AFMCI21-127.pdf

NOTICE: This publication is available digitally on the AFDPO WWW site at:

http://www.e-publishing.af.mil.

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

BY ORDER OF THE COMMANDER

AIR FORCE MATERIEL COMMAND

AFMC INSTRUCTION 21-127

23 JUNE 2005

Maintenance

DEPOT MAINTENANCE PLANT

MANAGEMENT

OPR: AFMC/LGPE (Chris Bucher) Certified by: AFMC/LGPE Supersedes AFMCI 21-127, 24 May 01 Pages: 40

Distribution: F

This instruction implements applicable provisions of AFPD 21-1 Managing Aerospace Equipment Main-tenance, AFI 21-102 Depot Maintenance Management, AFI 32-1001 Operations Management, AFI 23-111 Management of Government Property in Possession of the Air Force, AFI 21-113 Air Force Metrology and Calibration Program, TO 34-1-3 Inspection and Maintenance of Machinery and Shop Equipment, TO 00-20-1 Aerospace Equipment Maintenance Inspection Documentation Policies and Pro-cedures, AFMCI 21-107 Tool Control and Accountability, AFOSHSTD 91-501 Air Force Consolidated Occupational Safety Standard and T.O. 00-20-14 Air Force Metrology and Calibration Program. It pro-vides policy, procedures and responsibilities for the Industrial Support Divisions at the Air Logistics Cen-ters (ALC), the Aerospace Maintenance Regeneration Center (AMARC), and the ALC Product Divisions as applicable. This instruction does not apply to the Air National Guard or US Air Force Reserve Com-mand units and members. When developing local procedures, bargaining obligations must be met with the respective local union.

SUMMARY OF REVISIONS

This is a complete rewrite of this instruction. Information has been updated to reflect current operations and changes in documentation and management. Chapters were consolidated to make a more concise doc-ument.

Chapter 1— GENERAL 4

1.1. Purpose

1.2. Mission Functions

1.3. Operating Instructions

1.4. Categories of Industrial Services Division Work

1.5. Relationship to BCE (Work Accomplishment)

2 AFMCI21-127 23 JUNE 2005

1.6. Requests for BCE Support

Table 1.1. Industrial Services Versus BCE Responsibilities

1.7. Interpretation of Utility Tasks:

Chapter 2— EQUIPMENT MAINTENANCE 10

2.1. Maintenance Concept

2.2. Maintenance Program Determination

2.3. Maintenance Process

2.4. Maintenance Initiation:

2.5. Responsibilities:

2.6. Equipment Maintenance Documentation

Chapter 3— ENGINEERING AND INSTALLATION PROJECTS 17

3.1. Concept

3.2. Project Initiation:

3.3. Control

3.4. Design/Engineering

3.5. Planning

3.6. Execution

Chapter 4— PHYSICAL SCIENCE LABORATORIES 21

4.1. Mission

4.2. Functions

4.3. Instruction

4.4. Records

Chapter 5— MATERIAL 25

5.1. Control Concept

5.2. Program Responsibilities

5.3. Material Types

5.4. U6300 Requirements

5.5. U6910 Project Material Requirements

5.6. U7000 Hazardous Material Requirements

5.7. Residue Material Requirements

5.8. Shelf Life Material Requirements

AFMCI21-127 23 JUNE 2005 3

5.9. Material Acquisition Requirements

5.10. Labeling and Tagging Requirements

5.11. Inventory Requirements

Chapter 6— TOOL CRIB MANAGEMENT 28

6.1. Tool Management Concept

6.2. Responsibilities

6.3. Tool Kit Template Requirements

6.4. Tool Kit Custodial Receipt Listing (TKCRL) Requirements

6.5. Tool Acquisition Requirements

6.6. Tool Storage Requirements

6.7. Tool Inventory Requirements

6.8. Tool Issue and Turn-in Requirements

6.9. Lost, Damaged, or Destroyed Tool Requirements

6.10. Tool Disposal Requirements

6.11. Consumable and Expendable Items

Chapter 7— PRECISION MEASUREMENT EQUIPMENT LABORATORY 33

7.1. Precision Measurement Equipment Laboratory (PMEL)

7.2. Functions

7.3. Structure

7.4. Workload Definitions

7.5. PMEL Functional Area Chief Responsibilities

7.6. PMEL Total Quality Program (TQP)

7.7. Production Support Section

Attachment 1— GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 40

4 AFMCI21-127 23 JUNE 2005

Chapter 1

GENERAL

1.1. Purpose

1.1.1. This instruction provides guidance, procedures, and responsibilities for the Industrial Services Division and the organizations they support. The Industrial Services Division function includes Indus-trial Plant Equipment (IPE) and facilities maintenance, installation, engineering, Precision Measure-ment Equipment Laboratory (PMEL) and Physical Science Lab services and management support.

1.2. Mission Functions.

1.2.1. Install, relocate, modify or remove nonreal property facilities and equipment.

1.2.2. Manage, control and perform all non-real property facility maintenance and equipment preven-tive and predictive maintenance.

1.2.3. Manage, control and repair nonreal property facilities and equipment.

1.2.4. Manage, control and perform all nonreal property equipment installations, shop relocations, removal and facility modifications.

1.2.5. Receive work requests, plan, engineer, schedule, control, and manage material in support of

1.2.1. and 1.2.3.

1.2.6. Manage and operate the industrial Tool Management Center (TMC).

1.2.7. Assist the Base Civil Engineering (BCE) in the development and management of Depot Main-tenance Activity Group (DMAG) facility maintenance, repair, and minor construction programs.

1.2.8. Manage the DMAG service contract program.

1.2.9. Provide a focal point for requesting and monitoring BCE support of industrial real property facilities and equipment.

