designate a field team leader who will be responsible for the TCP and act as team lead On site to conduct any tool investigation.

(2) All employees are responsible for their tool inventory and for complying with tool control procedures.

(3) Field team members shall adhei~e to reference (a) and local tool control procedures and policy while, on site.

(4) Request a field team kit using the FRC East 10290/202, “Field Team Issue.”

1. All Division Directors and Branch Heads

(1) Determine, implement, and coordinate the TCP needs of the division and branch with support from Code 6.3.2/Shop 32310.

(2) Require shop supervisors in all work areas to accept custody and responsibility for all special tools required in their respective shops and to institute the tool accountability process as prescribed by this instruction and division procedures.

(3) Ensure supervisors hold artisans responsible for any and all tooling assigned to them from shop tool boxes at all times.

(4) Ensure inventories and inspections of tool containers are conducted and recorded on the FRC East 10290/16, “Daily Tool Inventory,” and FRC East 10290/1GB, “Daily Tool Inventory at Flight Check,” as required. Chapters 3, 4, and 6 of this instruction provide further guidance and policy.

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FRCEASTINST l0290.lP

(5) Ensure all supervisors coordinate any tool container and tool transfers with Cpde 6.3.2/Shop 32310 utilizing the FRC East 10290/207, “Kit Transfer.”

(6) Ensure supervisors monitor inventories •and certify all tool containers used to perform work on aircraft in the flight test area prior to flight check, engine run, and “log sell” of the aircraft. Artisans at flight check will require their signature and another artisan’s signature for inventories utilizing FRC East 10290/1GB as required.

(7) Ensure supervisors cause the turn-in of all tools/containers assigned to employees who have terminated employment or are unable to return to FRC East due to extended illness, hospitalization, or other causes that may preclude turn-in by the individual by submitting a Maximo work order.

(8) Ensure field service teams comply with the TCP requirements of the customer at off-site locations. This includes a complete physical inventory of all tool container kits prior to shipment and prior to departure from service sites.

m. All Supervisors (or designated representatives of each shift)

(1) Request from Code 6.3.2/Shop 32310, all required tool containers (request to build or to be turned in) and special tool kits and any changes of kits by submitting a Work Order in MAXIMO and/or all tools using the FRC East 10290/5.

All requests for turn in of a tool box or shop kit will be scheduled at least 10 working days prior to the requested turn in.

(2) Accept custody and responsibility for all shop tools and unassigned tool boxes required in their respective shops and to institute the tool accountability process prescribed by this instruction and their respective division procedures. Designate a tool control representative and alternate for each shop and submit the names to the TCPM in October and April yearly or sooner if they change.

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FRCEASTINST 10290. lP

(3) Hold artisans responsible for any shop tooling issued as sub-custody from the supervisor at any given time for use in completing assigned tasks.

(4) Conduct a weekly physical inventory inspection of at least one tool container selected at random for accountably of tools for tool control.

(5) Immediately notify the Production Activity Control Division Tool Rooms/HDSC’s (Code 6.3.2/Shop 32310) of any tool or tool container transfers or inventory discrepancies.

(6) Ensure relief supervisors comply with all supervisory responsibilities with regard to the TCP. This includes the ability to proxy in for the supervisor within eCAM in the supervisor’s absence.

(7) Prohibit the use of unauthorized tools and tool containers. Ensure only the tools that are included on the inventory, and have a silhouetted space provided1 are kept in each tool container.

(8) Prohibit hardware, work orders, magazines, and items not listed on the tool container inventory sheet from being stored in their kit containers. Tool container inventories are allowed.

Exception: Tools checked out on temporary issue may be retained in tool containers with the issue receipt for the tools. Air hoses may be maintained in the tool containers for temporary storage for security purposes. Artisans may also store personal items, i.e., keys, change, pens, certification stamps, and other loose pocket items, in a plastic zip lock bag inside the tool container. Machinists are authorized to have a machinist, chest-type box sitting on top of assigned rollaway toolboxes.

(9) Prohibit tools/material/government equipment, personal tools, and other non-issued/assigned items from being brought into or used at FRC East.

Note:: Unauthorized tools include: hand tools, shop produced tools, personal knives, pocket flashlights, multi-purpose tools, or any other tool not issued/authorized in accordance with the TCP. Tools must be identified by nomenclature and included on

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an inventory list as shop or individually issued. Unauthorized tools shall be confiscated by supervisors, TCPM, tool control coordinator, QAS, or distribution site personnel, and tagged with the shop number, owner’s name, and payroll number and turned over to the TCPM (Code 6.3.2). Proper proof of ownership

.is required for the return of a confiscated tool. Confiscated tool incidents will be reported to the appropriate supervisor, branch head, division director and the production department head or designee.

