ApndxB3_AFI21-101_Aerospace_Eqpt_MX_MGMT.pdf

DEPARTMENT OF THE AIR FORCE

HEADQUARTERS UNITED STATES AIR FORCE

WASHINGTON DC

AFGM2017-01

2 June 2017

MEMORANDUM FOR DISTRBUTION C

MAJCOMs/FOAs/DRUs

FROM: HQ USAF/A4

1030 Air Force Pentagon Washington, DC 20330-1030

SUBJECT: Air Force Guidance Memorandum to Air Force Instruction 21-101, Aircraft and Equipment Maintenance Management

By Order of the Secretary of the Air Force, this Air Force Guidance Memorandum immediately changes Air Force Instruction (AFI) 21-101, Aircraft and Equipment Maintenance Management. Compliance with this Memorandum is mandatory. To the extent its directions are inconsistent with other Air Force publications, the information herein prevails, in accordance with Air Force Instruction 33-360, Publications and Forms Management.

This Guidance Memorandum continues previously published guidance implemented under AFI 21-101. The attached memorandum implements Maintenance Cyber Discipline responsibilities and audit corrective action requirements.

This Memorandum becomes void after one year has elapsed from the date of this

Memorandum, or upon incorporation by interim change to, or rewrite of AFI 21-101, Aircraft and Equipment Maintenance Management whichever is earlier.

JOHN B. COOPER

Lieutenant General, USAF DCS/Logistics, Engineering & Force Protection

Attachment:

Guidance Changes

Revision to AFI 21-101

Attachment Guidance Changes

(ADD) 1.19. Maintenance Cyber Discipline (ADD) 1.19.1. For the purpose of this AFI, Electronic Tools (eTools) are portable electronic devices (e.g. laptop computer, hand held device) that operate in a disconnected mode and/or, are certified to inter-operate on Air Force (AF) networks, are mission critical because they are the primary method for viewing electronic technical publications, and in some cases are used to exchange maintenance data with approved Maintenance Information Systems (MIS) at the point of maintenance. Note: eTools do not include electronic devices and test equipment issued and configuration managed by a system Program Manager (PM). Improper procurement, sustainment, and use of eTools poses a significant cyber risk to AF systems. Protocols have been identified as a critical element in mitigating emerging cyber threats. The guidance below establishes requirements for developing and implementing daily/periodic cyber mitigation processes. The intent is to reduce cyber risk and assigns responsibilities that provide the best possible opportunity for success for achieving mission assurance in cyber threat environments.

(ADD) 1.19.2. Variations in eTools functionality across AF weapon systems must be approved by the applicable system Program Manager (PM) IAW AFI 63-101/20-101, Integrated Life Cycle Management. This is done to ensure the program’s product support strategy identifies and supports interrelationships and integration with programs and processes both inside and outside the program’s current Program Executive Officer (PEO) portfolio. Additionally, this ensures the program’s product support strategy aligns to Air Force enterprise priorities.

(ADD) 1.19.3. MAJCOMs/ANG will develop and implement guidance that ensures eTools standardization, management, and configuration control IAW 17 series publications. eTools are procured IAW AFI 63-138, Acquisition of Services, and sustained IAW AFI 63-101/20-101, Integrated Life Cycle Management.

(ADD) 1.19.4. MAJCOMs/ANG will coordinate with their CIO/A6 or equivalent to publish eTool sustainment and support guidance. In addition MAJCOMs will validate functional Air Force Specialty Code (AFSC) specific support is adequately allocated to ensure assigned units remain compliant with requirements directed in AFI 17-100, Air Force Information Technology (IT) Service Management, AFI 17-120, Management of Cyberspace Support Activities, AFMAN 17-1201, User Responsibilities and Guidance for Information Systems, AFMAN 17-203, Information Technology (IT) Asset Management (ITAM), AFMAN 17-1301, Computer Security (COMPUSEC), and AFMAN 17-1302, Communications Security (COMSEC) Operations.

(ADD) 1.19.5. MAJCOMs/ANG will provide standardized guidance on the use, storage, content update, security and cyber hygiene processes necessary to support the approved use of all assigned eTool devices.