1.2.10. Provide non-real property engineering support to product directorate functions.

1.2.11. The following functions may be performed by the Industrial Services Division:

1.2.11.1. Manage Maintenance Directorate transportation and material handling vehicles

1.2.11.2. Manage Maintenance directorates’ energy conservation program.

1.2.11.3. Manage Maintenance directorates’ program for collecting, reclaiming, and disposing of scrap material, except precious metal.

1.2.11.4. Maintenance

1.2.11.5. Manage and operate the Precision Measurement Equipment Laboratory (PMEL).

1.2.11.6. Manage and operate the Physical Sciences Lab.

1.2.11.7. Manage other DMAG workloads as determined appropriate by the individual ALC.

1.3. Operating Instructions.

AFMCI21-127 23 JUNE 2005 5

1.3.1. Each ALC will develop local procedures that will, as a minimum, meet the requirements of this instruction. (NOTE: Local directives will be developed or updated for implementation within 180 days from the publication of this instruction). Operating instructions will provide specific procedures for the following:

1.3.1.1. Processing, controlling, and accomplishing support of depot maintenance equipment and facilities through the Industrial Services Division.

1.3.1.2. Determining requirements, monitoring, and accomplishing preventive, corrective and predictive maintenance for depot equipment.

1.3.1.3. Developing plans and performing Industrial Services Division functions.

1.4. Categories of Industrial Services Division Work.

1.4.1. Work performed by the Industrial Services Division falls into the following general categories:

1.4.2. Repair. Work normally generated as a result of utility, facility, or equipment failures. The Industrial Services Division (MAD) will operate a trouble call desk for the receipt and processing of emergency repair work on nonreal property. Instructions on repair work are included in Chapter 2.

1.4.3. Project Work. Work resulting from management planning efforts. Examples of typical project-type workloads include the installation of new equipment and relocation of a production shop.

The planning, scheduling, and control functions will receive and process requests for this type of work according to Chapter 3.

1.4.4. Preventive and Predictive Maintenance. Work planned and performed to protect the capability of equipment by removing the cause of failure and making adjustments for normal wear before failure occurs. This work is performed on a predetermined time schedule according to the instructions con-tained in Chapter 2.

1.4.5. Direct Product. Work normally resulting from a requirement of a MAD customer for skills peculiar to the Industrial Services Division. When this occurs, procedures applicable to the direct pro-duction activity will apply to the Industrial Services Division resources involved. A direct production Resource Control Center (RCC) may be established in the Industrial Services Division where it per-mits the most efficient use of skills and directorate resources.

1.5. Relationship to BCE (Work Accomplishment).

1.5.1. Industrial Services Division versus BCE responsibilities. (see Figure 1.1). Availability of resources may drive changes to BCE and Industrial Services Division responsibilities listed in Figure

1.1. A local memorandum of agreement will be developed to reflect these changes.

1.5.2. BCE’s Mission and Function Statement. BCE is responsible for maintaining real property, roads and grounds, real property installed equipment (RPIE), and utilities. Real property facilities and equipment are defined as lands, buildings, structures, utility systems, improvements and accessories as accounted for in real property records. The BCE obtains project approval, executes facility projects, establishes and maintains programs to prevent real property deterioration, develops and conducts a facilities and infrastructure maintenance and operations program based on mission requirements and cost effectiveness.

1.5.3. Industrial Services Division’s Mission and Function Statement. See paragraph 1.2..

6 AFMCI21-127 23 JUNE 2005

1.6. Requests for BCE Support.

The Industrial Services Division reviews and processes AF IMTs 332; Base Civil Engineer Work Request, to the BCE for all DMAG organizations. The Industrial Services Division will serve as liaison between the production divisions and the BCE.

Table 1.1. Industrial Services Versus BCE Responsibilities.

TASK MAD BCE

1. Equipment Repair and Maintenance

a. Real Property Installed Equipment (RPIE) X

b. Industrial Plant Equipment (DIPE) X

2. Equipment Installation:(DIPE)

a. Installation/Relocation of Prefabrication Screens, Partitions, and Dividers X

b. False Floors and Platforms X

c. Excavation C*

d. Anchorage to Floors X

e. Foundation and Pads C*

f. Temporary Removal and Reinstallation of Existing Roofs, Walls, Utility Systems and Appurtenances

C*

g. Ventilation and Separate Exhaust System Requiring Wall or Roof Penetration

C*

h. Utilities:

(1) Electrical less than 600 volts, from the equipment to first service disconnect

X

(2) Electrical greater than 600 volts all connections X

(3) Other utilities, e.g., compressed air, chilled water, steam, potable water, natural gas, from the equipment to first connection providing the source of supply

(4) High pressure compressed air ( process air) X

(5) Industrial gases, e.g., argon, hydrogen, nitrogen, all government-furnished DIPE, valves, fittings, gauges, etc

X

(a) Air-conditioning strictly for equipment operation (DIPE) X

3. Permanent Real Property Facilities and Installed Equipment Repair and Maintenance (RIPE)

X

4. Portable Buildings/Offices

a. Repair and Maintenance C*

b. Siting X

c. Utility Connections C*

AFMCI21-127 23 JUNE 2005 7

NOTES:

X indicates the office of primary responsibility (OPR).

C indicates OPR, but BCE coordination/support required prior to Industrial Services performing work.

Local coordination procedures will be jointly determined by Industrial Services BCE. The OPR for C* tasks may vary based on the extent and/or nature of the work. These areas are negotiated if the OPR is not clear. This listing of MAD responsibilities versus BCE responsibilities was modified to require additional coordination. This increased coordination will protect utility systems from overload and help to maintain the structural integrity of real property.