(10) Monitor and ensure the timely turn-in of all shop and individually assigned calibrated measuring tools and preventive maintenance tools.

(11) Ensure tool containers/molds are kept clean/FOD free and are not modified to accommodate unauthorized added tools.

(12) Tool totes are not to be used for any purpose other than to tote tools to and from the job site. Tools will be removed from the tote tray upon the end of shift and secured to the rollaway. Do not store tote trays in personal lockers.

(13) Maintain kit containers in shop for future use if needed. Physically inventory the container, annotate on the FRC East 10290/16 the date inventoried and annotate that the container is not in use, lock the kit, and put a lead seal on the kit (seals may be obtained from Code 6.3.2/shop 32310). The kit will retain the seal and not have to be inventoried again until it is put back into use at which time another physical inventory will be performed and ownership transferred from the supervisor to the new artisan.

(14) Maintain the FEC East 10290/16 and FEC East 10290/163 for a minimum of one year for all assigned shop/ artisans tool kits. Supervisors will also maintain a copy for any artisan temporarily assigned to his/her shop and return original to artisan’s responsible shop.

(15) Ensure all artisans are held responsible for the security and accountability of the tools in their custody.

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(16) Ensure artisans are properly loaned or transferred into the respective area/shop. Loaned individuals will check in with the receiving supervisor and will follow the TCP procedure for the duration of the loan. The receiving shop supervisor shall perform a visual inventory of the tool kit and ensure the box and inventory and maintenance of the tools are in compliance with the TCP.

(17) Ensure all procedures for missing tool(s) are followed according to chapter 4 of this instruction.

(18) Ensure all artisans receive mandatory tool control training yearly by viewing the Tool Control 101 Power Point course (Course Number 0100148) . New employees shall receive the training within 15 days of assignment to a shop and before a kit is issued.

(19) Initiate corrective action when the TCP is not being adhered to, as deemed appropriate.

(20) Ensure the delinquent report is worked in a timely manner and, when follow-up action is unsuccessful, notify the appropriate branch head for assistance.

(21) Assume the duties of lost/missing tool investigator team leader and follow guidelines in Chapter 4 of this instruction.

(22) It will be the responsibility of the shop supervisor to ensure any new employee follows the TCP requirements of his/her shop.

(23) The supervisor or his/her designee shall perform a visual inventory of all containers within his/her shop monthly and make annotations by signing and dating the FRC East 10290/16.

n. Employees using tools shall ~

(1) Accept custody and responsibility for all shop tools assigned to them from the supervisor for use in completing assigned tasks.

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(2) Conduct visual inspections of all assigned tools in tool container as directed by the area in which they work.

(3) Record inventories on the FRC East 10290/16 and FRC East 10290/lEE.

(4) All artisans are held responsible for the security and accountability of the tools assigned to them.

(5) Ensure all tools are returned to the tool container and the tool container is locked when stored or not in use. Not in use is defined as when the artisan leaves the shop area for at least 30 minutes i.e. lunch, training, end of shift, etc. at all times, security of assigned tools is the responsibility of the artisan to whom the tools are assigned.

Note: The artisan is responsible at all times for tool containers and tools assigned to them.

(6) The employee shall have a current tool inventory listing (not older than one year) of all the assigned tools in the assigned tool container(s) . The inventory will be listed by drawer (left justified) and description.

o. Research and Engineering Group Head (AIR-4.0) and Logistics Group Head (AIR E.OH)

(1) Ensure all Research and Engineering Group (AIR-4.0) and Logistics (AIR-6.6, 6.7, 6.8, and 6.9) department/divisions comply with the requirements of reference (a) and this instruction.

(2) Coordinate all requests for special/common hand tools with Code 6.3.2/shop 32310.

p.. Total Force Strategy and Management Department (Code 7.3)

(1) Ensure all civilian employees out-process with Code 6.3.2/shop 32310 prior to retirement, separation, or transfer.

Enclostare (1)

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(2) Notify Code 6.3.2/Shop 32310 of any civilian employee unable to out-process due to extreme illness, extended hospitalization, or other reasons beyond their control. The central tool room will out-process the employee electronically after proper notification.

q. Military Personnel onduty at the FRC East will

(1) In-process through Code 6.3.2/Shop 32310, Building 137, upon arrival.

(2) Abide by this instruction during their tenure at the facility.

(3) Out-process through Code 6.3.2/Shop 32310, Building 137, upon departure.

r. Commercial Contractor Personnel/visiting Field Teams

(1) Commercial contractors providing facilities maintenance support are bound by the terms and conditions of the contract and any associated specifications in the contract.

