FRCSWINST_4855.1D_Quality_Program_Manual.pdf

FRCSWINST 4855.10

6.4.1

JUN 2 9 2015

QUALITY PROGRAM

MANUAL

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER SOUTHWEST

P.O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

IN REPLY REFER TO:

FRCSWINST 4855.10 CH-3

6.4.1

JUL 1 1 2016

FRCSW INSTRUCTION 4855.lD CHANGE TRANSMITTAL 3

From: Commanding Officer

Subj: QUALITY PROGRAM MANUAL

Encl: (1) Revised Page 4-9

(2) Revised Page 4-12

1. Purpose. To transmit a new page 4-9 and page 4-12, which reassigned specific responsibilities involving technical publications/data on FRCSW work documents' operation lines from the certifiers to the Examination and Evaluation personnel.

2. Action. Remove pages 4-9 and 4-12 of the basic instruction and replace with enclosures (1) and (2), respectively.

,;1. IJ. to/~

T. H. PFANNENSTEIN

Distribution: Electronic only, via https://myteam.navair.navy. mil/frc/SouthWest https://myteam.navair.navy.mil/frc/SouthWest

P.O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

IN REPLY REFER TO:

FRCSWINST 4855 . l D CH-2 6 . 4 . 1

MAY 0 5 2016

FRCSW IN STRUCTION 4855 . lD CHANGE TRANSMI TTAL 2

From: Commandi ng Office r

Subj : QUALITY PROGRAM MANUAL

Encl: (1) Revised Page 4- 8 - 3

1. Purpose. To transmit a new page 4- 8 - 3 , to clarify the Quality Veri f icati on personnel respon s ibility on section 4 . 8 . 2 . 3 .1. 2 whe n receivi ng a Cert ificat i on Stamp Action Request .

·2. Ac t ion. Remove page 4- 8 - 3 of t he basic instruction and repl ace with enc l osur e (1).

-?. ti. If Alt ~ -

T . H. PFANN ENSTEIN

Distribut i on: Electroni c only , via https : //myteam . navair . navy . mil/frc/SouthWest/SitePages/Default.a spx https://myteam.navair.navy.mil/frc/SouthWest/SitePages/Front%20Page%20Archive/2016-03-06-Default.aspx

P .O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

IN REPLY REFER TO:

FRCSWINST 4855. 1 0 CH- 1

6 . 4 . 1

JUL 1 7 2015

FRCSW INSTRUCTION 4855.10 CHANGE TRANSMITTAL 1

From: Commanding Officer

Subj: QUALITY PROGRAM MANUAL

Encl: ( 1) Revised Chapter 4

1. Purpose. To transmit a new Chapter 4, which establishes requirements for the addition/inclusion of applicable technical publications/data on FRCSW work documents ' operation lines.

2 . Action. Remove pages 4-1 through 4-14 of the basic instruction and replace with enclosure (1) .

Distribution:

N. C. OWEN

Acting

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

P.O. BOX 357058

SAN DIEGO, CALIFORNIA 92135-7058

FRCSW INSTRUCTION 4855.10

From: Commandi ng Officer

Subj: QUALITY PROGRAM MANUAL

Ref: (a) COMNAVAIRFORINST 4790.28

IN REPLY REFER TO:

FRCSWINST 4855.10

6.4.1

JUN 2 9 2015

Encl: (1) Summary of Changes From FRCSWINST 4855.1C to

FRCSWINST 4855.10

1 . Purpose. To establish and update FRCSW Quality Program policy and procedures for the Fleet Readiness Center Southwest (FRCSW) to control and continually improve all FRCSW products, processes and services, per reference (a) .

2. Cancellation. FRCSWINST 4855.1C. This instruc tion should be reviewed in its entirety due to extensive revision.

Enclosure (1) provides summary of significant changes.

3. Policy. The FRCSW Quality Program Manual establishes quality policy guidelines and operational procedures guidance for a standardized Quality Program at FRCSW. The format of this FRCSW Manual is patterned in conformance with reference (a).

Responsible FRCSW organizations may deviate from any requirement in this Manual, with documented justification, by the authorization of the Commanding Officer unless the requirement originates from higher authority, e . g., reference (a).

4. Responsibilities. All depot-level maintenance civilian and military personnel assigned to or attached to FRCSW shall comply with the quality procedures contained in the ,FRCSW Quality Program Manual and applicable quality procedures conta ined in reference (a) . Intermediate-level maintenance personnel shall comply with the applicable quality procedures contained in reference (a) and in applicable FRCSW Local Command Procedures (LCP) . Contractor personnel shall also comply with the quality procedures contained in this Manual as required by contract, performance work statement (PWS), statement of work (SOW), or memorandum of agreement (MOA) .

FRCSWINST 4855.1D

JUN 2 9 2015

5 . Chapters and Appe ndices . All Chapters and Appendices mentioned within these chapters are listed in t he Table of Contents.

6 . Records Management. Records created as a result of this instruction, regardless of media and format , shall be managed per the SECNAV Manual 5210 . 1, Department of the Navy Records Manageme nt Manual .