1.7. Interpretation of Utility Tasks:

1.7.1. Electrical, less than 600 volts. MAD will maintain all branch circuits within a production divi-sion occupied facility from power distribution panel or bussway to non-RPIE utilization equipment.

BCE will be responsible for power supply and electrical components to the first buss switch on the main distribution service and all electrical installations to RPIE. BCE will make all connections to the supply point in electrical vaults for RPIE and non-RPIE, unless approval is granted to MAD through an AF IMT 332, Base Civil Engineer Work Request.

5. Painting

a. Industrial Plant Equipment (DIPE) X

b. Process Related Areas and Structures X

c. Real Property Facilities and Equipment X

6. Pavement Construction, Repair and Maintenance X

7. Sign Construction, Modification, and Replacement

a. Facility and Exterior Organizational Identification X

b. Interior Organizational Signs X

8. Duplicate Keys

a. Real Property Facilities Integral Type Locks X

b. Padlocks and Organizations Equipment X

9. Grounds Keeping (Mowing and Policing)

a. Within 50 feet for assigned facilities, or as designated locally X

b. Other X

10. Landscaping (Planting, Spraying, and Fertilizing) X

11. Interior Lighting

a. Up to 10 feet in height X

b. From 10 feet and above X

12. Exterior Lighting X

TASK MAD BCE

8 AFMCI21-127 23 JUNE 2005

1.7.2. Electrical, greater than 600 volts. BCE will be responsible for maintenance and repair of all power supply, electrical equipment and connections to RPIE as well as non-RPIE.

1.7.3. Potable Water Systems. BCE will be responsible for maintenance and repair of the systems to be used for personnel and sanitary installations as well as the supply and complete distribution system up to and including the backflow preventing device at the service connection to all process and non-RPIE industrial systems. (Fire water supply and distribution systems are BCE responsibility.)

1.7.4. Chilled Water and Hot Water Systems. Chilled water and hot water systems are considered util-ity systems if any part of either system is being utilized for “creature comfort” or other RPIE support.

As a utility, BCE will be responsible to maintain the chilled water plant or boiler plant supply and return piping main loop as well as all RPIE support secondary distribution systems. Process and other non-RPIE hot or chilled water supply and return DIPE systems will be maintained by the MAD from the service connection at the supply main to the service connection at the return main or first valve installation in service loop if no disconnecting means is available at the service connection. The chilled water will be of such a quality that it meets a maximum standard of 45 degree dew point with a particulate of 5 micron or less at point of use.

1.7.5. Steam and Condensate Return, Natural Gas, and Compressed Air. All plant and main distribu-tion systems are the responsibility of the BCE. Secondary branch systems to support non-RPIE will be maintained by MAD from the service connection at the main distribution system (or closest valve in the branch line if no service disconnect is available) to the non-RPIE or utilization process. BCE will make all connections to the source of supply. The compressed air will be of such a quality that it meets a minimum standard of 32 degree dew point with a particulate of 5 micron or less at point of use.

1.7.6. Industrial Gases (argon, hydrogen, nitrogen, etc.) and High Compressed Air. All plants, storage reservoirs, DIPE systems, gauges, etc. will be maintained by MAD.

1.7.7. Waste Water Collection Systems. BCE will be responsible for all collection systems supporting sanitary or personnel comfort facilities as well as RPIE producing waste water from point source to disposal plant. Waste water from non-RPIE or industrial process discharge sources will be conveyed by process piping or other means to the BCE industrial waste collection system. MAD will be respon-sible to maintain the non-RPIE waste water conveying systems from its source to the nearest floor drain, sump or lift station wet well. These latter locations are collection points for the BCE industrial sewage systems. Below grade sumps that have no gravity drain connection to the industrial waste sys-tem and collect waste water from non-RPIE sources only will be considered the same as floor drains and will be maintained by the BCE. Small waste water forwarding pumps (1 horsepower or less) com-plete with discharge piping, valves, fittings and controls as required to service these small pumps will consequently be included as a part of the conveyance system and will be a MAD responsibility. BCE will be informed by process owners within MA anytime a change in production processes will result in increased volume of waste collection.

1.7.8. Storm Water Collection System. Maintenance of storm drains is a BCE responsibility. No other than nonpolluted run off flows from rain water shall be conveyed to the storm water collection system. Oil-water separators in the storm water systems will be maintained and repaired by BCE.

1.7.9. Irrigation Sprinkler Systems. Maintenance and repair of automatically or manually controlled irrigation and sprinkler systems is a BCE responsibility and as RPIE will be a part of landscaping.

1.7.10. Newly-Constructed Facilities and Substantial Additions or Alterations to Existing Facilities.

MXD will be notified when BCE has accepted the formal issuance of a certification of beneficial

AFMCI21-127 23 JUNE 2005 9

occupancy. Prior to occupying a new facility, MAD and BCE will meet to confirm all BCE responsi-ble equipment and MAD responsible equipment (IOE). When responsibility is determined, MAD and BCE will install a tag on their identified equipment to indicate recognition of their maintenance responsibility. BCE will turn over to the MAD representative all operator maintenance (OM) manuals, spare parts lists, drawings, start-up instruction, etc., for industrial equipment which are provided by the contractor as a requirement of the construction contract. To assure that warranty conditions are properly satisfied, it is imperative that BCE promptly surrenders all non-RPIE PM and OM data to MAD and timely arranges for the preoccupation meeting with MAD representatives.Chapter 2

10 AFMCI21-127 23 JUNE 2005

Chapter 2

EQUIPMENT MAINTENANCE

2.1. Maintenance Concept.

2.1.1. This chapter provides guidance for maintenance procedures and practices to ensure reliability and mission support capability of Depot Industrial Plant Equipment (DIPE) and non-DIPE.

