Attachment_07p_4855.3V.pdf

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER EAST

PSC BOX 8021

CHERRY POINT NC 28533-0021

FRCEASTINST 4855. 3V

Code 6.2.2-DEW

FEB 01 2016

FRC EAST INSTRUCTION 4855.3V

From: Commanding Officer, Fleet Readiness Center East

Subj: PROCESSING SCHEDULED REWORK AND NONSCHEDULED

IN-SERVICE REPAIR AIRCRAFT

Ref: (a) FRCEASTINST 4790.11H

(b) COMNAVAIRFORINST 4790.2 CH-1 Cc) FRCEASTINST 4855.1P Cd) FRCEASTINST 4855.8D Ce) NAVAIRINST 13023.3 CH-l

1. Purpose. To establish responsibilities for processing subject aircraft physically inducted at the Fleet Readiness Center East (FRC East) per references (a) through Ce)

2. Cancellation. FRCEASTINST 4855.3U.

3. Scope. This instruction applies to aircraft inducted for repair, strip/paint, modification, and validation/verification of technical directives, engineering investigations, or any other special projects.

4. Responsibilities

a. Research and Engineering Group (AIR 4.0) . Provide assistance to resolve technical problems not currently specified in existing technical data when requested by production personnel

b. Director of Operations (Code 6.0DB) . Determine whether a specific discrepancy will or will not be corrected if it cannot be resolved by the aircraft assessment planner and estimator (P&E)

c. Flight Check Officer (Code 6.0DB)

(1) Secure aircraft and install adequate protective devices/caps/covers (barrier paper may be used to cover intakes, doors, etc.) as required.

“UNSURPASSED SERVICE TO THE FLEET AND RELENTLESS FOCUS ON QUALIT’~’ ENVIRONMENT

AND OCCUPATIONAL HEALTH AND SAFETY”

FRCEASTINST 4855. 3V

FEB 012016

(2) Review the ferry pilot’s discrepancies.

(3) Perform functional check flights when required.

(4) List all discrepancies on a FRC East 3710/1, “Flight Test Discrepancies.”

(5) Hand-carry all inspection results and discrepancies to the cognizant P&E when required.

d. Planning and Estimation Branch (Code 6.2.2.2) . Code

6.2.2 shop personnel will respond to P&E requests in accordance with references (b) through (e) by:

(1) Inspecting any damaged aircraft per P&E request.

(2) Determining appropriate maintenance location requirement (either. field or depot)

(3) Upon Completion of. the Evaluation, coordinate funding source and pbtain concurrence for the P&E recommendation with the applicable Requesting Activity and Aircraft Controlling Custodian (ACC)

(4) Provide initial cost estimate and schedule via preliminary “Condition and Disposition” (C&D) message.

(5) Ensuring all special rework and nonscheduled in-service repair (ISR) aircraft awaiting induction for repair shall be preserved in accordance with existing regulations to prevent further deterioration of material condition. Parts shall not be cannibalized or removed from damaged aircraft unless specifically authorized by the ACCand the payback method is documented.

(6) Coordinate with the cognizant Integrated Product Team regarding repair/mod event requirements and aircraft arrival dates. .

(7) Coordinate with cognizant Examination and Evaluation Branch (Code 6.2.2.1) and the appropriate aircraft Production Trade Division (Code 6.2.1) to ensure engine Foreign Object Debris (FOD) inspections are conducted, per reference (a) , on all Special Rework (SRWK) and nonscheduled ISR aircraft that are

FEB 01 2016

to be flown or ground turned by the FRC East personnel. Ensure FOD inspections are properly documented on FRC East 4730/21, “FOD Check,” and placed in the appropriate aircraft record package.

(8) When required, request Code 6.2.2.1 examine and inventory the aircraft and submit a list of discrepancies.

(9) Review the discrepancies (to include ferry pilot’s discrepancies) and code those items requiring rework as required.

(10) Prepare Manufacturing Resource Planning II (MRP II) work orders and either a FRC East 4854/l4E, “Standard Work Order Supplement for In-Service Repair/Modification Aircraft,” including the work to be accomplished, i.e., repair, paint, flight check, or if the aircraft is funded via SRWK, assign a work scope, attach a complete MRP II work deck, and schedule/process the aircraft as a scheduled induction. Review all discrepancy lists and approve for repair, modification, rework, etc. according to customer contract.

(11) Ensure the Aircraft Quality Assurance Branch (Code 6.4.2.1) reviews all work orders created. Include in the aircraft data package any additional quality verification requirements identified by quality assurance personnel.

(12) Negotiate with AIR-4.0 when a listed discrepancy requires technical assistance or if the repair contracted for cannot be accomplished as outlined in existing procedures.

(13) Prepare correspondence to the COMNAVAIRSYSCOM, customer, and type commander if the contracted work date cannot be met and/or if work scope is increased beyond that requested by the COMNAVAIRSYSCOM/customer.

(14) Author and transmit final C&D message upon completion of cost estimate.

(15) Ensure all log book/log sets are updated as required by reference (b)

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FEB 012016

e. Examination and Evalu~ation Branch (Code 6.2.2.1. Shop personnel will respond to P&E requests in accordance with references (b) through (e) by:

(1) When requested, perform engine FOD inspections on each aircraft per reference (a)

(2) Inspect for safety of flight discrepancies and/or conduct all trades incoming inventory on all aircraft when requested by the cognizant P&E.

(3) Inventory the aircraft and furnish the cognizant P&E the missing on induction items. Evaluate damage when requested, disposition parts, or route components using the teardown and disposition workbench.