7 . Forms , References and Acronyms/Abbreviat ion s . All forms referenced within this Manual , and where they may be obtained , are listed in Table 1. All references used within this Manual are listed in Table 2. All acronyms and abbreviations used within this Manual are listed in Table 3.

d· !/. f2(((/YVY'IlA~

T . H. PFANNENSTEIN

Distribution :

Electroni c only, via https : //mynavair . navair . navy . mil/frcsw https://mynavair.navair.navy.mil/portal/server.pt/community/fleet_readiness_center_southwest/1673

TABLE OF CONTENTS

CHAPTER TITLE PAGE

1 Guidelines and Operational Procedures ................. 1-1 Appendix 1-A Quality Training Appendix 1-B Quality Training Procedures/Requirements

2 Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 Control of Incoming Material and Material Handling . . . . 3-1 Appendix 3-A Material Handling

4 Certification Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Appendix 4-A Job Task Descriptions (JTD)/Skill Based

Qualifications (SBQ), Individual Qualification Records (IQR) and Training Jackets

Appendix 4-B Requesting and Granting Certification/Inspection Authority and Issuance of Certification/Inspection Stamps

Appendix 4-C Certification Program Training Appendix 4-D Types of Certification/Inspection Stamps Appendix 4-E Voiding of Stamp Imprints and Recertification of Work Documents Appendix 4-F Requalification and Recertification of

Personnel Appendix 4-G Returning Certification/Inspection Stamps Appendix 4-H Reporting and Replacing Lost or Damaged

Stamps Appendix 4-I Violations, Revocations and Suspensions of

Certification/Inspection Authority

5 Special Process and Unique Skills Certification Program ............................... 5-l

Appendix 5-A Special Process Certifications Appendix 5-B Procedures for Initiating and Processing

Operator Certification/License Request, Form FRCSW 12410/1 for Special Process Certification

Appendix 5-C Aeronautical Antifriction Bearings Appendix 5-D Soldering Operations Appendix 5-E Non-Destructive Inspection (NDI) and Acid

Etch Appendix 5-F Shot Peen Operations Appendix 5-G Thermal Spray Coating Operations Appendix 5-H Aviation Life Support Systems (ALSS) Appendix 5-I Welding, Brazing and Silver Brazing Appendix 5-J Plating Processes Appendix 5-K Metallic Surface Preparation for Structural

Adhesive Bonding i

TABLE OF CONTENTS

JUN 2 9 2015

CHAPTER TITLE PAGE

Appendix 5-L Appendix 5-M Appendix 5-N Appendix 5-0 Appendix 5-P Appendix 5-Q

Electrical Drill")

Appendix 5-R Appendix 5-S

Composite Repair/Fabrication (Level II) Cold Work and Ring Pad Hole Coining Plastic Media Blast Operations Ion Vapor Deposition (IVD) of Aluminum Visual Inspection of Weldments Removal Of Titanium Hi-Lok Fasteners Using

Discharge Machining (EDM) Technology ("E-

Tire and Wheel Maintenance Safety Unique Skills Programs

6 Special Operator Licensing Program .................... 6-1 Appendix 6-A Procedures for Initiating and Processing

Operator Certification/License Request, Form FRCSW 12410/1

Appendix 6-B Aircraft Turn-up and Rotor Engagement Operators

Appendix 6-C Test Cell Operators

7 Quality Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Appendix 7-A Sampling Procedures Appendix 7-B Surveillance Procedures Appendix 7-C First Article Test (FAT)

8 Work Definition and Documentation ..................... 8-1

9 Quality Characteristics ............................... 9-1

10 Quality Audits and Investigations .................... 10-1 Appendix 10-A Audit Subjects Appendix 10-B Monitoring Procedures

11 Quality Analysis .................................... 11-1

12 Quality Costs ....... . 12-1

13 Corrective and Preventive Action ..................... 13-1 Appendix 13-A Procedures for Initiating and Processing

Discrepancy Work Order (DWO) Appendix 13-B Processing of the Request for Engineering

Information-Temporary Engineering Instruction (REI-TEI) ii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

14 FRCSW Customer Liaison Program ....................... 14-1 Appendix 14-A Aircraft Acceptance Inspection Report

Typical Outline Appendix 14-B Trip Report

15 Material Review Board ................................ 15-1 Appendix 15-A Material Review Board (MRB) Procedures

16 Contracting ......... . 16-1

17 Acceptance Inspection Deficiency Reports and Product Quality Deficiency Reports .......................... 17-1

Table 1 - Forms . . . . . . . . . . . ............................. T-1-1

Table 2 - References ................................... T-2-1

Table 3- Acronyms and Abbreviations .................... T-3-1

Index I-1 iii

CHAPTER 1

JUN 2 9 2015

GUIDELINES AND OPERATIONAL PROCEDURES

1.1 Introduction/Purpose. The Quality Program Manual is a

standardized, consolidated guide consisting of quality procedures, responsibilities and accountability requirements to document and authorize the Quality Program requirements for depot-level (D-level) maintenance at the Fleet Readiness Center Southwest (FRCSW). The Manual is patterned according to the Office of the Chief of Naval Operations Instruction, OPNAVINST 4790.2J, Naval Aviation Maintenance Program (NAMP). OPNAVINST 4790.2J outlines command, administrative and management relationships, and establishes the Commander, Naval Air Forces (COMNAVAIRFOR) as primary authority for assignments of maintenance responsibilities and tasks. COMNAVAIRFOR identifies Fleet Readiness Center (FRC) NAMP responsibilities and tasks in COMNAVAIRFORINST 4790.28. The requirements identified in this Manual are applicable to all D-level maintenance work performed by FRCSW personnel, including Field Service Teams/Voyage Repair Teams (VRT), on weapon systems/components and major end items, such as F/A-18, E-2, C-2, H-1, H-53 and H-60 aircraft; LM2500 engines; components; manufacturing; calibration; support equipment (SE); aircraft launch and recovery equipment (ALRE);

visual landing aids (VLA) equipment; air capable ship aeronautical equipment; and mobile facilities.

1.2 Information

1.2.1 Intermediate-level (I-level) maintenance and

organizational-level (0-level) maintenance Quality Program requirements are determined by the Commander, Naval Air Forces, and are documented in COMNAVAIRFORINST 4790.28, paragraph 7.2.

1.2.2 The FRCSW Commanding Officer is ultimately responsible

for the quality of products produced and services provided by D level maintenance personnel of the FRCSW, and has delegated the establishment and review of compliance with the Quality Program to the Industrial Quality Department (IQD).

1.3 Responsibilities. To achieve the objectives of the Quality Program, all D-level maintenance entities of the FRCSW are responsible for compliance with COMNAVAIRFORINST 4790.28, paragraphs 7.3 and 7.6 requirements.