2.2. Maintenance Program Determination.

2.2.1. Types of Equipment. The Industrial Services Division, with the aid of the Production Divi-sions, determines which equipment requires specific operator maintenance (OM) and the equipment to be included in the preventive maintenance (PM) and predictive maintenance (PDM) programs man-aged by Industrial Services. Equipment such as bench grinders, bench drill presses, etc, generally requires only OM because of its simplicity and intermittent use. Equipment such as numerically-con-trolled machine tools, lathes, milling machines, boring machines, surface grinders, breathing air sys-tems, hoists test stands, etc., must be capable of producing to specific tolerances, normally requires specific PM or PDM, in addition to OM.

2.2.1.1. DIPE is defined as permanently affixed/fixed location equipment not readily movable or other equipment as determined by Industrial Services Equipment Specialists and local operating instructions. DIPE is used for, but not limited to cutting, abrading, grinding, shaping, forming, joining, testing, measuring, heating, treating, or otherwise altering the physical, electrical, or chemical properties of materials, components, or end items, entailed in manufacturing, mainte-nance, supply, processing, and assembly operations. Industrial equipment such as material con-veyance systems, process compressed air and vacuum systems, specialized industrial gas systems, hoists/bridge cranes, and breathing air systems may be included. DIPE will be identified with an Industrial Services Division identification number in accordance with (IAW) paragraph 0 of this document.

2.2.1.2. Non-DIPE support equipment will be defined IAW paragraph 0of this document.

Non-DIPE will include all equipment required to perform support functions except when it is, or becomes, an integral part of mission equipment. Support Equipment (SE) does not include any equipment required to perform mission operation functions. SE will include test equipment and automatic test equipment (when it accomplishes a support function), field and depot SE, and related computer programs and software. Support equipment includes the following major catego-ries:

2.2.1.2.1. Direct Support Equipment (DSE).

2.2.1.2.2. Powered and non-powered Aerospace Ground Equipment (AGE).

2.2.1.3. 3400 Series Machinery and Shop Equipment

2.2.1.3.1. Equipment which does not require specific OM, specific servicing inspections, or for which technical data does not exist will be tagged with condition status tags, IAW Techni-cal Order (TO) 34-1-3, Inspection and Maintenance of Machinery and Shop Equipment, and TO 00-20-3, Maintenance Process of Reparable Property and the Repair Cycle Asset Control System. Examples of this class of machinery and shop equipment include small bench grinders

AFMCI21-127 23 JUNE 2005 11

and buffers, drill presses or other equipment that requires only On Condition Maintenance

(OCM).

2.2.2. Maintenance Program Criteria. The following criteria will be applied to determine if equip-ment will be included in the maintenance management PM or PDM program.

2.2.2.1. Equipment creating an unsafe or hazardous environment if failure occurred, due to lack of PM or PDM, will be included.

2.2.2.2. All weapon peculiar equipment having specific PM requirements delineated by an appli-cable TO will be included.

2.2.2.3. Equipment subject to breakdown repairs that are expensive compared to PM or PDM will be included.

2.2.2.4. Equipment critical to production and where failure would result in costly downtime will be included.

2.2.2.5. Equipment not critical to the depot maintenance process (e.g., small drill press) and can be repaired without regard to downtime or equipment availability should be excluded.

2.2.2.6. Equipment of small dollar value, where the cost of PM or PDM is likely to exceed the cost of replacement upon failure, should be excluded.

2.3. Maintenance Process.

2.3.1. Preventive Maintenance (PM):

2.3.1.1. PM is the normal upkeep and preservation of equipment through systematic inspection, detection and correction of discrepancies to prevent failures, to verify serviceability, or restore complete-serviceability of equipment that has been subjected to usage, wear and tear, or deteriora-tion caused by environmental elements. It is performed on a periodic basis, according to a specific set of instructions and a predetermined time schedule and includes such actions as locating and correcting minor vibrations or tool chatter, adjusting or replacing drive belts, accomplishing lubri-cation requirements, making adjustments in gibs, bearings, and lead screws, and leveling of machines.

2.3.1.2. Perform preventive maintenance for Industrial Services maintained equipment IAW locally developed procedures.

2.3.1.3. PM Frequency. PM inspections should be spaced as far apart as possible to reduce cost, yet, stay within safe time limits during which defects do not ordinarily develop to the point of needing attention. Use the following sources to establish PM frequencies:

2.3.1.3.1. Technical Orders (TO). Follow TO prescribed frequencies when weapon system peculiar equipment is covered by a TO, unless written approval is obtained to adjust the requirement.

2.3.1.3.2. Manufacturer’s Recommendations. These normally assume a high degree of use;

that is, eight or more hours per workday. Estimated usage rates will be used to compensate for the less than high use rates to preclude unnecessary PM costs.

2.3.1.3.3. Judgment. In the absence of other sources, judgment based on similar pieces of equipment should be applied.

12 AFMCI21-127 23 JUNE 2005

2.3.1.3.4. Historical Data. Historical maintenance data may indicate the need to adjust PM frequencies. If frequent repair is required, increased PM may be justified. Conversely, lack of repair may indicate the PM frequencies should be reduced. Repair data is maintained on the AFMC IMT 388, Machine Tool and Equipment Historical Record, or in the Computerized Maintenance Management System (CMMS).

2.3.1.4. The PM is overdue when the original PM due date has been exceeded.

2.3.1.5. The PM is past due when the original PM due date has been exceeded by one frequency cycle or 60 days, whichever is less. Equipment with past due PM must be taken out of service by production shop personnel in coordination with Industrial Services maintenance personnel.

2.3.1.6. The Industrial Services equipment specialists prepare PM instructions, which are reflected on AFMC IMTs 306, Preventative Maintenance Instruction, or computer generated equivalent. A Work Authorization Document (WAD) may be used in lieu of AFMC IMTs 306 and is not required to be attached to the equipment. The WAD should contain the PM number, due date, next due date and minimum interval of inspection for the specified equipment.

