OT-22-20017 - Ground Operation Procedures.pdf

DATA ITEM DESCRIPTION

Title: GROUND OPERATION PROCEDURES

Number: OT-22-20017 Approval Date: 20220207 AMSC Number: N/A Limitation: N68520-21-R-0007 DTIC Applicable: N/A GIDEP Applicable N/A Office of Primary Responsibility: AS Project Number: DKC 7 FEB 2022 Applicable Forms: N/A

Use/relationship: These procedures apply to contractor personnel whose duties include the operation, production, modification, development, or maintenance of any aircraft (with or without a wing or engine attached) where the Government has a vested interest in ownership and indemnifies contractors of liability under Government aircraft contracts.

This Data Item Description (DID) contains the format, content, and intended use information for the data product resulting from the work task described by the contract PWS and DCMAINST 8210.1C, Change 1, Chapter 3.

This DID is for one-time use for Depot Level Maintenance contract N68520-21-R-0007.

Requirements:

1. Reference Documents. The applicable issue of the documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract.

2. Format. Use format as defined below. If the element does not apply to the platform or project, annotate as Not Applicable for that paragraph.

3. Content. The Ground Operations Procedures (GOP) shall include the following:

3.1. The contract number.

3.2. The type of aircraft and their locations.

3.3. Date.

3.4. A Master Training Plan that entails a method to ensure personnel are qualified / certified to perform tasks and entails the following:

3.4.1. A roster of instructors.

3.4.2. Initial and continuation training shall include, as applicable, written and/or practical exams (identify minimum passing score).

3.4.3. Course nomenclature.

3.4.4. Course outlines and programs of instruction for each GOP.

OT-22-20017

3.4.5. A process that ensures courses are current.

3.4.6. A controlled process for tracking and forecasting training to ensure employees do not go non-current or perform tasks if their currency has expired.

3.4.7. A process to identify/establish training for new or emerging requirements.

3.4.8. A process for evaluating the previous training, qualification, and certification of new personnel.

3.4.9. A process for recertifying/requalifying personnel.

3.5. Training, qualification, certification, and training records. Employee Training Records (Electronic or Manual) will contain at a minimum:

3.5.1. Initial, recurring, currency/proficiency and re-certification training status for employees.

3.5.2. A record of successful course completion, date completed and next due date, as applicable.

3.5.3. Other certifications, as appropriate and, Records of medical examination type and currency as required (date accomplished & next due). Note: Follow all Health Insurance Portability and Accountability (HIPAA) Privacy Rules regarding protection of medical records.

3.6. Testing control measures that include:

3.6.1. Processes to ensure tests are not memorized or compromised over a period of time (e.g., multiple versions of each test, or randomly generated questions (computerized)).

3.6.2. A process for securing test material.

3.6.3. A method to retain latest exam results for each test taken (e.g., pass/fail, score).

3.7. A Foreign Object Damage (FOD) prevention and Tool Control program which is planned, integrated, and developed in conjunction with Safety, Test, Engineering, Quality, Maintenance, Production, Manufacturing and Facility offices as applicable.

3.7.1. FOD and Tool Control Processes shall be established for manufacturing, maintenance, modification, assembly, disassembly and flight test/acceptance operations.

3.7.2. FOD and Tool Control processes shall mitigate the FOD risk using control methods factoring the level of risk of migration, entrapment, encapsulation and damage.

3.7.3. Strategies to mitigate the risk of FOD can include containment, accountability, documentation, use of technology, Non-Destructive Testing/Inspection (NDT/NDI), work instructions, design, inspection process, etc.

3.7.4. Specific FOD procedures shall address at a minimum:

3.7.4.1. Metrics, measures, data collection, analysis, trend identification, root cause analysis and corrective action.

3.7.4.2. Management’s role in FOD prevention (e.g., use of tool checks, response to lost tools, training program, etc.).

3.7.4.3. FOD Prevention Training. Initial, recurring.

3.7.4.4. Designation of FOD zones/areas (as appropriate), and controls governing each zone/area (e.g., increased restrictions/vigilance). Zones may be differentiated based on the level of risk.

3.7.4..5. Housekeeping procedures. Shall include timely cleaning activities of areas off the product when generated work debris poses a migration potential increasing the risk of FOD.

3.7.4.6. Clean-As-You-Go. Shall include timely cleaning activities of areas within the aircraft/product when generated work debris poses a potential for migration and entrapment.

3.7.4.7. Use and control of FOD protection devices/barriers (e.g., caps/plugs, dust covers, intake/exhaust/pitot covers, pads, etc.) for open component ports, tubing, lines, ducting, electrical connectors, protection of surfaces/edges, etc.

3.7.4.8. Control of FOD on runways, taxiways, flight line, parking areas, aprons, hardstands and aircraft/engine run up areas to include trim pads, hush houses, and test cells through the use of sweepers, FOD walks, etc.