1-1

1.3.1 Industrial Quality Department personnel shall develop and coordinate the FRCSW Quality Program and ensure its continued effectiveness. The basic requirements are, but not limited to, the foll01ving:

1.3.1.1 Interpreting higher authority instructions into usable, understandable guidelines of quality requirements and techniques to evaluate conformance.

1.3.1.2 Ensuring incorporation of quality requirements into

applicable technical data and work documents through active participation in workload planning, starting with the conceptual phase.

1.3.1.3 Reviewing and monitoring, using approved techniques, to ensure quality is a built-in attribute and products, processes and services meet specifications and are reviewed periodically for continuing improvement.

1.3.1.4 Performing active product, industrial process and

systems audits and reviews to: identify and eliminate root causes of defective work and spoilage, i.e., root cause analysis (RCA), ensure positive corrective actions to prevent recurrence, monitor/verify systems compliance and capabilities, and identify opportunities for process improvement.

1.3.1.5 Actively participating in and chairing, as appropriate, team activities such as audits, investigations, evaluations for process improvements and Material Review Boards (MRB) .

1.3.1.6 Acting as the FRCSW focal point while preparing for, or 1vhile participating in, quality audits or reviews by Naval Air Systems Command (NAVAIR)/Commander, Fleet Readiness Centers (COMFRC) Headquarters or other higher authority.

1.3.1.7 Providing training related to the Quality Program per Appendices 1-A and 1-B of this Chapter.

1. 3 .1. 8 Complying v1ith NAVAIR 00-25-100 and FRCSWINST 5216. SA concerning the use of all technical data.

1.3.1.8.1 QA personal are not authorized to have uncontrolled technical data. One of the most prevalent forms of uncontrolled

1-2 technical data is an official technical manual permanently borrowed from its rightful custodian or squadron.

1.3.1.8.2 Additionally, out-of-date technical data shall not be retained by QA personnel for "reference only" purposes. If QA personnel require historical technical data for inspection purposes, they may obtain it from NATEC, data managers, or engineering. For assistance in this process, contact the Central Technical Publications Library.

1.3.2 Industrial Quality Management Division personnel shall

maintain, update and revise, as necessary, this Manual.

1.3.3 Corporate Operations Group

1.3.3.1 Information Technology (IT)/Information Management (IM) Department personnel shall provide technical support, programming and maintenance of a standardized Quality Program information data base and collection system for quality data accounting and reporting.

1.3.3.2 Program and Business Analysis Department personnel

shall ensure, prior to publication, all FRCSW directives are reviewed by the Industrial Quality Department for quality issues and incorporation of quality requirements.

1.3.4 Research and Engineering Group personnel shall

1.3.4.1 Review specifications and establish the depth and scope of work requirements.

1.3.4.2 Provide material engineering support to determine

process methods, testing procedures, chemical analysis and skill levels required.

1.3.4.3 testing 1.3.4.4

Provide technical data to direct proper processing, and identification of equipment.

Evaluate deviations from normal repair practices and directing corrective actions.

1.3.4.5 Request Industrial Quality Department involvement, starting with the conceptual phase of specification development, in the incorporation of quality requirements.

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1.3.4.6 Provide technical data, analysis and specification

support for process improvement opportunities.

1.3.4.7 Provide membership in such team activities as audits, investigations and MRBs.

1.3.5 Industrial Production Department/Industrial Production

Support Department personnel shall

1.3.5.1 Adhere to the fundamental concept that properly trained and experienced personnel performing the work are the most important contributors to the quality and reliability of each item produced.

1.3.5.2 Recognize individual qualifications are the foundation of an effective and credible Certification Program.

1.3.5.3 Pursue a vigorous training program for assigned

personnel to enhance skill and knowledge levels, and to ensure the availability of a skilled work force.

1.3.5.4 Adhere to and comply with applicable current, officially authorized and released technical data and engineering specifications, and with quality requirements when accomplishing work. Technical data shall include:

1.3.5.4.1 Technical manuals (TM), e.g., Maintenance Instruction Manuals (MIM), Illustrated Parts Breakdowns (IPB), Instrument Calibration Procedures (ICP), Interactive Electronic Technical Manuals (IETM), Maintenance Requirements Cards (MRC), Manual Change Releases (MCR) .

1.3.5.4.2 Technical Directives (TO), e.g., bulletins, changes, Rapid Action Minor Engineering Changes (RAMEC), Rapid Action Changes (RAC), Interim Rapid Action Changes (IRAC).

1.3.5.4.3 Local Engineering Directives (LED), e.g., Local

Engineering Specifications (LES), Local Process Specifications (LPS), Local Industrial Specifications (LIS), Local Calibration Procedures (LCP), Temporary Engineering Instructions (TEI).

1.3.5.4.4 Engineering drawings.·

1.3.5.4.5 Technical orders (TO).

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1.3.5.4.6 Provisioning information.

JUN 2 9 2015

1.3.5.4.7 Military/Federal specifications, standards, handbooks.

1.3.5.4.8 Inspection and test procedures.

1.3.5.4.9 Instruction cards.

1.3.5.4.10 Equipment placards.

1.3.5.4.11 Toughbooks.

1.3.5.4.12 Special purpose computer programs.

1. 3. 5. 5 Comply with NAVAIR 00-25-100 and FRCSWINST 5216. SA concerning the use of all technical data.

1.3.5.5.1 Artisans are allowed to have partial technical

manuals. There are two types of partial manuals authorized for use at FRCSW:

1.3.5.5.1.1 Controlled- Controlled partials are distributed

and updated by the technical library. These may be kept by the artisans indefinitely.

1.3.5.5.1.2 Temporary one-time issue - Data printed from the

website must include title page, A-page, notices, applicable IRACs, and the rest of the list of effective pages (B, C, D, etc.) if any. The person printing the data shall write their name legibly next to the date that data was printed. The data must be verified daily against the electronic version.