2.3.1.7. Use the following sources to establish PM Instructions:

2.3.1.7.1. Maintenance Technical Orders. Follow the prescribed periodic maintenance instruc-tions when weapon system peculiar equipment is covered by a TO.

2.3.1.7.2. Manufacturer’s Recommendations. Commercial operating manuals, data, or speci-fications will be used to determine PM instructions if no Maintenance Technical Orders exist or are no longer applicable due to approved modifications that have been done to the equip-ment and the maintenance TO updates have not been received.

2.3.1.7.3. Judgment/Historical Data. For equipment that has no tech data available containing PM instructions, judgment based on experience or similar equipment historical data may be used to document PM instructions.

2.3.2. Predictive Maintenance (PDM):

2.3.2.1. Predictive maintenance is the process of using electrical and mechanical testing and diag-nostic devices to predict when a piece of equipment is deviating from its normal operating param-eters. It is designed to protect equipment capability and investment by removing causes of failure and making adjustment to compensate for normal wear before failure or an unsafe condition occurs. Predictive maintenance technology may aid in optimizing PM frequencies by utilizing data trends.

2.3.2.2. Perform PDM for Industrial Services maintained equipment.

2.3.3. Corrective Maintenance (CM):

2.3.3.1. CM is the unscheduled repair or service of equipment to verify serviceability, or to restore complete serviceability of equipment that has been subjected to usage, wear and tear, component failure or deterioration caused by environmental elements. It is performed on a customer demand basis.

2.3.3.2. Industrial Services Division will perform CM IAW locally developed procedures.

2.3.4. Operator Maintenance:

AFMCI21-127 23 JUNE 2005 13

2.3.4.1. OM requirements are documented and maintained with the equipment or are readily accessible. They will include, as a minimum, the nomenclature of the equipment, equipment iden-tification number, frequency of maintenance action, and the actions required. Maintenance per-formed by the equipment operator falls into one of the following categories.

2.3.4.1.1. General OM. Applies to all equipment to ensure serviceability and safety of the equipment prior to use. It consists of a review of equipment documentation for current status and a visual inspection of the equipment for defects, adequate servicing and general state of cleanliness.

2.3.4.1.2. On Condition Maintenance (OCM). This type of maintenance generally applies to equipment that does not have any published technical data requiring specific inspections. It may also apply to less costly and less complex equipment whereby the cost of scheduled PM is not feasible and only requires general OM. Equipment of this type may be repaired by Industrial Services personnel, as required. Documentation will be IAW TO 34-1-3, Inspection and Maintenance of Machinery and Shop Equipment.

2.3.4.1.3. Specific OM. This is equipment maintenance or inspection of a specific nature as identified on AFMC IMT 306, Preventative Maintenance Instructions or equivalent and per-formed by the owning organization/operator. The AFMC IMT 306 must be attached to the equipment or in a readily accessible location. These instructions will include OM of a critical nature that, if neglected, could result in costly equipment damage or create an unsafe condition for shop personnel.

2.3.4.2. Using organizations preparing internal preventive maintenance instructions may utilize the AFMC IMT 306 to identify these inspections. Using organizations will identify on the AFMC IMT 306 all organizational inspections.

2.4. Maintenance Initiation:

2.4.1. Production shop personnel in coordination with Industrial Services maintenance personnel will lockout/tagout the DIPE based on any safety hazard. This will be accomplished IAW AFOSH STD 91-501 and local directives.

2.4.1.1. Requesting organization will provide the following information when contacting the maintenance organization for repairs.

2.4.1.2. Status of the equipment (operational or inoperative).

2.4.1.3. Type or nature of repair service required.

2.4.1.4. Equipment type and the equipment identification number.

2.4.1.5. Justification to establish priority code IAW paragraph 2.5.1.1.

2.4.1.6. Name of the reporting individual.

2.4.1.7. Equipment location including building number, post or room number, shop name, shop RCC, and any other pertinent information.

2.4.1.8. Name and telephone number of requesting organization, point of contact, and alternate to be contacted at repair site.

14 AFMCI21-127 23 JUNE 2005

2.5. Responsibilities:

2.5.1. Industrial Services Division Responsibilities:

2.5.1.1. Establish a preventive maintenance program and assign identification numbers for Indus-trial Services maintained equipment IAW locally developed procedures.

2.5.1.2. Establish a PDM program for Industrial Services maintained equipment.

2.5.1.3. Perform CM, PM, and PDM on Industrial Services maintained equipment.

2.5.1.4. Industrial Services will maintain a master listing of equipment requiring OM, PM, and PDM by equipment number. The master listing may be maintained within the CMMS, and made available upon request.

2.5.1.5. Input updates to the CMMS.

2.5.1.6. Maintain maintenance technical data required for Industrial Services performed PM and CM of DIPE including commercial technical publications, technical orders, etc. as locally deter-mined.

2.5.1.7. Ensure PM and CM status for Industrial Services Division maintained equipment is made available to MA Divisions through a web access interface to the CMMS.

2.5.1.8. Receives work request and determines applicable repair shop.

2.5.1.9. Prepares Work Order or WAD by entering the data into the CMMS.

2.5.1.10. Track equipment maintenance history and costs in the CMMS.

2.5.1.11. Establishes priority code IAW the following criteria:

2.5.1.11.1. Priority Code 5 – Repair work that demands immediate response to prevent injury to personnel due to a safety hazard. Equipment will be secured IAW AFOSHSTD 91-501, Air Force Consolidated Occupational Safety Standard and local directives.