(4) Generate a list of all discrepancies on FRC East 4720/7, “Aircraft Discrepancy Work Sheet and/or in Automated Data Collection System (ADCS) and FRC East 4720/10, “Noted But Not Corrected (NBNC) Listing,” when required. Provide copies of all discrepancy worksheets to the cognizant P&E.

(5) Generate MRP II work orders to address discrepancies and/or requirements provided by the P&E on the FRC East 4854/14E when requested or process SRWK inductions as scheduled aircraft per instructions on P&E’s production work order. All work orders will be assigned workload priority “3” per reference (e)

(6) Creation of work orders for emergent work (Handwritten Shop Order (HWSO) and add-a-lines) shall contain the type/model/series, part number, serial number (if applicable) , manual reference, and description of work process to be accomplished. All work orders shall be forwarded to the cognizant Quality Assurance Specialist (QAS) for review and assessment of verification requirements.

f. Quality Assurance Branch (Code 6.4.2.1) . The QAS will:

(1) Review aircraft work documents/planning work orders for accuracy and identify and classify quality characteristics prior to work beginning. Review technical directives as necessary to designate quality characteristics and verification requirements.

FEB 01 2018

(2) Provide documented comments on aircraft work package inadequacies and any additional quality characteristics required to the P&E. If no inadequacies or additional quality characteristics are required, hand-carry the package to the next work center in the sequential operation of the work orders.

(3) Cognizant QAS shall review all emergent work orders (HWSO and add-a-lines) for quality requirements and the inclusion of all necessary information to successfully complete the task(s) . Stamp and date the Quality Assurance (QA) labor line that has been added by the examiner and evaluator (E&E)

(4) Perform verification actions and document in the MRP II QA Workbench.

(5) Monitor work areas for compliance to the FOB Prevent ion Program in accordance with •reference (a) . Take corrective actions as required.

g. Workload Production Control Aircraft and Execution Branch (Code 6.3.2.2). Shop personnel will respond to P&E request in accordance with references (b) through (e) by:

(1) Assign a Production Controller to assist in day-to-day support.

(2) Provide a secure area for material received.

(3) Notify the P&E when material is received.

(4) Ensure components are removed from In-Service Repair/Commander, Naval Air Systems Command (COMNAVAIRSYSCOM), Fleet Support (FS) custody aircraft only when the following conditions prevail and are adequately documented:

(a) When non-availability of components will create a production work stoppage and all normal resources have been exhausted.

(b) A Request for FRC East 13100/17, “Cannibalize /Backrob Authorization,” has been prepared and approved by the Workload Scope Determination (Code 6.2.2) or his/her designated representative.

FRCEASTINST 4855.3V

FEB 01 2O16~

Note: Backrobbing from COMNAVAIRSYSCOM FS aircraft will be accomplished as directed by COMNAVAIRSYSCOM and the concurrence of the Naval Inventory Control Point.

h. Defense Logistics Agency Annex Cherry Point

(1) Assign a Customer Support specialist as required to provide material support for nonscheduled aircraft.

(2) When notified by the planner, order, follow up, and/or maintain records on all outstanding material requests for nonscheduled aircraft.

i. Production Trades Division (Code 6.2.1)

(1) Secure aircraft and install adequate protective devices/caps/covers (barrier paper may be used to cover intakes, doors, etc.) upon receipt of appropriate work orders.

(2) Perform FOD inspections on each aircraft per reference (a) . Ensure all areas of responsibility are free of FOD hazards and stress the importance of a hardware control effort.

(3) Perform required work listed on the work order and added attachments, such as FRC East 3710/1, “Flight Test Discrepancies,” and/or the FRC East 4710/1, “ISR Discrepancy Worksheet.” Certify all documents in accordance with reference (d).

Note 1: The artisans shall notify QAS if verification is required in accOrdance with reference (d)

Note 2: Air Force aircraft and those programs not associated with ADCS will utilize FRC East 4710/1.

(4) Contact AIR-4.0 for guidance and specific instructions to perform required work when technical assistance is needed.

(5) Maintain a short summary in the production pass-down for applicable TMS BUNO A/C. Log maintenance actions or tests performed to include progress on none completed actions at the end of each shift.

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Use a FRC East 4855/41, “Removal and Reinstallation List,” for components removed and installed following rework, access, or replacement.

(6) For aircraft requiring flight tests, deliver a repair data package to QA Branch (Code 6.4.2.1) that will include all completed work orders, FRC East 4710/1, “ISR Discrepancy Worksheets and/or the ADCS discrepancy, FRC East 4720/10, “Noted But Not Corrected Listing,” and Quality Characteristic List.

5. Records Management. Records created as a result of this instruction, regardless of media and format, will be managed per SECNAV M-5210.l, Department of the Navy Records Management Manual.

6. Forms. The following forms may be found on the Naval Forms Online Web site:

a. FRC 4855/41, “Removal and Reinstallation List”

b. FRC East 4720/7, “Aircraft Discrepancy Work Sheet”

c. FRC East 3710/1, “Flight Test Discrepancies”

d. FRC East 4854/l4E, “Standard Work Order Supplement for In-Service Repair/Modification Aircraft”

e. FRC East 4730/21, “FOD Check”

f. FRC East 4720/10, “Noted But Not Corrected Listing”

6.Instruction Responsibility. Workload Scope Determination Division (Code 6.2.2) will maintain this instruction in a current status.

7 ‘~KENNETH R. HARPER

By direction

Distribution:

Electronic only via the FRC East Master List Web page:

https://mynavair.navair.navy.mil/portal/server.pt/community/issc tools/l742/index.cfm?processHyperL±nk=true&crt=