3.7.4.9. Reporting and tracking of degraded ramp/taxiway/runway surfaces and interim procedures for operating in or around degraded areas and during construction activities.

3.7.4.10. Vehicle traffic entering aircraft operational areas (e.g., rollover checks, FOD shakers, etc.).

3.7.4.11. Recurring FOD Prevention Meetings (no less frequent than quarterly). Includes lessons learned;

problem areas; trend analysis/results.

3.7.4.12. FOD awareness briefings and/or procedures for visitors.

3.8. Tool, Equipment and Item Control procedures shall address at a minimum:

3.8.1. Inventory, Accountability, Traceability (e.g., shadow boxing, automated inventory systems, tool chits), automated dispensing units, tool tags, serializing/etching, kitting, documenting work plans, inspections, tool/item issue/return process, control logs, etc.).

3.8.2. Items too small to etch/mark shall be listed by description on inventories (e.g., 12 apexes + kit/container), and containerized with like items (if applicable).

3.8.3. Inventory lists shall be of sufficient detail to identify tool type, location in the toolbox (if applicable), and description of sub-components (e.g., feeler gauge/12 blades).

3.8.4. Control and inventory of specialty tools and test equipment.

3.8.5. Management Responsibilities (e.g., documented periodic surveillance/assessment of tool inventories, etc.).

3.8.6. Tool Crib Attendant Responsibilities (e.g., issue, turn in, inventories, etc.).

3.8.7. User Responsibilities (e.g., pre and post-use inspections to include inventory and serviceability;

taking the minimum required to accomplish the task, etc.).

3.8.8. Methods for controlling specialty tools, shop aids, clamps, clecos, fixtures, etc., required to be installed on the aircraft/product for extended periods of time (over one shift).

3.8.9. Unserviceable Tools. Procedures shall ensure unserviceable tools are removed from use.

3.8.10. Methods for controlling consumables. This includes: perishable tools such as drill bits, cutters, reamers etc., that are periodically replaced due to wear, and expendable items such as rags, wipes, tongue depressors, acid brushes, sandpaper, applicators, sealant, glue, tape rolls, scrapers, etc. that are expended during use.

3.8.11. Methods for controlling small hardware and miscellaneous small parts (e.g., fasteners, nuts, bolts, and washers) used in, on, and around the aircraft and aircraft components (e.g., uninstalled wing, fuselage, tail section, engines etc.), and support equipment.

3.8.12. Methods for controlling personal items (e.g., pens, pencils, jewelry, cell phones, watches, keys, lighters, coins, wallets) during ground operations.

3.8.13. Lost Tool/Item Procedures shall include:

3.8.13.1 Non-attribution reporting.

3.8.13.2. Search process. Note: Aircraft shall not be released for flight until the contractor has concluded the search process.