2.5.1.11.2. Priority Code 4 – Repair work that demands immediate response to correct criti-cal workload stoppage.

2.5.1.11.3. Priority Code 3 – Routine maintenance that is scheduled or unscheduled. This would include actual work stoppage of a non-critical workload.

2.5.1.11.4. Priority Code 2 – Potential for minor property damage.

2.5.1.11.5. Priority Code 1 – Repair work that can be deferred

2.5.1.12. Provide familiarization documents and operating procedures for the operation of the CMMS web access interface.

2.5.2. Production Division Responsibilities:

2.5.2.1. Verify equipment status prior to use.

2.5.2.2. Report the acquisition, installation, relocation, and removal of all industrial production equipment to the Industrial Services Division in writing.

2.5.2.3. Perform specific operator inspections/maintenance of DIPE and document on AFMC IMT 355, Operator Maintenance Certification, or the AFTO Form 244/245, in accordance with

AFMCI21-127 23 JUNE 2005 15

T.O. 00-20-1 and local policy. The AFMC IMT 355 will be located on or in close proximity to the equipment and will be kept on file for 1 year.

2.5.2.4. Ensure AFTO Form 244/245 Industrial/Support Record, will be used on equipment iden-tified as non-DIPE to document specific operator inspection, PM actions or discrepancies. The AFTO Form 244/245 will be located on the equipment or readily accessible.

2.5.2.4.1. Ensure equipment operators review the AFTO Form 244/245 prior to use of equip-ment.

2.5.2.5. Confirm all assigned DIPE is clearly identified with an identification number before being released for operation.

2.5.2.6. Ensure Industrial Services PM equipment specialists are notified of actions concerning new, relocated, turned-in DIPE and provided technical data. An AFMC IMT 388 or a local equiv-alent will be used on all newly acquired equipment to provide data necessary for input/update to the CMMS, along with the applicable technical manuals and commercial data.

2.5.2.7. Report any changes in owning organizational symbols to Industrial Services division as they occur.

2.5.2.8. Ensure all OM is accomplished at the prescribed frequencies.

2.5.2.9. Release equipment in a timely manner to Industrial Services personnel to ensure that PM and CM are completed promptly and as scheduled.

2.5.2.10. Follow lockout/tagout procedures IAW AFOSHSTD 91-501 and local directives for equipment discrepancies that endanger personnel safety.

2.5.2.11. Ensure form documentation is maintained for equipment under their control.

2.5.2.12. Ensure personnel will have initial training using the AFMC standard, AFTO Form 244/ 245 Familiarization Training Program IAW local directives.

2.5.2.13. Ensure TMDE PM is accomplished IAW TO 00-20-14, Air Force Metrology and Cali-bration Program, Section 3.

2.6. Equipment Maintenance Documentation.

2.6.1. DIPE Documentation.

2.6.1.1. DIPE will use the depot CMMS for equipment maintenance documentation purposes, the AFTO Form 244/245, or a combination of both.

2.6.1.1.1. As a minimum, the CMMS will contain the same data elements as described on the AFTO Form 244/245.

2.6.1.1.2. References to maintenance personnel signatures and initials regarding AFTO Form 244/245 will be entered automatically into the CMMS as the employee number and full name.

References to minimum signature will be entered as first name initial followed by last name.

2.6.1.2. DIPE with specific OM and PM inspections, and tracked in the CMMS, will not require an AFTO Form 244/245 unless the AFTO Form 244/245 is being used in conjunction with the CMMS to document the inspections and equipment conditions in accordance with T.O. 00-20-1 and local policy. DIPE status will be made available to production shop supervisors by Industrial

16 AFMCI21-127 23 JUNE 2005

Services through a web access interface to the CMMS. The CMMS web access interface will be visible as “read only” and will be printable by DIPE users. DIPE user change requests to the CMMS will be made to the Industrial Services function.

2.6.1.2.1. Specific OM for DIPE must be performed and documented by the operator on AFMC IMT 355 or the AFTO Form 244/245 and attached to the equipment or readily accessi-ble.

2.6.1.2.2. For DIPE, Industrial Services personnel will ensure all instructions for current inspections and PM requirements are reflected on a WAD, AFMC IMT 306 or a computer gen-erated equivalent. The WAD should contain the PM number, due date, next due date and min-imum interval of inspection for the specified DIPE.

2.6.2. Support Equipment Documentation (non-DIPE).

2.6.2.1. Non-DIPE with specific OM or PM requirements will use the AFTO Form 244/245.

2.6.2.1.1. An AFTO Form 244/245 will be used IAW TO 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures.

2.6.2.1.2. Shop supervisory review of AFTO Form 244/245 will be documented in Part IV.

Review intervals will be at center discretion.

AFMCI21-127 23 JUNE 2005 17

Chapter 3

ENGINEERING AND INSTALLATION PROJECTS

3.1. Concept.

3.1.1. Industrial Services performs equipment installation, relocation, removal, and facility modifica-tions in response to DMAG (Depot Maintenance Activity Group) submitted requests. In general, except for unpredicted situations, installation projects are designed, planned, scheduled, and imple-mented in an orderly manner to provide the best use of Industrial Services’ resources.

3.2. Project Initiation:

3.2.1. Initiator/Requesting Organization. The requesting organization will perform the following functions:

3.2.1.1. Submit written requests to Industrial Services Division for project work through a coordi-nated AFMC IMT 304, Service Order Request, or IAW locally developed procedures.

3.2.1.2. Provide shop layouts/drawings.

3.2.1.3. Provide equipment installation manuals when applicable.

3.2.1.4. Prepare and coordinate AFMC IMT 299, Safety Fire and Health Review or IAW locally developed procedures.

3.2.1.5. Prepare and coordinate AF IMT 813, Request For Environmental Impact Analysis or IAW locally developed procedures.