(2) Local or visiting field teams shall comply with the hosting activity TCP.

(3) The Escort competency point of contact shall be responsible for briefing and supplying a copy of Chapter 5 of this instruction to applicable FRC East field teams and contractor supervisors upon arrival and completion of work.

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Chapter 2

Tool Control Procedures

1. Tool Containers

a. Locally designed silhouetted or contoured tool inserts with contrasting background will be used in work areas designated as critical and non-critical. Some work areas may not be furnished with silhouetted/contoured tool inserts/boxes due to the wide variety of assigned tools. Those areas will use foam to cut out silhouettes for the tools. Layouts are of uniform design for each type tool kit container.

Note: Tool tote trays or tool carrying containers will only be used to transfer tools to and from an aircraft or work area.

Tool tote trays will not contain excess rivets, nuts, bolts, stir sticks, acid brushes, personal items, food, etc. Tools will be put back in the kit container at the end of the shift or’ immediately upon return to the shop. This applies to all Fleet Readiness Center East (FRC East) personnel. Where it becomes necessary to tote tools to critical areas, container inventories will be performed upon arrival and immediately at the conclusion’ of the task with the shop supervisor or his designated representative of the critical area. Empty tote trays can be secured to the tool container at the end of the day.

b. Modifications to approved tool containers may be requested via the respective supervisor to the Tool Control Program Manager (TCPM) (Code 6.3.2) . Any request to modify an approved tool container using the FRC East Employee Improvements Program must •first be processed through the appropriate supervisor. Requests not meeting this requirement will be forwarded to the respective supervisor for recommendation prior to the TCPM’s approval/disapproval:

c. Tool custody records of all tools, tool container inventory lists, and a master inventory of tool containers and contents are maintained in the Central Tool Room of the Production Activity Control Division, Tool Rooms/ Hazardous Distribution Service Center (HDSC) (Code 6.3.2/Shop 32310).

d. All work bench stations, desks, cabinets, etc. with drawers that have tools in them will be treated the same as any other tool container and will be silhouetted.

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e. Aircraft Machinist Branch/Shop 91105 and Metals

Processing Branch/Shop 91108) - These competencies are authorized to have a machinist, chest-type box on top of assigned rollaway tool boxes. Authorized items for storage in this container are limited to the following:

(1) Machinist literature (to include drill, tap and decimal equivalency charts and machinist handbook) drawings, blue prints, and work documents for the current job assignments.

(2) Artisan certification stamp.

(3) Personal protection equipment.

(4) Watch, rings and jewelry, if temporarily removed for safety reasons.

(5) calculator.

(6) Pen, pencil, pad of paper.

(7) consumable/Expendable tooling (drills, reamers, end mills, specially ground tool bits, carbide inserts and holders, mounted stones, wire brushes, sanding disk, and arbors, etc.).

See chapter 3 of this instruction for definitions.

(8) Artisan unique process improvement items.

(9) Miscellaneous hardware used as process improvement items.

NOTE: When work is performed in critical work areas, the higher dritical requirements apply for tools and material. When blue prints or work documents are used in the.work area, the mechanic is responsible for following shop procedures for the proper storage after work hours. Personal items to include, but not limited to, food, condiments, eating utensils, over the counter medicine, and prescription medications are PROHIBITIED from being stored in any tool container. Tools in excess of those listed on the assigned inventories and all hazardous materials are strictly forbidden and will not be stored in the tool container. The container will be locked when not in use.

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2. Tool Container Care and Maintenance

a. .Code 6.3.2 Shop 32310. Issue tool containers with plywood tops secured with nuts and bolts to provide a usable work surface. Containers will be painted with the organization code of FRC East, which is WC2, and a kit number. If applicable, the kit/box/container will also have the following statements painted on them:

Note: Tool Containers with tools too small to etch must be painted accordingly: •“contains tools too small or unsuitable for etching”.

Note: Tool containers that have tools for oxygen use shall have spayed on the outside “OXYGEN USE ONLY”.

b. Fleet Readiness Center East

(1) After receiving supervisory approval, employees may display pictures, posters, or other items on top of their assigned tool containers; however, a Plexiglas panel must be secured to the tool container’s plywood top, at the corners with nuts and bolts. This should be done to secure any items placed on the top of the tool containers (between the plywood and Plexiglas. This will be done to avoid the Plexiglas, plywood, or contents from becoming FOD (foreign object damage) or a safety hazard.

(2) Pictures, posters, etc., displayed in accordance with the above instructions, will not be offensive to other employees.