(ADD) 1.19.6. MAJCOM/ANG in coordination with their supporting Lead Commands will develop and implement assigned Mission Design Series (MDS) specific cyber threat mitigation strategies. These strategies must be directly linked to supporting publication and technical order references and monitored to ensure the most current cyber threat mitigation capabilities are sustained in the deployed or in-garrison Mission Generation environments. MAJCOM/ANG will ensure as a minimum the processes include contingency eTool comm-out/cyber-out bare base operating procedures.

(ADD) 1.19.7. Unit Commanders will ensure eTools are used for official and authorized purposes only IAW -17 Series publications and locally developed procedures as needed. (T-1).

(ADD) 1.19.8. Assigned eTool users will NOT install, download, and access any unauthorized files or software on any eTool. (e.g. games, mp3s, tablet, phone applications). (T-1).

(ADD) 1.19.9. Users will NOT use, access, or insert unauthorized external media devices to any eTools. (T-1).

(ADD) 1.19.10. Unit Commanders will establish procedures that prohibit the introduction of government or personal cellular/personal communications system and/or RF, IR wireless devices, and other devices such as cell phones and tablets, and devices that have photographic or audio recording capabilities into areas (e.g., rooms, offices) where classified information is stored processed or discussed IAW AFMAN 17-1301. (T-1). Coordinate waiver requests with the applicable MAJCOMs/ANG, and ensure adherence to TEMPEST requirements IAW DoDD 8100.02, written approval by the AF CTTA IAW AFI 16-1404, NIST SP 800-53A Revision 4, Assessing Security and Privacy Controls in Federal Information Systems and Organizations, Building Effective Security Assessment Plans, and the Enterprise Authorizing Official (AO) IAW AFI 31-101, AFMAN 17-1301 & AFMAN 17-1305 (when published). (T-1).

(ADD) 1.19.11. Maintenance Group Commanders or equivalents with approved waivers will coordinate with the Communication Squadron Cyber Security Liaison and/or Information System Security Managers to identify specific requirements and publish local guidance on restrictions of the use of Portable Electronic Devices (PED) in classified processing areas. (T-1).

(ADD) 1.19.12. Maintenance Supervision will establish procedures and validate that users routinely, and whenever malware is suspected, run all required scans to validate the content integrity of eTools, electronic/cyber devices, test/support equipment and components as part of the unit cyber hygiene mitigation protocol IAW MDS/equipment TOs. (T-1).

(Replace) 2.2.3. Ensure a coordinated wing/base instruction is developed that implements procedures to control tools, equipment, electronic devices, and establishes cyber discipline requirements that provides operational guidance across all wing/base agencies dispatching to aircraft runway/taxi/parking and maintenance areas. (T-1).

(ADD) 2.4.9.1.1. Ensure Master Training Plans (MTPs) include annual Maintenance Cyber Discipline training. (T-1).

(ADD) 2.4.55. Appoint in writing a Wing Avionics Manager (WAM) or designated official who will:

(ADD) 2.4.55.1. Serve as the maintenance focal point for all avionics related interactions between PMs, MAJCOMs, Lead Commands, Wing, Operations and Maintenance or equivalent activities to discern and implement changes in avionics configuration requirements.

(ADD) 2.4.55.2. Verify Reliability, Availability, Maintainability for Pods (RAMPOD) updates are completed daily IAW 21-103. (T-1).

(ADD) 2.4.55.3. Ensure classified pods/components or equipment are stored in authorized areas IAW DODM 5200.01-V3, DOD Information Security Program; Protection of Classified information, and AFI 16-404, Air force Information Security Program. (T-1).

(ADD) 2.4.55.4. Ensure classified aircraft/Support/Test equipment are stored in authorized areas IAW DODM 5200.01-V3 and AFI 16-1404. (T-1).

(ADD) 3.9.1.1. Ensure accurate and timely pod and support equipment status is updated or verified daily in Reliability, Availability, Maintainability, for Pods (RAMPOD) IAW AFI 21- 103 for pods under the control of the Aircraft Maintenance Squadron (AMXS). (T-1).

(Replace) 4.11.7.2. Track and schedule all inspections and Maintenance/removal/installation/ transportation trailers and adapters in the MIS. (T-1).

