FRCSWINST_10290.1C_Tool_Control_Program.pdf

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER SOUTHWEST

P.O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

IN REPLY REFER TO:

FRCSWINST 10290.1C CH-1

6.3

NOV 24 ·2014

FRCSW INSTRUCTION 10290 . 1C CHANGE TRANSMI TTAL 1

From: Commanding Officer

Subj: COMMAND TOOL CONTROL PROGRAM

Encl: (1) Revised page 5 and page 1 of enclosure (2)

1 . Purpose . To transmit new page 5 and page 1 of enclosure ( 2) •

2 . Action . Remove page 5 and page 1 of enclosure (2) and replace with enclosure (1).

nJ ~ -r.. . ', -2. 1-1. 1'\.~

T. H. PFANNENSTEIN

Distribution :

Electronic only, v i a https : //mynavair.navair.navy . mil/frcsw

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER SOUTHWEST

P.O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

FRCSW INSTRUCTION 10290.1C

From: Commanding Officer

Subj: COMMAND TOOL CONTROL PROGRAM

Ref: (a) COMNAVAIRFORINST 4790.28

(b) FRCSWLCP 4790. (CH 10.11)

(c) FRCSWINST 4855.1C

IN REPLY REFER TO:

FRCSWINST 10290. 1C

6.3

NOV 0 7 2014

Encl: (1) Tool Container Inventory Requirements

(2) Missing Tool Reporting and Investigation Requirements

(3) Annual Wall to Wal l Tool Container Inventory Schedule

1. Purpose. The purpose o f this instruction is to es tabl ish Tool Control Program (TCP) policies and procedures including the assignment of responsibilities for the acquisition, issu e , control and accountability of all tools used in the repair and maintenance of a ircraft , aircraft component s , and al l other products , services and related equipment performed by Fleet Readiness Center Southwest in accordance with references (a) through (c) .

2 . Cancellation . FRCSWINST 10 290 .18 . Due to extens i ve revi sions , changes are not noted.

3 . Objective . The primary objective of the Tool Control Program is to e nhance flight safety by preventing a ircraft acci dents attributable to missing tools during and fo llowing maintenance or repairs . Secondary objectives include reduction of expenditures through accountability , improved inventory control , and improved quality of aircraft maintenance .

4 . Policy . The policy of FRCSW is to establish and maintain a cost-effective , comprehensive, integrated, and monitored TCP that i s rigorous l y enforced and documented per reference (a) .

Specific measurements of program effectivenes s will be maintained by Industrial Production Support Department (Central Tool) and monitored by Industrial Quality and Airspeed Department.

FRCSWINST 10290.1C

NOV 0 7 2014

5. Tool Control Responsibilities/Roles. This instruction allows for the delegation of duties to reliefs/designees as necessary to accomplish tasks.

a. TCP Manager

(1) Assume the responsibilities of the TCP Manager.

(2) Appoint a TCP Committee Chairperson.

(3) Act as point of contact for all TCP issues that cannot be resolved at the Committee Chairperson's level.

b. TCP Committee Chairperson

(1) Serve as NAMP Program Manager.

(2) Report directly to the TCP Manager.

(3) Chair monthly TCP Committee meetings.

(4) Be responsible to the TCP Manager for TCP compliance.

(5) Perform monthly unannounced TCP inspections.

(6) Recommend changes from TCP committee members to the TCP Manager.

(7) Provide minutes of the monthly TCP Committee meeting and attendance roster to the chain of command.

c. TCP Committee Members

(1) Consist of primary and alternate representatives at grade WG-10 or above from the following area:

(a) All Product Lines

(b) Industrial Plant Maintenance Division

(c) Test Line Flight Check Control Center

(d) Industrial Quality Department (QA)

(2) Act at the direction of the TCP Manager, will attend monthly meeting. The meeting agenda 1vill include a review of training requirements, an inspection, discussion of problems and recommended improvements to the Tool Control Program.

(3) Will be appointed by the Third Line Supervisor.

d. Production Director. Review and sign all Missing Tool Reports.

e. Third Line Supervisors

(1) Hold Second Line Supervisors accountable for insuring compliance with this instruction.

(2) Maintain continual day-to-day accountability and custodial control of all tool containers/tools utilized in their areas, see enclosure (1).