1.3.5.5.2 The work center supervisor shall ensure that all

printed material is accounted for and destroyed upon completion of the maintenance action.

1.3.5.5.3 Employees who perform maintenance activities without the proper authorized technical data present shall be subject to administrative actions. These actions begin with revocation of certification authority, and may include disciplinary actions up to and including termination.

1-5

1. 3. 5. 6 Perform all 1wrk operations accurately and completely as directed by current work documents. Evaluate and inspect one's own work to ensure it conforms to applicable specifications. Work documents shall include:

1.3.5.6.1 Work orders (WO).

1.3.5.6.2 Router~.

1.3.5.6.3 Temporary Engineering Instructions (TEI).

1.3.5.6.4 Quality Verification requirements/check points/call points may supplement any of the above.

1.3.5.7 Comply with, as applicable: instructions, notices, Local Comn1and Procedures (LCP), Standard Operating Procedures (SOP), and Standard Work Packages (SWP).

1.3.5.8 Ensure the only work performed is that stated on work documents and any additional work is defined and approved before work accomplishment and certification, i.e., performance of undocumented maintenance is prohibited.

1.3.5.9 Assume ownership of the certification role. Ensure all work documentation is certified, verified and dated for accountability and traceability purposes before movement to the next area of 1vork assignment.

1.3.5.10 Ensure material and equipment handling, transportation and storage meet specifications and quality requirements.

1.3.5.11 Maintain the Calibration Program and recall system.

1.3.5.12 Evaluate needs and designs, supply facilities and

perform facilities' maintenance.

1.3.5.13 Design and produce production tooling and fixtures.

1.3.5.14 Design, produce and issue rollaway tool containers and hand carried toolboxes, and serialize them for tool control accountability. Maintain tool issue facilities throughout the

FRCSW.

1-6

1.3.6 Industrial Production Department/Industrial Production

Support Department Production Control (PC) personnel shall

1.3.6.1 Ensure all work documentation is certified, verified

and dated for accountability and traceability purposes before movement to the next area of work assignment.

1.3.6.2 Provide a system for retention and retrieval of

completed work documentation for all aircraft and components produced by the FRCSW until the next scheduled maintenance.

1.3.7 Industrial Production Department/Industrial Production

Support Department Planning and Estimating (P&E) personnel shall coordinate workload and work scheduling to ensure adequate time and resources that will allow for an effective quality performance to specifications.

1.3.8 Production Planning Division Industrial Engineering

Technicians (IET) shall produce documentation for work accountability with proper product and process sequencing, time allotment and required worker skills for all phases of work on aircraft and components.

1.3.9 Logistics Group personnel shall coordinate procurement

and contract documents to ensure appropriate revie\v and inclusion of engineering and quality requirements.

1.3.9.1 The Central Technical Publications Library (CTPL) shall procure, receive, control, distribute, maintain, and audit all controlled technical data, per COMNAVAIRFORINST 4790.28, NAVAIR 00-25-100, and FRCSWINST 5216.88.

1.3.9.2 Per NAVAIR 00-25-100, technical manuals may be

cancelled without being superseded by other manuals. Included in this category are manuals supporting aircraft or equipment no longer in the NAVAIR inventory. If FRCSW has been authorized by higher authority to maintain equipment no longer in the NAVAIR inventory, maintenance personnel may continue to use such cancelled manuals. All such cancelled manuals will be stamped \·lith a "CANCELLED" watermark or a "CANCELLED" imprint on the title page.

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1.3.10 Industrial Operations Compliance Department personnel

shall oversee the Command Environmental Program and Hazardous Material and Waste Control Program.

1.3.11 Industrial Production Department/Industrial Production Support Department Test Line Maintenance personnel shall

1.3.11.1 Determine the final airworthiness of aircraft.

1.3.11.2 Provide feedback data, e.g., Maintenance Action Forms (MAF), to enhance the prevention and elimination of common cause defects.

1.3.12 All cognizant FRCSW personnel shall:

1.3.12.1 Review work procedures for opportunities to

continually improve shop practices and processes.

1.3.12.2 Collect and record process control and other data, as appropriate, to evaluate quality levels, and to correct and improve processes, products and procedures.

1.3.12.3 Discuss openly and freely common goals, participate in team improvements, and search for improvements that will increase our competitive abilities, reduce cost, improve product quality and increase customer satisfaction.

1.3.12.4 Emphasize that quality requirements must be satisfied, thereby encouraging workers to express ideas, ask questions, and report out of order equipment, material unsuitable for its intended purpose, inadequate facilities, or any situation that may be detrimental to the quality of the final product.

1.3.12.5 Have the right and responsibility to notify their

chain of command, without reprisal, of any condition that compromises their ability to comply with technical data during the performance of their assigned duties.

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1.A.1 Information

APPENDIX 1-A

QUALITY TRAINING

FRCSWINST 4855.1D

JUN 2 9 2015

1.A.1.1 Inherent in the FRC community is FRCSW recognition of a continuing need to provide the capability to satisfy new technical and product requirements and to develop pertinent skills and techniques.

1.A.1.2 Continuous training shall be given to all FRCSW personnel who directly or indirectly affect the quality of products produced. Training shall agree with the concepts and requirements contained in COMNAVAIRFORINST 4790.2B (all applicable chapters).

1.A.1.3 Quality training includes, but is not limited to the following

1.A.1.3.1 Technical training, as required for FRCSW production operations, especially training leading to qualification for certification authority.

1.A.1.3.2 Initial indoctrination and refresher training (every four years) in the Certification Program for certifiers, supervisors of certifiers, Quality Assurance Specialists (QAS) and Industrial Quality Department managers.

1.A.1.3.3 Continuous training for QASs in Quality Program methods, practices and principles.

1.A.2 Responsibilities

1.A.2.1 All managers and supervisors shall

1.A.2.1.1 Ensure assigned personnel are thoroughly trained in the performance of their duties. Training shall consider the latest state-of-the-art processes, techniques and procedures.