3.2.1.6. Prepare and coordinate AF IMT 332 if BCE work/approval is required.

3.2.2. Project Review/Validation. Projects shall be reviewed for completeness and applicability.

Upon review, acceptance/determination will be made by the Industrial Services organization. Projects not meeting criteria (ref 3.2.1. & BCE responsibilities as outlined in Chapter 1) shall be returned to the requesting organization for corrective actions.

3.3. Control.

3.3.1. Project Folders. Project folders are created for each valid request and assigned a unique project number. The project folder should contain the following:

3.3.1.1. A written request submitted to the locally designated Industrial Services Division organi-zation.

3.3.1.2. Engineering drawings or sketches.

3.3.1.3. AFMC IMT 305, Plant Management Work Order or computer generated equivalent.

3.3.1.4. Bill of Materials (BOM) when required.

3.3.1.5. AF IMT 813 if needed, with proper coordination obtained by the requesting organization.

3.3.1.6. AFMC IMT 299 with proper coordination.

3.3.1.7. Vendor or manufacturer's data or copies of current catalog sheets of material required, when appropriate.

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3.3.1.8. Automated Hazard Abatement Printout for projects with a Safety Hazard Risk Assess-ment Code (RAC) 3 or higher.

3.3.2. Prioritization/Local Established Working Group. An Industrial Working Group shall be established to review and monitor project requests. The Industrial Working Group will coordinate all facility/equipment work priorities and accomplishments. The charter and membership of the Indus-trial Working Group will include representatives from all Maintenance Divisions, Base Civil Engi-neering (BCE), and other organizations, or IAW locally developed procedures. Industrial Services Division will chair Industrial Working Group.

3.3.3. Tracking & Monitoring

3.3.3.1. CMMS shall be used to track and monitor projects, to ensure efficient use of resources and maximum responsiveness to customer needs.

3.3.3.2. Project history, backlog, and status shall be obtained using updated CMMS data, and/or reports may be generated for Maintenance Divisions.

3.3.4. Project Closure. Project closure includes the following:

3.3.4.1. The completed AFMC IMT 305, or computer generated equivalent, is reviewed for com-pleteness and accuracy.

3.3.4.2. Work accomplished shall be reviewed by Engineering, or IAW locally developed proce-dures, to ensure the customer approved work was performed according to design.

3.3.4.3. Maintenance documentation is updated on the CMMS and all documents are assembled for the completed project folder.

3.3.4.4. The project folder is closed out and placed in the completed project file.

3.3.5. Record Disposal.

3.3.5.1. Completed project folders are to be disposed of after two years, unless a written request exists to maintain the files longer.

3.3.5.2. Project files are disposed of IAW AFI 37-138, Records Disposition Procedures and Responsibilities.

3.4. Design/Engineering.

3.4.1. All product division requests for facility and equipment installation, relocation, modification, or removal are processed through Industrial Services Engineering.

3.4.2. Pre-Design Consultation.

3.4.2.1. Pre-Design consultations with Product Divisions are held when appropriate.

3.4.2.2. Projects are reviewed to ensure the feasibility of meeting the customer’s intent.

3.4.2.3. Alternatives shall be offered when considered to be in the Government’s best interest.

3.4.3. Site Survey. As required, Industrial Services Engineering shall perform site surveys to review project requirements, consider utility requirements within the facility (i.e. electrical, air, water, steam, etc.), and for location suitability.

3.4.4. Design Drawings.

AFMCI21-127 23 JUNE 2005 19

3.4.4.1. All engineering, drafting, and planning associated with project design shall be accom-plished taking into account load calculations on existing utility distribution systems and any safety/environmental concerns.

3.4.4.2. Good judgment must be exercised in preparing engineering drawings and sketches to be used by the Industrial Services organizations. Design drawings and sketches should be no more sophisticated than necessary to accomplish the project.

3.4.4.3. Engineering design drawings or sketches are developed to support BCE Work Requests for tasks required by the Industrial Services and Maintenance Divisions that do not have an Engi-neering staff.

3.4.5. Customer Design Review. When applicable (i.e. BCE involvement, significant changes after pre-design consultation, etc.), final design drawings will be sent to the customer for approval.

3.4.6. Project Consultation. Industrial Services Engineering duties shall include the following:

3.4.6.1. Provide general oversight as needed during the entire project process (i.e. material selec-tion/substitution, customer coordination, adaptation, removing constraints, etc.).

3.4.6.2. Provide technical guidance to the installation function on execution of project designs detailing sequence of accomplishment and/or best methods. If professional certifications are required to comply with applicable directives, Industrial Services Engineering will specify the type of certifications required.

3.5. Planning.

3.5.1. Labor & Skill Requirements.

3.5.1.1. The planning function determines the skills required, the organization to perform each project task, and estimates the work hours required.

3.5.1.2. Labor hour estimates are based on available standards, the Engineer/Planner's experience, and discussions with shop personnel.

3.5.1.3. Estimated labor hours are entered into the CMMS.

3.5.2. Material Requirement/BOM.

3.5.2.1. Material required for a project will be entered on a Bill of Material (BOM).

3.5.2.2. The planning functions will determine the type and quantity of material required by the installation function to complete each project. The quantity of material must be determined with care to avoid both material shortages and undue excesses. The engineering function is responsible for developing the material specifications used in developing the BOM. The BOM shall be entered into the CMMS.

3.5.2.3. The planning function will review on-hand and residue material inventories for utilization in the performance of installation, removal, or repair projects requiring a BOM. Projects will be planned to utilize on-hand or residual inventories whenever possible to reduce on-hand invento-ries and generate stock turnovers.