(3) Review and sign all Missing Tool Reports, ensuring all processes are met, and direct an additional search as required, prior to forwarding to the Production Director/Tool Control Program Manager or Production Officer, see enclosure ( 2) •

(4) Review and sign the Annual Tool Container Inventory FRCSW 10290/5 and forward to Industrial Production Support Department (Central Tool).

(5) Determine tool control inventory requirements for facilities personnel in their areas.

(6) Assign Primary and Alternate TCP Committee Members.

f. Second Line Supervisors

(1) Hold First line supervisors accountable for insuring compliance with this instruction.

(2) Maintain continual day-to-day accountability and custodial control of all tool containers/tools utilized in their areas, see enclosure (1).

(3) Review and sign all Missing Tool Reports, ensuring all processes have been met, and direct an additional search as required, prior to forwarding to the Third Line supervisors for review and endorsement, see enclosure (2) .

(4) Review the Annual Tool Container Inventory FRCSW 10290/5 and forward to the Third Line Supervisor for review.

g. First Line Supervisors

(1) Ensure all mandatory training procedures for missing tools are adhered to.

(2) Request tool containers/tooling via their chain of command from Industrial Production Support Department (Central Tool) .

(3) Accept custody and responsibility for all tool containers, tools, pad locks, and keys issued to their respective areas.

(4) Hold artisans responsible for all tool containers/tooling assigned to them.

(5) Conduct a Physical Inventory, enclosure (1) of all assigned tool containers. One tool container will be inspected per week and compliance will be documented in a local Weekly Physical Tool inventory log and on the left side of Positive Tool Control Logbook Form FRCSW 10290/11 with date of inventory and findings.

(6) Verify tool container Positive Tool Control Inventory, FRCSW 10290/7, from Central Tool on an annual basis.

(7) Ensure all tool container modifications are requested through the Industrial Production Support Department using Tool Container Change Request FRCSW 10290/2.

(8) Follow missing tool requirements:

(a) Notify the area Quality Assurance Supervisor (QAS) immediately upon discovery of a missing tool.

FRCSWINST 10290.1C CH-1

NOV 2 4 Z014

(b) Have discretion to stop, search, and authorize the return of artisans to work.

(9) Missing tool reports:

(a) Submit, review and sign all Missing Tool Reports ensuring all processes have been met prior to forwarding to the area QAS.

(b) Ensure a paper copy of the Missing Tool Report FRCSW 10290/3 is submitted if the electronic Continual Analysis and Metrics (eCAM) database is down.

(10) Ensure a lost tool placard is affixed to the aircraft if the tool has not been located, when applicable.

(11) Perform an annual ftwall to wall" inventory using the Annual Tool Container Inventory FRCSW 10290/5 and Annual Wall to Wall Inventory Schedule Table, enclosure (3), as a guide for due dates, for reconciliation with the Automated Tool Inventory Control and Tracking System (ATICTS) listing of the Industrial Production Support Department (Central Tool) . The inventory will be forwarded to the Second Line Supervisor for revie1v and endorsement.

(12) Appoint a Shop Tool Coordinator (as needed) to act as the Point of Contact (POC) for the reporting and replacement of broken and worn tools using the Broken/Worn Tool Report, FRCSW 10290/8. The Shop Tool Coordinator, or Point of Contact, and Shop Supervisor shall submit a Consumable Tooling Request, FRCSW 10290/4, to the Central Tool Room (CTR) for consumables.

(13) Ensure that the transfer of the tool container is documented using the Transfer of Custody, FRCSW 10290/9, and is endorsed by the Second Line Supervisor and QA upon inventory verification.

h. Artisans

(1) Inventory their assigned TCP container per enclosure

(1) and enter the date inventoried, the results of inventory and stamp the Tool Control Logbook attesting that all tools are accounted for.

(2) At NO TIME leave a loose tool or unlocked container unattended on an aircraft, workbench, or shop floor.

is defined as within line-of-sight.

"Attended"

(3) Ensure an accurate inventory list is provided to the work site QA 1vhere work will be performed away from the routine work site. The inventory will be provided upon arrival and prior to departure from the work site. QA will inventory, date, and sign the inventory listing.