1.A.2.1.2 Ensure assigned personnel understand their responsibilities concerning the Quality Program.

1.A.2.1.3 Ensure all personnel are provided NAMP indoctrination training within 30 days of reporting. This may be extended to

1-A-1

60 days if mitigating circumstances exist. Indoctrination training may be tailored to accommodate different levels of experience of personnel and their duties/responsibilities.

Document indoctrination training on the FRCSW NAMP Indoctrination Training form (FRCSW 4790/47).

l.A.2.1.4 Maintain a Required Reading File containing, at a minimum, maintenance information such as messages such as Aviation Maintenance Advisories (AMA), notices, directives, instructions, or memos. Also, maintain, as necessary, a Required Reading Cross Reference Locator Sheet to list the location of any item not available to an individual shop/office or too bulky to be included. Ensure each employee logs their reading of applicable items on a Required Reading and Maintenance Information Record (CNAF 4790/34). Review the Required Reading File monthly to ensure the material is current and all shop/office personnel are logging their progress.

l.A.2.2 Supervisors of certifiers/candidates for certification authority shall l.A.2.2.1 Ensure assigned personnel receive continuous technical training in skills related to certification authority per Chapter 4 of this Manual.

l.A.2.2.2 Ensure assigned personnel receive initial indoctrination and refresher training (every four years) in the Certification Program, per Chapter 4 of this Manual.

l.A.2.2.3 Document this training on an Individual Qualification Record (IQR), Forms FRCSW 4855/250 through 4855/253, per Chapter 4 of this Manual.

l.A.2.3 Industrial Quality Department personnel shall l.A.2.3.1 Provide Certification Program refresher training every four years, as directed by COMNAVAIRFORINST 4790.28, paragraph 7.6.4. Refer to Chapter 4 of this Manual for further Certification Program details.

l.A.2.3.2 Provide continuous training for QASs in Quality Program methods, practices and principles per Appendix 1-B of this Chapter.

1-A-2

APPENDIX 1-8

JUN 2 9 2015

QUALITY TRAINING PROCEDURES/REQUIREMENTS

1.8.1 Information. Non-supervisory QASs shall receive periodic refresher training in Quality Assurance (QA) techniques and procedures, including procurement and quality requirements for aeronautical/shipboard material contained in Chapters 3 and 16 and in FARs/DFARS, certification procedures contained in Chapters 4 through 6, verification procedures contained in Chapter 7; audit procedures in Chapter 10; and Discrepancy Work Order (DWO) procedures in Chapter 13.

1.8.2 Responsibilities

1.8.2.1 Industrial Quality Department Managers shall

1.8.2.1.1 Establish and document standardized entry-level and full-performance level requirements for QASs via the development of Job Qualification Requirements (JQR). Develop and provide standardized entry-level QAS training.

1.8.2.1.2 Provide on-the-job training (OJT) specific to the

areas assigned for all QASs.

1.8.2.1.3 Develop and provide Industrial Quality Department

personnel with Quality Program refresher training.

1.8.2.1.4 Maintain an IQR, Forms FRCSW 4855/250 through

4855/253, for those tasks pertaining to the Quality Program for each assigned QAS.

1.8.2.1.5 Develop and maintain/update Job Task Descriptions

(JTD)/Skill Based Qualifications (S8Q) for QASs who have been designated to be OJT Instructors. OJT Instructors shall usually be holders of a current verification stamp, be trained, proficient and qualified in the skills for which they are giving and documenting OJT, and be qualified as an OJT Instructor for these skills.

1.8.2.1.6 Develop and maintain a training jacket for each

assigned QAS containing the IQRs and any other applicable documentation pertaining to the QAS's training and qualification.

1-B-1

1.8.2.2 Industrial Quality Department Administrative Assistant shall

1.8.2.2.1 Receive and review all manager/supervisor training

requests and coordinate scheduling with the training instructor.

1.8.2.2.2 Maintain a training record for each member of the

Department.

1-8-2

CHAPTER 2

RELIABILITY

FRCSWINST 4855.1D

JUN 2 9 2015

2.1 Introduction. Naval aviation is dedicated to the

application of the Reliability Centered Maintenance (RCM) concept to in-service and future Naval aircraft, engines, aircrew systems, weapon systems, aircraft launch and recovery equipment, and support equipment (SE). The ultimate goal is to maintain maximum weapon system availability at minimum cost, as established by the objectives contained in COMNAVAIRFORINST 4790.28, Naval Aviation Maintenance Program (NAMP).

2.2 Purpose. To assign responsibilities to FRCSW personnel for the implementation of reliability practices within the FRCSW, and to provide a definition of reliability and reliability procedures as used at the FRCSW.

2.3 Definitions. Reliability is defined in COMNAVAIRFORINST

4790.28, as the probability that an item will successfully perform its designated or intended function for a specified interval/period of time under specified operational conditions.

2.4 Responsibilities

2.4.1 Research and Engineering Group and Logistics Group, i.e., the In-Service Support Center (ISSC) personnel shall

2.4.1.1 Establish and adjust preventive maintenance

tasks/intervals, analyze system/equipment/aircraft and data to determine fleet support improvement opportunities, project repair requirements, and develop maintenance specifications, per COMNAVAIRFORINST 4790.28 and NAVAIR 00-25-403, Guidelines for the Naval Aviation Reliability-Centered Maintenance Process.

2.4.1.2 Develop, manage, and control design modifications

within the operating envelope as defined in the Operational Requirement and Specifications, to gain advantages in maintenance, readiness, or cost.

2.4.1.3 Establish, monitor, and adjust the logistics

requirements, including configuration management, technical information, training, parts, and SE.

2-1

2.4.1.4 Provide technical support, feedback, and supportability analysis for application to new or upgraded weapon systems/equipment/aircraft.

2.4.1.5 Respond to technical questions from operating and

maintenance personnel and develop technical solutions to operating and maintenance problems for assigned systems/equipment/type aircraft.