(3) All pictures, posters, etc., displayed in accordance with the above instructions, will be removed when the tool container is either transferred to another employee or turned in to Code 6.3.2/Shop 32310.

(4) All tooling, and containers (paint guns/cups, grease guns, etc.) will be properly cleaned prior to return to Code 6.3.2/Shop 32310.

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3. Tool Container Inventories

a. The frequency of tool container inventories is based on the FOD potential, with the exception of specialized shop tool containers as noted within this instruction.

b. A FRC East 10290/16, “Daily Tool Inventory,” and a current (no more than one year old) inventory list of all tools will accompany each tool container assigned to a shop or individual. The FRC East 10290/16 and inventory list will be kept in the tool container at all times. Shop supervisor will maintain the previous copies (up to one’ year of inspections) of the Daily Tool Inventory.

c. Supervisor issued tools that are intended for shop use must be stored in a container, silhouetted in accordance with this instruction, and visually inventoried twice per shift, at the beginning and end of each shift, by the supervisor or desigx~ee.

d. This pertains to shop containers in all work areas, regardless of FOD potential. The FRC East 10290/16 for tool control will be maintained as indicated above. In addition to the FRC East 10290/16, shops will use the FRC East 10290/lA, “Shop Tool Container Sign Out Sheet,” or the FRC East 10290/ic, “Shop Tool Sign Out,” depending on the area, to record daily sign-out and sign-in of shop tools by shop employees. These forms will be retained by the shop supervisor for one year.

e. It is the responsibility of the custodian/assigned employee of any tool container to contact the central tool room if there is a discrepancy with an inventory sheet. Once the tools are issued and the kit is signed for the custodian is responsible for the tools itemized on the inventory sheet. The inventory sheet and the tool kits must match.

f. Flight Check Work Areas. All tool inventories at Flight Check (Code 6.ODE) will be certified and signed by a second artisan using FRC East l0290/l6B, “Daily Tool Inventory for Flight Check,” at Flight Check, as required.

g. Critical Work Areas. A complete visual inventory will be performed at the start of each shift, upon completion of each maintenance task, prior to changing aircraft, engine, or

2-4 component work assignments, and prior to the completion of a shift. The following information must be maintained daily:

(1) Legible signature of the person performing the inventory.

(2) Date and time the container is inventoried.

• (3) shop Number/Aircraft Number.

(4) Annotation of any missing tooling.

Note: In critical areas when a tool is missing from a container and has been properly reported, it must be legibly annotated daily on the FEC East 10290/16 in the remarks column opposite the corresponding date until it is replaced in the box.

• (S) In addition to the daily visual inventory, a physical inventory of each tool container must be conducted once every month. The Production Trades Division (Code 6.2.1) will conduct monthly inventory on the first regular workday of each month. This monthly inventory will be annotated with the letters “INV” written legibly in the remarks column of the FEC East 10290/16 opposite the corresponding date indicative of a physical inventory. A physical inventory is when an employee physically verifies the kit number and the organizational code on an individual tool. Any discrepancies will be noted in the remarks column, reported to the supervisor, and continue to be annotated until the discrepancy is remedied. Tools without a kit number will use the inventory for verification purposes.

Note: At the end of each month, the FRC East 10290/16 and 10290/1GA will be passed to the shop supervisor, who will retain them for a period of one year. An exception to this is the machine shops within Code 6.2.1/shops 91105 and 91108, where trainees are on a recurring shop rotation for training purposes. In these cases, the FRC East 10290/16 will be collected and maintained by the assigned training leader. After graduation from the assigned training program, the training leader will turn the tool inventory sheets over to the supervisor of the employees’ permanent shop.

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ii. Non-Critical Work Areas

(1) Employees will conduct a visual tool inventory of assigned tool containers at the end of each shift, whenever work is interrupted for a period of four hours or more, and when’ a maintenance task is completed. A visual inventory at the beginning of the shift is not mandatory unless the employee moves to a different work area or unless there is reason to believe a tool container has been tampered with. The employee will record each inventory on the FRC East 10290/16. The entries will include:

(a) Date and time the container is inventoried.

(b) Legible signature of the individual performing the inventory in accordance with reference (f)

(c) Annotation of any missing tooling and ensure the missing tools are properly reported. Missing tooling must be annotated daily on the FRC East 10290/16 in the remarks column opposite the corresponding date until it is replaced in the kit.

(2) Tools assigned to shops will be visually inventoried daily and recorded on the FRC East 10290/16 consistent with this instruction.

(3) In addition to the visual inventory, a physical inventory of each shop tool…