(4) Follow broken tool requirements:

(a) Turn in all broken/worn hand tools to the local area tool control point for replacement. A serialized Broken Tool Replacement (tag), FRCSW 4940/2, will be issued for power tools or PME tools that are turned in for repair or replacement.

The lower half of the tag or the request shall be kept with the tool container inventory.

(b) Use Broken/Worn Tool Report, FRCSW 10290/8, to turn in broken/worn tools for reporting and replacement. A duplicate copy of the Broken/Worn Tool Report marked NIS and signed by CTR personnel will be issued for common tools not in stock (NIS) as a turn-in proof. Broken tools with missing pieces will be treated as a missing tool. A Missing Tool report will be submitted.

(5) Notify the first line supervisor immediately upon discovery of a missing tool from any tool container.

(6) Place personal items in a sealed zip lock bag in personal rollaway for the duration of the shift.

i. Contractors

(1) Contractors and their employees are required to comply with the requirements of this instruction. Contract employee's toolboxes and tools shall be marked with the first letter of the last name followed by the last four of their Social Security Number (SSN) (e.g. N0428). All other requirements of this instruction apply.

(2) Provide the Industrial Production Support Department

(Central Tool) and the Industrial Quality Department an updated tool container inventory on an annual basis.

(3) Inform the Contracting Supervisor, who shall notify the Contracting Officer Representative upon the discovery of a missing tool.

j. Test Line Branch

(1) Ensure designated "Safe for Flight" personnel are responsible for ensuring that all lost tool reports are cleared prior to releasing an aircraft SAFE FOR FLIGHT.

(2) Ensure that Test Line QA verifies all "out of area" artisan tool containers, squadron personnel tools, consumables, and expendables prior to, and after completion of, work on aircraft or facilities. In the event that a QAS is unavailable, Test Line Flight Check personnel shall perform the verification and make an entry in the QA check-in and check-out log.

(3) Ensure lost tool entries are made on Aircraft Inspection and Acceptance Record, form OPNAV 4790/141 for any tool reported as lost on an aircraft where the search has been abandoned.

k. Industrial Production Support Department (Central Tool)

(1) Maintain a current and up to date master tool inventory of all tool containers and their contents utilizing ATICTS.

(2) Provide all tool container inventory sheets printed on Positive Tool Control Inventory Form FRCSW 10290/7 and issued to the Shop Supervisor, stamped "original" and signed by the Central Tool Room Supervisor.

(3) Validate the Annual Tool Container Inventory FRCSW 10290/5 submitted by the Third Line Supervisor within 30 days of the annual inventory.

(4) Provide delivery of consumables and laser/etched serialized tools (starting with the organization code WC8), and the replacement of standard inventory tools on a one for one exchange basis to all production areas. Broken tools with missing pieces shall be reported on a Missing Tool Report.

(5) Deliver all tooling and establish a delivery schedule and point of contact for all production areas.

(6) Provide procurement services for tool containers with contrasting silhouette foam, tools, and pad locks with two keys for all production areas.

(7) Monitor all Missing Tool Reports and replace missing tools, per enclosure (2).

(8) Provide serialized numbers starting with WC8 for all tool containers to all production areas.

(9) Provide contractors with a Positive Tool Control Logbook FRCSW 10290/11.

1. Industrial Quality Department (QA)

(1) Establish and maintain a documented quality auditing plan for TCP.

(2) Monitor and audit TCP compliance in all production areas and the Industrial Production Support Department (Central Tool).

(3) Monitor Missing Tool Reports daily ensuring they meet all requirements, see enclosure (2).

(4) Assist in the search for missing tools upon notification by the First line supervisor.

(5) Verify that a missing tool is entered on the left hand side of the Positive Tool Control Logbook (FRCSW 10290/11).

(6) Ensure a copy of all Missing Tool Reports are forwarded to the Test Line Branch via the Test Line QAS, for entries in the Miscellaneous History Section of the Aircraft Logbook (only if tool was not found) .

(7) Inventory, date, and sign a local out of area temporary tool inventory list upon an artisan's arrival and departure from out of an area work sites' activity.

(8) Verify a missing tool placard is affixed to aircraft when applicable.

(9) Validate Broken/Worn Tool Report, FRCSW 10290/8.