(Add) 5.2.2.1.7.1. When the Pro-super or equivalent notifies the Maintenance Operations Center (MOC) that an aircraft is “Crew Ready” the MOC will review the Maintenance Information Systems (MIS) for each Crew Ready aircraft to ensure there are no open Red Xs. (T-1). If open Red X(s) are present in the MIS, the MOC will notify the Pro-super or equivalent for action.

(T-1).

(Add) 5.2.2.1.7.2. The MOC will verify aircraft status and Estimated-Time-In-Commission (ETIC) using the MIS before reporting it. (T-1). Note: MAJCOMs/ANG will provide Comm/MIS/Cyber out operating procedures in their supplements to this AFI.

(ADD) 6.7.2.8.4.26. Maintenance Cyber Discipline. (T-1).

(Replace) 6.13.1.1. OCFs should be kept to a minimum and are not used to replace TO 1-1-300 or MDS specific -6 TO Functional Check Flight (FCF) requirements. Operational Check Flight (OCFs) must be flown by experienced aircrews (not required to be an FCF qualified aircrew), must be briefed by QA for aircraft condition, and accomplished following the same maintenance criteria as FCFs. (T-1).

(Replace) 7.5.4. Following an un-commanded flight control movement. (T-1). Following impoundment for uncommanded flight control movement, the Maintenance Group Commander (MXG/CC) and Operations Group Commander (OG/CC) will determine the need for an FCF.

(Replace) 8.3.6.2. When items such as dis-patchable support equipment or dis-patchable special tools are issued separately (not contained in a Composite Tool Kit (CTK)) and contain multiple parts that are required for its use (e.g. cartridges containing consumables, cables, hoses, adapters), an inventory of all the items will be provided with the support equipment or special tools to facilitate positive accountability of all items during checkout, transfer, and check in.

(Replace) 8.3.6.5.1. Do not include common hardware items such as bolts, nuts, and/or screws unless they are required for the tool to perform its intended function. Cartridges or equivalents containing consumable items whether disposable or not will be accounted for to mitigate Foreign Object Damage (FOD) hazards. (T-1).

(ADD) 8.3.6.6.1. Items identified as too small to be marked, etched, or stamped, as approved by Quality Assurance (QA), will be annotated with a description of the individual items contained within the set on the CTK MIL. (e.g., the variation in the size of the items contained within the set, Apex, file, drill bit, size). (T-1).

(Replace) 8.5.5. ETools are portable electronic devices (e.g. laptop computer, hand held device) that operate in a disconnected mode and/or, are certified to inter-operate on Air Force (AF) networks, and are mission critical because they are the primary method for viewing electronic technical publications and in some cases are used to exchange maintenance data with approved MIS at the point of maintenance. Note: eTools do not include electronic devices and test equipment issued and configuration managed by a system Program Manager (PM) IAW AFI 63- 101/20-101, Integrated Life Cycle Management.

(Replace) 15.1.1.1. Prioritize development and distribute MxCAP2 models and supporting guidance as available. Note: The MxCAP2 model establishes a standardized and empirically supported process for projecting MDS-specific, wing-level maintenance capability and capacity.

It provides maintenance units the ability to accurately develop and support flying hour projections and accommodate FHP reflows. For additional information on the MxCAP2 model contact: usaf.pentaton.af-a4.mbx.a4lm-workflow@mail.mil or AF/A4LM at DSN 227-2228, Comm: (703) 697-2228. For technical support contact: MxCAP_2_Team@bah.com, Mon-Fri, 0900-1700 EST, DSN: 224-8314, Comm: (703) 614-8314.

(ADD) Terms and definitions Maintenance Cyber Discipline: A focus on daily cyber hygiene activities which requires continuous attention in order to mitigate daily threats by creating a culture of cyber awareness, discipline, and strict compliance.

mailto:usaf.pentaton.af-a4.mbx.a4lm-workflow@mail.mil mailto:MxCAP_2_Team@bah.com

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

AIR FORCE INSTRUCTION 21-101

21 MAY 2015

Maintenance

AIRCRAFT AND EQUIPMENT

MAINTENANCE MANAGEMENT

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available on the e-Publishing website at www.e-publishing.af.mil.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AF/A4LM

Supersedes: AFI21-101, 26 July 2010

Certified by: AF/A4L (Mr Eugene Collins)