2.4.1.6 Serve as liaison with other aviation technical

communities for in-service technical problems.

2.4.1.7 Ensure safety and prudent operation through technical assessment of problems requiring aircraft grounding/restricted operations, and the development of solutions to those problems.

2.4.1.8 Analyze/recommend adjustments to the specified service for systems, equipment, and aircraft.

2.4.1.9 Maintain operating cost data on assigned

systems/equipment/aircraft.

2.4.1.10 Manage in In-Service Warranty Program.

2.4.1.11 Recommend changes to the Naval Air Training and

Operating Procedures Standardization (NATOPS) Flight Manual per OPNAVINST 3710.7U, NATOPS General Flight and Operating Instructions.

2.4.1.12 Develop a systematic plan for accomplishing

modifications of assigned systems/equipment/aircraft.

2.4.2 Cognizant FRCSW personnel shall

2.4.2.1 Perform inspections called for in the applicable D

level maintenance specifications.

2.4.2.2 Report inspection results to the ISSC.

2.4.2.3 Notify the ISSC of any additional candidates for RCM

analysis as potential Structurally Significant Items (SSI).

2.4.2.4 Maintain a program that constantly checks proper

application of maintenance procedures.

2-2

2.4.2.5 Maintain a program that identifies and prevents

unjustified or unauthorized processing of FRCSW products.

2.4.2.6 Ensure product reliability by proper application and

administration of maintenance plans.

2.4.2.7 Include in the reliability program, all management and technical actions essential to adequately instill confidence that all items processed by FRCSW personnel conform to established reliability requirements.

2.4.2.8 Ensure adequacy of controls over material and component usage in the production process.

2.4.3 Industrial Quality Department personnel shall

2.4.3.1 Provide monitoring, analysis, and specialized product and process knowledge to identify degraders of product and process reliability.

2.4.3.2 Evaluate process and procedural controls, and identify changes which will improve reliability.

2.4.3.3 Determine failure modes and trends to judge the

adequacy of production processes and maintenance plans, and to initiate corrective and preventive actions.

2.4.3.4 Recommend and facilitate corrective and preventive

actions by engineering, logistics, production, and other FRCSW personnel.

2.4.3.5 Follow-up to evaluate the effectiveness of corrective and preventive actions.

2.4.3.6 Report reliability data/concerns to cognizant

management personnel.

2-3

CHAPTER 3

JUN 2 9 2015

CONTROL OF INCOMING MATERIAL AND MATERIAL HANDLING

3.1 Introduction

3.1.1 The policy concerning incoming aeronautical and shipboard material control is that there be a FRCSW-wide awareness of responsibilities and a systematic approach to the control of all requisitioned and contracted material.

3.1.2 An integral part of the FRCSW processing cycle is

identification, transporting, handling and storage of raw stock and aeronautical/shipboard material received and processed at the FRCSW. Aeronautical/shipboard material is complex and consequently prone to physical damage due to the functional end use and reliability demands. Therefore, upon receipt and while in the custody of the FRCSW, aircraft/shipboard material must be protected at all times against physical damage, corrosion and other forms of deterioration during handling, processing, transporting and storage.

3.2 Purpose. To assign responsibilities and establish

procedures for the inspection, control, proper material identification and storage of aeronautical/shipboard material and supplies, including raw stock, entering the FRCSW through the Defense Logistics Agency (DLA) Aviation at San Diego, per COMNAVAIRFORINST 4790.28, and NAVSEAINST 4440.22, Control of Receipts of Material Accepted at Source. See Appendix 3-A of this Chapter for material handling requirements.

3.3 Information

3.3.1 The requirements of this Chapter apply to all areas of

the FRCSW where incoming aeronautical/shipboard material is received by the FRCSW and DLA. All organizations have the inherent responsibility for assuring that only aeronautical/ shipboard material conforming to contractual specifications are introduced into FRCSW processes or products and are tested and verified for such conformance before FRCSW acceptance.

3.3.2 Requirements and responsibilities for the procurement of aeronautical/shipboard material and supplies, including raw stock, are contained in the Commercial Procurement Blue Book/Desk Guide, available on the FRCSW Intranet.

3-1

3.3.3 Requirements and responsibilities for hazardous material (HAZMAT) are contained in FRCSWINST 5090.18, Environmental Protection Program.

3.3.4 Requirements and responsibilities for the manufacture of flight critical parts are contained in FRCSWINST 4790.4, Local Manufacture of Aviation Parts.

3.3.5 The Supply Discrepancy Report (SDR), which replaced the Report of Discrepancy (ROD), shall be used to report packaging and shipping discrepancies, misidentified material, incorrect quantities, and other discrepancies that are not covered under NAVAIR/NAVSEA regulations/requirements. The SDR shall be initiated per FRCSW 4440.1A.

3.3.6 A Product Quality Deficiency Report (PQDR) shall be used to report products, with zero operating hours, which do not meet quality requirements. The PQDR shall be initiated per Chapter 17 of this Manual.

3.3.7 Definitions

3.3.7.1 Material includes all types of aeronautical/shipboard parts and components, including raw stock.

3.3.7.2 Source inspection is inspection performed by the

Government at the vendor or contractor site prior to release to the Government.

3.3.7.3 Destination inspection and acceptance is performed when the material reaches the requesting shop. Inspection at the destination may include functional tests or visual checks. In the case of raw stock, and in the absence of a Certificate of Material (COM) from the vendor, testing shall be performed by Research and Engineering Group Materials Engineering Division personnel.

3.3.8 Defense Logistics Agency (DLA) Aviation at San Diego

shall perform the following functions

3.3.8.1 Ensure that aeronautical/shipboard material and

supplies are procured from an approved source, and that the approved source is located in an approved country of origin when

3-2 required. See FRCSWINST 10420.18 for requirements related to aeronautical bearings.