3.5.2.4. The BOM will serve as a source document for use by the material control function to issue and requisition materials, and will also be used to accept the return of unused material from the installation function at the completion of the project.

20 AFMCI21-127 23 JUNE 2005

3.6. Execution.

3.6.1. Scheduling.

3.6.1.1. Determine Material Supportability. The CMMS will be updated to reflect project status.

Project status will be reviewed on a regular basis to determine supportability.

3.6.1.2. Workload Labor Review. Workload labor review will consist of the following:

3.6.1.2.1. Availability of labor resources by skill.

3.6.1.2.2. Satisfying the mission through time phased work accomplishment.

3.6.1.2.3. Updating schedules in response to changing production requirements, availability of resources and work progress.

3.6.2. Project Accomplishment. Generally, all projects should be both material and labor support-able prior to the installation phase.

3.6.2.1. Receipt of Work Package.

3.6.2.1.1. Project work packages (including drawings, AFMC IMT 305, BOM, and AFMC IMT 299) will be provided to the installation function by the scheduling function.

3.6.2.1.2. No installation work shall be conducted without an approved AFMC IMT 305, or computer generated equivalent. This form authorizes the installation function to perform the work, provides information on the major tasks, and denotes planned skills required to accom-plish the project.

3.6.2.2. Assignment of Resources.

3.6.2.2.1. Pre-construction meetings will be held as required.

3.6.2.2.2. The installation function shall allocate appropriate skills to accomplish work according to the AFMC IMT 305, or computer generated equivalent.

3.6.2.2.3. Skills not planned on AFMC IMT 305, or computer generated equivalent, shall be adjusted by the planning function.

3.6.2.3. Installation. Installation function will perform the following:

3.6.2.3.1. Initial the AFMC IMT 305, or computer generated equivalent, when the task is completed.

3.6.2.3.2. Report project status as required to the scheduling and control function.

3.6.2.3.3. Ensure the CMMS is updated with the previous workday’s actual hours expended on each project.

3.6.2.3.4. Return all excess materials (project residue) to the material control function.

3.6.2.3.5. Return all project documents to the scheduling and control function when the project is completed.

AFMCI21-127 23 JUNE 2005 21

Chapter 4

PHYSICAL SCIENCE LABORATORIES

4.1. Mission.

4.1.1. The Physical Sciences Laboratories are versatile Metallurgical, Chemistry, Precision Dimen-sional Measurement, and Special Skills Qualification Laboratories that are an indispensable resource in today’s logistic support environment. The laboratories mission is to provide a vast array of analyti-cal support to on-base engineering, manufacturing and repair organizations as well as to other Depart-ment of Defense, Federal Aviation, Federal Law Enforcement, and Allied Forces (NATO) agencies.

The chemists, engineers, technicians, and support staff share broad expertise in aircraft mishap and industrial accident investigation, manufacturing process monitoring, prototype and first article evalu-ation, metallurgical analysis, evaluation of shelf life items, and management of the Special Skills Qualification program (OC-ALC).

4.2. Functions.

4.2.1. The Physical Sciences Laboratories provide scientific and engineering skills and instrumenta-tion necessary for the maintenance of assigned weapon systems, aerospace items, and industrial pro-cesses. The laboratories test and evaluate a wide variety of chemicals, materials, and shop processes that are integral to the ALC mission and must be tested in a timely manner to maintain safety, reliabil-ity, and quality. This combined technical expertise substantially and uniquely contributes to the weapon system sustainment processes. Skills may include, chemical engineering, electronic engineer-ing, industrial engineering, materials engineering, mechanical engineering, chemistry, metallurgy, and physics. Testing capabilities may include chemical, composite material evaluation, dimensional, elec-tronic, environmental, joint oil analysis program, material, mechanical, metrology, non-destructive, and structural analysis. These capabilities are vital to meeting today’s technologically advanced weapon system sustainability demands, the Command’s environmental challenges, aircraft mishap analysis, and the industrial process optimization requirements

4.3. Instruction.

4.3.1. Workload Planning and Scheduling. The following is a sequence of events which provides requirements to be adhered to by planning, scheduling, and laboratory personnel to ensure uniformity of methods and processing control from the initial receipt of laboratory support projects to final close-out by production scheduling.

4.3.1.1. Laboratory Preplanning:

4.3.1.2. The planner will provide preplanning for both prime and support workload requirements assigned to MADL Direct Labor Production Support organizations. This may include, but is not limited to: Nondestructive Inspection Operations, Material Science Projects, Chemical Laboratory processes, Environmental and Industrial Safety support requirements and Dimensional and Form analysis verification.

4.3.1.3. The planner is responsible for classifying each labor task and coordinating with other affected offices as deemed necessary or appropriate.

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4.3.1.3.1. All labor standards with current workload will be reviewed yearly. If an inactive standard is observed, the standard shall be deleted.

4.3.1.3.2. The planner develops and maintains an active labor standard file that contains sup-porting and backup data for the labor standard. Documentation requirements for engineered standards are identified in AFMCI 21-105, Atch 5. Non-engineered standards should include all available documentation (minimum requirements are identified in AFMCI 21-105, para-graph 3.4.4.).

4.3.2. Laboratory Planning.

4.3.2.1. The planner will assist and coordinate on new or transferring workloads that require MADL laboratories support.

4.3.2.2. The planner shall process the appropriate documentation for all new or renewing work-load.

4.3.2.2.1. The planner will evaluate the status of laboratory workload for new or existing requirements. If it is a new requirement the Planner will assign an operation number.

4.3.2.2.2. The planner will input labor hour information into the E046B, Labor Standard Mechanization System for new requirements and update the system for existing requirements.

4.3.2.2.3. The planner will obtain applicable laboratory supervisors, section supervisor and branch chief coordination on labor standard review documentation…