6. Tool Container Inventory Requirements

a. Artisan assigned Tool Containers/Bags must comply with enclosure (1) of this instruction.

b. Point of Use Tool Containers/Shop Boxes:

(1) Must comply with enclosure (1) of this instruction.

(2) Inventories shall be conducted at the beginning and end of each shift and logged in the Tool Control Logbook.

(3) FRCSW Tool Check-Out Log FRCSW 10290/1 shall be maintained for the purpose of tool check-in and check-out by the artisan. A single entry will be made for each tool checked out.

Use pay number only if artisan does not have a stamp. Any tool not returned prior to the end of shift will be annotated in the logbook with the reason tool was not returned.

(4) All PME Tools requiring calibration shall be checked out on FRCSW Tool Check-Out Log, FRCSW 10290/1, with line and link filled for tracking.

c. Tools Too Small To Etch. Tools/consumable items that are too small to be marked in practical manner will be included on the tool container inventory marked with an asterisk to include number of items plus the case they are held in. The outside of the case and the tool container shall be labeled "contains tools too small to etch.u

d. Consumable Tooling. These tools are to be considered as critical as any other tool and a one for one swap will be adhered to at all times. All broken pieces must be returned for a "one for oneu swap. A Missing Tool Report shall be submitted where pieces are missing.

e. Traveling Tool Containers. All containers will be prepared for shipment in a secured manner preventing the loss of tools during shipment.

f. Certification Stamps. Certification stamps are to be considered as tools. Upon the discovery of a missing stamp, this will be treated as a missing tool and a Missing Tool Report will be initiated. The MTR will be routed to the Industrial Quality Department for replacement upon completion of the investigation.

7. Forms

a. Positive Tool Control Logbook, FRCSW 10290/11; FRCSW Tool Check-Out Log, FRCSW 10290/1; Missing Tool Report, FRCSW 10290/3; Broken/Worn Tool Report, FRCSW 10290/8; Tool Container Change Request, FRCSW 10290/2; Transfer of Custody, FRCSW 10290/9; Annual Tool Container Inventory, FRCSW 10290/5;

Consumable Tooling Request, FRCSW 10290/4; and Aircraft Inspection and Acceptance Record, form OPNAV 4790/141 are available online via the Naval forms Online website at https://navalforms.documentservices.dla.mil/web/public/forms.

b. Positive Tool Control Inventory, FRCSW 10290/7 and Broken Tool Replacement tag, FRCSW 4940/2 are available from Central Tool.

Distribution:

nl~ .:;. 1/. '1

T. H. PFANNENSTEIN

Electronic only, via https://mynavair.navair.navy.mil/frcsw

TOOL CONTAINER INVENTORY REQUIREMENTS

1. Tool containers will be maintained in a professional manner.

All tool locations within the container will be silhouetted with contrasting silhouetted foam in all drawers for ease of inventory purposes. All container locks and keys will be accounted for on a daily basis. A Tool Control Logbook, (FRCSW 10290/11) and an up to date inventory list of all tools will accompany each tool container. Only tools on the inventory list are authorized in the container.

2. Visual inventory will be performed and documented in the Tool Control Logbook (FRCSW 10290/11) at the beginning and end of each shift or prior to changing assignments.

3. Physical inventory will be performed by the Supervisor. One tool container will be inventoried per week and compliance documented in a weekly tool inventory log and on the left hand side of the Tool Control Logbook (FRCSW 10290/11).

DEFINITIONS

1. Visual inventory: A visual inspection is to ensure that all tools are visually accounted for per the inventory. The inventory will be documented on the right hand side of the Tool Control Logbook (FRCSW 10290/11).

2. Physical inventory: A physical inspection is to verify individual tools are legibly marked and match the tool container number, organization code, and inventory listing. A physical inspection also verifies all tools are in serviceable condition.

This inspection will be documented in a weekly tool inventory log and on the left-hand side of the Tool Control Logbook (FRCSW 10290/11).

Note: All Managers/Officers, Supervisors, Quality Assurance Representatives, Tool Control Program Manager and Tool Control Program Coordinator shall be authorized to enter any FRCSW tool container at any time for inventory purposes and shall be required to sign the left hand side of the Tool Control Logbook (FRCSW 10290/11).