3.8.13.3. Documentation process. Note: The aircraft records shall be annotated to reflect the lost items.

3.8.13.4. COR notification.

3.8.13.5. Incident closeout.

3.8.13.6. Aircrew brief of all incidents of lost tools/items reported missing and not recovered.

3.9. Aircraft Engine/APU/GTC Operations.

3.10. Medical Requirements for Ground Personnel.

3.10.1. Physical Requirements.

3.10.2. Records.

3.11. Aircraft Ground Support Equipment.

3.11.1. Periodic Inspection/Maintenance Program.

3.11.2. Management of Equipment and Records.

3.11.3. User Requirements.

3.11.4. Tracking Systems for Preventative Maintenance.

3.11.5. Equipment Identification Process.

3.11.6. Configuration Control/Management.

3.11.7. Corrosion Control.

3.11.8. Overdue Equipment.

3.12. Aircraft Servicing.

3.12.1. Refuel/Defuel Process .

3.12.2. Fuel Servicing Equipment.

3.12.3. Fuel Storage.

3.12.4. Fuel Quality.

3.12.5. Hydraulic Systems, Engines, Gearboxes, Propellers.

3.12.6. Oxygen.

3.12.7. Aircraft Tires.

3.12.8. Grease Guns, Dispensing Cans, Spray Bottles.

3.12.9. Process for Preventing Cross Contamination.

3.13. Aircraft Ground Handling.

3.13.1. Towing.

3.13.2. Mooring and Tie down.

3.13.3. Jacking.

3.13.3.1. Identification of Jacking Supervisor.

3.13.3.2. Pre-Briefing.

3.13.3.3. Required Personnel.

3.13.3.4. Jacking Team Communication.

3.13.3.5. Pre-Operational Inspection of Jacking Equipment.

3.13.3.6. Pre-Jacking Location Inspection.

3.13.3.7. Proper Securing/Configuration of Jacks.

3.13.3.8. Aircraft Specific Requirements.

3.14. AFE/ALSE/ALSS.

3.14.1. Training Requirements.

3.14.2. Service or Commercial Tech Guidance.

3.14.3. Proper Documentation of Equipment Records.

3.14.4. Work Center Explosive Safety Program.

3.14.5. Temperature and Relative Humidity Requirements.

3.14.6. Serviceability/Calibration Requirements for Equipment.

3.14.7. ALSE Storage .

3.14.8. Monitoring/Recording of Temperature.

3.14.9. Moisture and Oil Free Air Source.

3.14.10. Oxygen System Maintenance Requirements.

3.15. EGRESS SYSTEM/COMPONENT MAINTENANCE AND STORAGE.

3.15.1. Training.

3.15.2. Initial/Annual “Safe-for-Maintenance” Training.

3.15.3. Service or Commercial Technical Guidance.

3.15.4. Proper Documentation of inspection Records.

3.15.5. Proper Inspection, Maintenance, Handling, and Storage of CAD/PADS.

3.15.6. Work Center Explosive Safety Program.

3.15.7. Access to Egress Seats/Components.

3.15.8. Proper Storage of Egress Seats/Components.

3.16. Aircraft/Equipment Hydraulic Fluid Analysis Program.

3.16.1. Hydraulic Fluid Contamination Surveillance Program.

3.16.2. Sampling.

3.16.3. Proper Handling of Samples.

3.16.4. Testing Methods.

3.16.5. Testing Results.

3.16.6. Required Actions for Abnormal Results.

3.17. Test, Measurement, and Diagnostic Equipment (TMDE).

3.18. Tire and Wheel Maintenance.

3.18.1. Use of Technical Data in Tear-down and Build-up.

3.18.2. Storage of Wheels, Components, and Tires.

3.19. Welding and Brazing.

3.19.1. Authorized Locations.

3.19.2. Welding Fire-Safety Checklist.

3.19.3. Process and Authority for Issuing a “Hot Work Permit”.

3.19.4. Pre-operational Inspection of Equipment.

3.20. MAINTENANCE MANUALS.

3.20.1. Methods to Ensure Currency.

3.20.2. Receipt, Distribution, and Currency of Technical Publications.

3.20.3. Foreign Disclosure.

3.21. Aircraft Records Management.

3.21.1. Safe-For-Flight Release.

3.22. Battery Handling.

3.22.1 Use of Technical Data .

3.22.2. Tracking of Batteries.

3.22.3. Separation of Non-compatible Batteries.

3.23. Corrosion Control.

3.23.1. Use of Technical Data .

3.23.2. Cleaning, Washing, Lubrication.

3.23.3. Corrosion Prevention/Control .

3.24. Aircraft Weapons, Munitions, and Cartridge Actuated Devices (CADS).

3.24.1. Use of Technical Data.

3.24.2. Use, Storage, Handling, and Transportation.

3.25. Fuel System Maintenance.

3.25.1. Use of Technical Data .

3.25.2. Fuel Cell Entry Operations.

3.25.3. Fuel Systems Purging Procedures.

3.25.4. Lower Explosive Level (LEL) Procedures.

3.26. Storage of Hazardous Materials (HAZMAT).

3.26.1. Handling and Storage Requirements.

3.26.2. Proper Use, Labeling, and Identification.

3.26.3. Emergency Procedures.

3.27. Gases (Inert and Flammable).

3.27.1. Handling, Transportation, and Storage Requirements.

3.27.2. Ventilation.

3.27.3. Proper Use, Labeling, and Identification.

3.27.4. Emergency Procedures.

3.28. Application of Electrical and Hydraulic Power to Aircraft.

3.28.1. Use of Technical Data .

3.28.2. Minimum Required Personnel.

3.29. Operation of Landing Gear, Powered Doors, and Flight Control Surfaces.

3.29.1 .Use of Technical Data .

3.29.2. Minimum Required Personnel.

3.29.3. Minimum Clearance Distances from Objects .

4.0. Safety Content.

4.1. Aviation Safety Program Elements.

4.2. Mishap Prevention Program.

4.3. Risk Management.

4.4. Hazard Identification and Elimination Procedures.

4.5. Aviation Safety Council.

4.5.1. Action Items.

4.5.2. Company Mishaps.

4.5.3. Airfield Hazards.

4.5.4. Members.

4.6. Flight Safety Meetings.

4.7. Safety Audits.

4.8. Safety Publications.

4.9. Aircraft Damage Reporting Procedures.

4.10. Aircraft Mishap Notification Procedures.

4.11. Privileged Data.

4.12. Company Internal Distribution.

4.13. Release of Privileged Data to Third Parties.

4.14. Training Requirements.

4.15. Mishap response Plan.

4.15.1. Immediate Action Checklist.

4.15.2. Notification Plan.

4.15.3. Cooperation and Participation in Mishap Investigations.

End of OT-22-20017