3.3.8.2 Ensure technical quality requirements and requests for manufacturers' Certificates of Conformance (COC) and Certificates of Material (COM) are included on applicable FRCSW originated aeronautical/shipboard material requests. COMs are required for all raw stock material; COCs alone are not acceptable.

3.3.8.3 Receive all incoming material, including

aeronautical/shipboard parts and components in support of FRCSW material requirements.

3.3.8.4 Retain material shipping, receiving and movement

documents.

3.3.8.5 Ensure receipt documents match the material and

quantities received from supply sources or vendors. Ensure a COC/COM accompanies raw stock material.

3.3.8.6 Attach the material movement document to the material delivered to FRCSW's designated delivery points.

3.3.8.7 Provide transportation of material in support of

FRCSW's product lines. Per Material Receipt Policy dated 7 September 2011, designated personnel at FRCSW material delivery points shall be responsible for signing the required documents to acknowledge receipt and acceptance of material.

3.3.8.8 Submit Supply Discrepancy Reports (SDR) on material

receipts with delivery discrepancies (i.e., incorrect quantity, incorrect price, incorrect National Stock Number (NSN), etc.).

NOTE: For material quality discrepancies, FRCSW Industrial Quality Department (IQD) will initiate a Product Quality Deficiency Report (PQDR) on wholesale provided inventory.

3.4 Responsibilities

3.4.1 Research and Engineering Group personnel shall

3.4.1.1 Define and specify characteristics of design and

testing, as applicable, to determine the acceptability of

3-3 material over which they have responsibility, e.g., flight critical manufacturing.

3.4.1.2 Provide assistance, when requested, for local purchase of material when no applicable specification exists.

3.4.1.3 Assist, when requested, in the inspection or test of

incoming material to determine conformance to quality specifications. Provide laboratory analysis, as applicable, to determine material acceptability.

3.4.1.4 Provide timely engineering evaluation of Requests for Engineering Information (REI) requesting deviations from previously identified deviations from manufacturing specifications of open purchase material.

3.4.1.5 Inform Industrial Quality Department personnel either verbally or by memorandum of the need to initiate a PQDR following the deviation.

3.4.2 Industrial Quality Department personnel shall

3.4.2.1 Investigate quality problems relating to incoming

material and initiating appropriate corrective/preventive actions.

3.4.2.2 Monitor incoming material to preclude intrusion of

nonconforming material into FRCSW processes. See FRCSWINST 10420.1B for requirements related to aeronautical bearings.

3.4.2.3 Monitor raw stock received with a COM to ensure the

integrity of the COM process.

3. 4. 2. 4 Ensure a COM accompanies ra1v stock.

3.4.2.5 If a COM does not accompany the raw stock, contact the cognizant DLA personnel who shall contact the buyer or vendor to obtain the COM. If the need is urgent, the raw stock may be accepted without the COM by having the material tested and verified by the Materials Engineering Division.

3.4.2.6 Perform destination acceptance of material received on a DD 250, as required, and when notified by shop. Sign, date and return the DD 250 to DLA.

3-4

3.4.2.7 Conduct Material Review Boards (MRB) per Chapter 15 of this Manual when the material received is a critical item and does not conform to quality requirements. A critical item is defined as an essential item that is in short supply or expected to be in short supply for an extended period.

3.4.2.8 Issue PQDRs per Chapter 17 of this Manual, when

required.

3.4.3 Industrial Production Department Production Control (PC) personnel shall

3.4.3.1 Route or store all properly identified incoming

material. Material later found to be nonconforming shall be retained until a PQDR or SDR is issued, as applicable.

3.4.3.2 Maintain the identity of raw stock in storage by

identifying it with a COM. Maintain the identity of each piece of raw stock during processing by attaching a copy of the COM to the processing documents.

3.4.3.3 Initiate a processing document and route all flight

critical material to the Materials Engineering Division for analysis.

3.4.3.4 Receive material on a DD 250 requiring destination

acceptance and notify the user shop that acceptance inspection is required.

3.4.3.5 Transport material to the proper processing shop or

receiving/assembly area.

3.4.3.6 Attach a completed PQDR or SDR to rejected material, as required.

3.4.3.7 Route rejected material to cognizant DLA personnel.

3.4.4 Industrial Production Department production personnel

shall

3.4.4.1 Determine receipt inspection requirements.

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3.4.4.2 Inspect and test incoming material requiring

destination inspection, and any other tests required by the Industrial Quality Department, to determine conformance to technical requirements.

3.4.4.3 Present the results of these inspections and tests

together with samples to Industrial Quality Department personnel for verification and acceptance or rejection.

3.4.4.4 When material previously accepted into the shop is

later found to be nonconforming, notify Industrial Quality Department personnel for initiation of a PQDR.

3. 4. 4. 5 Fonvard nonconforming material to PC personnel.

3.4.5 Cognizant FRCSW personnel shall ensure only those

aeronautical/shipboard materials conforming to contractual requirements are introduced into FRCSW processes or products and are tested and verified for compliance of procurement requirements before FRCSW acceptance.

3-6

3.A.1 Information

APPENDIX 3-A

MATERIAL HANDLING

FRCSWINST 4855.1D

JUN 2 9 2015

3.A.1.1 Detailed procedures for material identification, transporting and handling during processing and storage at the FRCSW are provided in FRCSWINST 4400.6A, Material Identification, Transportation and Handling During Processing and Storage.

3.A.1.2 Personnel engaged in material rework, routing, and transportation must be indoctrinated and made a1vare of the protective demands of the specific item and the potential hazards of its routing pattern.

3.A.1.3 Industrial Quality Department services provided to PC personnel in support of material handling normally include monitoring and surveillance actions. These actions (considered an "all hands" responsibility) are taken to ensure environmental protection against airborne dust, humidity, corrosion, and the pre~ention of shock damage before, during, and after processing.

3.A.1.4 The Quality Program shall ensure raw materials to be used in fabrication or processing of products conform to the applicable physical, chemical and other technical requirements, and are so identified. Laboratory testing shall be employed, as necessary.