Enclosure (1)

FRCSWINST 10290.1C CH-1

NOV 2 4 2'014

MISSING TOOL REPORTING AND INVESTIGATION REQUIREMENTS

1. Reference (a), Chapter 10, Paragraph 10.12.4.4 establishes the requirements for Fleet Readiness Center (Depot Level) missing tool procedures, some of which are clarified below.

a. All missing tool investigations and associated documentation, regardless of level of tool control, shall be immediately initiated and closed appropriately.

b. When an employee discovers that a tool is missing, he/she shall notify the First Line Supervisor immediately.

c. The First Line Supervisor shall immediately notify the area QAS and Deputy IPT Lead. If the tool belongs to a contractor, the Contracting Officer Representative (COR) will be notified. All work activity in the affected area of the aircraft or system shall cease and an immediate search for the item will begin.

d. The First Line Supervisor shall identify those areas where work was, or may have been, performed. The First Line Supervisor shall stop work and begin an intensive search in the suspected areas until the missing tool is found or permission to resume work with a lost tool is given.

e. Immediately after permission to resume work with a lost tool is given, the First Level Supervisor shall initiate an electronic Continual Analysis and Metrics (eCAM) Missing Tool Report and forward it to the area QAS. If the eCAM data base is down, then a paper copy of the Missing Tool Report (FRCSW 10290/8) shall be submitted, and it shall be transcribed to eCAM by the First Level Supervisor as soon as the system is up, for ease of tracking and filing.

(1) The "Brief Outline of Eventsn section should include answers to the following questions:

(a) When was the tool discovered missing?

(b) Who discovered the tool missing?

(c) How was the tool discovered missing?

Enclosure (2)

(d) When were the First Line Supervisor, QA and

Deputy Integrated Project Team Leader (DIPTL) notified?

(2) The ~First Line Supervisor Investigation" section should include answers to the following questions:

(a) When was the tool last inventoried?

(b) Who last inventoried the tool?

(c) When was the tool last used?

(d) Who last used the tool?

(e) What aircraft/systems/areas/components were worked since the tool was last used/inventoried (whichever is later)?

(f) When was work stopped?

(g) Who stopped work?

(h) Who searched?

(i) When was work resumed?

(j) Who authorized the resumption of work, and how was authorization communicated.

(k) What was the rationale for resuming work?

f. The First Line Supervisor shall notify the oncoming shift supervisors of the lost tool and actions taken to locate the tool.

g. If a lost tool is suspected to be the result of theft, the First Line supervisor shall notify Security.

h. Area QAS shall immediately verify the Missing Tool Report is complete before forwarding it to the Second Level Supervisor and contacting the Supervisor.

i. Second Level Supervisor shall immediately revie1-1 and complete the Missing Tool Report (or direct an additional

2 Enclosure (2) search), forward the Missing Tool Report to the Third Level Supervisor, and contact the Supervisor.

j. Third Level Supervisor shall immediately review and complete the Missing Tool Report, forward it to the Production Director/Officer, and contact the Production Director/Officer.

k. Production Director/Officer shall review and complete the Missing Tool Report. The finalized report shall be sent to Logs and Records.

1. Logs and Records shall ensure a lost tool entry is made on the Aircraft Inspection and Acceptance Record (Form OPNAV 4790/141), for any tool reported as lost on an aircraft when the tool was not recovered.

m. Industrial Production Support Department (Central Tool) shall replace tool ensuring markings on the tool reflects appropriate "Dash" number to designate a missing tool replacement, and will annotate the permanent record with the "Dash" number and place a copy of the Missing Tool Report in the tool box folder, and will provide the First Level Supervisor with an updated inventory.

n. Test Line QAS shall receive a Missing Tool report from eCAM and shall ensure that a Log Book entry is made in the miscellaneous history section of the aircraft Log Book.

3 Enclosure (2)

ANNUAL WALL TO WALL TOOL CONTAINER

INVENTORY SCHEDULE

910 Vertical Lift JANUARY

920 Props FEBRUARY

930 Components MARCH

940 Calibration APRIL

950 F/A 18 MAY

951 F/A-18 JUNE

970 Manufacturing JULY

980 F/A-18 AUGUST

981 Paint SEPTEMBER

984 Test Line OCTOBER

986 Field Service NOVEMBER

Enclosure (3)