3.A.1.5 Suppliers shall be required by the FRCSW Quality Program to exercise equivalent control of the raw materials used in the production of parts and items that they supply.

3.A.1.6 Materials that are unidentified, corroded, damaged, or defective upon receipt shall be processed per Chapter 17 of this Manual. A sample of unidentified material shall be forwarded to the Materials Engineering Division for identification.

Unidentified material shall not be issued until positive identification is made.

3.A.2 Responsibilities

3.A.2.1 Industrial Quality Department personnel shall

3-A-1

3.A.2.1.1 Perform surveillance and periodically audit the methods of identifying, handling, and storage of FRCSW material, as well as preservation, packaging, and packing procedures.

3.A.2.1.2 Monitor material, parts, or components being handled, transported and stored throughout the FRCSW.

3.A.2.1.3 Initiate a Discrepancy Work Order (DWO), per Chapter 13 this Manual, when a material handling discrepancy is found to be the FRCSW's responsibility.

3.A.2.2 Cognizant FRCSW personnel shall comply with the requirements of FRCSWINST 4400.6A and NAVSEAINST 4600.1B, Material Transportation Program.

3-A-2

CHAPTER 4

CERTIFICATION PROGRAM

FRCSWINST 4855.1D CH-1

JUL 2 0 2015

4.1 Introduction. Certification is documented validation that all product characteristics affecting quality conform to applicable work documents, specifications and requirements.

4.2 Purpose. To provide requirements, responsibilities and

procedures for the FRCSW Certification Program.

4.3 Information

4.3.1 COMNAVAIRFORINST 4790.2B, paragraph 7.6.4 requires

certification of all items processed by FRCSW. Certification responsibility, accountability and authorization are applicable to all personnel engaged in the evaluation, repair, rework, testing, manufacture, and movement of products, including:

4.3.1.1 Production artisans

4.3.1.2 Examination and Evaluation (E&E) personnel

4.3.1.3 Special Process Operators. See Chapter 5 of this

Manual for more information.

4.3.1.4 Production Control (PC) personnel

4.3.1.5 Planning and Estimating (P&E) personnel

4.3.1.6 Materials Engineering Division personnel

4.3.1.7 Aircraft Examiners (AE)

4.3.1.8 Artisan Inspectors (AI)

more information.

4.3.1.9 Contractors

See FRCSWINST 4855.3A for

4.3.2 The Certification Program is managed by the Industrial

Quality Department (IQD). Certification authority can be granted only by the IQD.

4.3.3 Shop supervisors depend on subordinates to build quality into the products. It is impossible for shop supervisors to be

4-1

FRCSWINST 4855.1D CH-1

JUL 2 0 2015

qualified in every aspect of work operations performed within their area of responsibility. Technical trade knowledge is not required of shop supervisors.

4.3.3.1 Certification authority shall not be granted, nor

stamps issued, to shop supervisors.

4.3.3.2 Personnel with certification/inspection authority who are promoted to supervisory positions (temporarily or permanently) shall lose their certification/inspection authority and shall be required to surrender to the Quality Management Division (QMD) all certification/inspection devices issued to them.

4.3.4 Due to the inherent training status of apprentices, and the transient nature of their work/shop assignments, they shall not under normal circumstances be issued certification stamps.

Exceptions to this policy may be made by the Industrial Quality Department with appropriate justification, which shall include, at a minimum, definitive documentation of their training and qualification for the performance of specific operations/tasks.

4.3.5 Materials Engineering Division personnel who are required to perform product certification actions in the Materials Engineering Division or various production areas of the FRCSW shall be certified. This applies specifically to any person who tests fuels, oils, chemicals, adhesives, metals, or anything that affects, directly or indirectly, the quality of a product.

Each process for 1vhich the individual may perform certification actions shall be documented in their IQR/training jacket.

Requests for certification of Materials Engineering Division personnel shall be made per Appendix 4-B of this Chapter.

4.3.6 A signature does not constitute a certification action

under any circumstances. Signatures (not initials) may be used only to void erroneous certification actions.

4.3.7 The training, qualification and certification of former Government employees of FRCSW who have later become contractor employees shall be acceptable to the Industrial Quality Department without further retraining, requalification or recertification, but only if such training, qualification and certification have not otherwise become·overdue/expired. This

4-2

FRCSWINST 4855.10 CH-1

policy also applies to former contractor employees who later become Government employees.

4.3.8 Inventories of all certification/inspection stamps, both active (issued) and inactive (not issued), shall be performed.

4.3.8.1 Issued certification/inspection stamps shall be

inventoried at least every four years concurrently during Certification Program refresher training using a Stamp Inventory form (FRCSW 4855/263). The inventory shall include capturing the imprints of all stamps to verify their legibility. Ad hoc reports of the quantities of issued stamps by type are available from the Skills database.

4.3.8.2 Not issued certification/inspection stamps (stored in the IQD Office) shall be inventoried at least quarterly. The inventory shall include recording the quantities of each type of stamp in the IQD stamp database.

4.3.9 Additional guidance is provided by Appendices 4-A through 4-J, as follows:

4.3.9.1 Appendix 4-A provides procedures for developing and

maintaining Job Task Descriptions (JTD)/Skill Based Qualifications (SBQ), Individual Qualification Records (IQRs), Forms FRCSW 4855/250 through 4855/253, and training jackets.

4.3.9.2 Appendix 4-B provides procedures for requesting and

granting certification/inspection authority and issuance of certification/inspection stamps.

4.3.9.3 Appendix 4-C provides information and responsibilities concerning Certification Program Training.

4.3.9.4 Appendix 4-D provides information concerning types of certification/inspection stamps.

4.3.9.5 Appendix 4-E provides procedures and responsibilities concerning voiding and recertification of work documents.

4.3.9.6 Appendix 4-F provides procedures for requalification

and recertification of personnel.

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4.3.9.7…