Pages: 315

This publication implements Air Force Policy Directive (AFPD) 21-1, Maintenance of Military

Materiel; and is consistent with AFPD 13-5, Air Force Nuclear Enterprise. It is the basic Air

Force instruction (AFI) for all weapon system and support equipment maintenance management guidance. It provides the minimum essential guidance and procedures to safely and effectively maintain, service, and repair weapon systems and support equipment. It applies to all Major

Commands (MAJCOMs), including Air Force Reserve Command (AFRC), and the Air National

Guard (ANG), along with their subordinates. Supplements and addendums must be written in accordance with (IAW) AFI 33-360, Publication and Forms Management. Supplements must identify required deviations (applicability, variance, and/or differences in organizational placement of responsibilities/processes) on the supplement with the abbreviation “(DEV)” directly preceding the affected paragraph number. Only supplements and addendums containing deviations must be submitted to AF/A4L for approval. The authorities to waive wing/unit level requirements in this publication are identified with a tier (“T-0, T-1, T-2, T-3”) number following the compliance statement. See AFI 33-360, Table 1.1 for a description of the authorities associated with the tier numbers. Submit requests for waivers through the chain of command to the appropriate tier waiver approval authority IAW AFI 33-360. For questions on interpreting this instruction, first contact your MAJCOM maintenance functional activity. Refer recommended changes and questions about this publication through your MAJCOM, to the

Office of Primary Responsibility (OPR) using the AF Form 847, Recommendation for Change of

Publication. Ensure that all records created as a result of processes prescribed in this publication are maintained IAW Air Force Manual (AFMAN) 33-363, Management of Records, and disposed of IAW Air Force Records Disposition Schedule (RDS) located in the Air Force

Records Information Management System (AFRIMS). The use of the name or mark of any http://www.e-publishing.af.mil./

2 AFI21-101 21 MAY 2015

specific manufacturer, commercial product, commodity, or service in this publication does not imply endorsement by the Air Force.

SUMMARY OF CHANGES

This publication has been substantially revised and must be completely reviewed in its entirety.

Chapter 1—MANAGEMENT PHILOSOPHY AND POLICY 10

1.1. Introduction

1.2. Organization

1.3. Maintenance Concept

1.4. Aircraft Maintenance Tactics, Techniques and Procedures (TTP)

1.5. Aircraft and Equipment Readiness

1.6. Maintenance Discipline

1.7. Communications Security (COMSEC)/Controlled Cryptographic Item (CCI)

Accountability

1.8. Environmental Compliance

1.9. Publications

1.10. Maintenance Training

1.11. Modification Management

1.12. Maintenance Information Systems (MIS)

1.13. General Safety Guidance

1.14. Duty Shifts and Rest Periods

1.15. Communications

1.16. Maintenance Repair Priorities

Table 1.1. Maintenance Repair Priority Designators

1.17. Associate Unit Program/Total Force Integration (TFI)

1.18. Performance-Based Activities

Chapter 2—GENERAL RESPONSIBILITIES FOR COMMANDERS AND KEY

LEADERS 18

2.1. General

2.2. Wing Commander (WG/CC) Responsibilities

2.3. Wing Vice Commander (WG/CV) Responsibilities

2.4. Maintenance Group Commander (MXG/CC) Responsibilities

2.5. Deputy Maintenance Group Commander (MXG/CD) will:

AFI21-101 21 MAY 2015 3

2.6. MXG Superintendent Responsibilities

2.7. Wing Weapons Manager (WWM)

2.8. Squadron Commander (SQ/CC) Responsibilities

2.9. Maintenance Supervision Responsibilities

2.10. Flight Commander/Flight Chief (Flight CC/Chief) or Aircraft Maintenance Unit

(AMU) Officer in Charge (OIC)/Chief

2.11. Production Superintendent (Pro Super)

2.12. Section NCOIC/Chief

Chapter 3—AIRCRAFT MAINTENANCE SQUADRON (AMXS) 38

3.1. General

3.2. Maintenance Supervision Responsibilities

3.3. Aircraft Maintenance Unit (AMU)

3.4. AMU OIC/Chief Responsibilities

3.5. Production Superintendent (Pro Super)

3.6. Flightline Expediter

3.7. Aircrew and Maintenance Debrief Section

Table 3.1. Landing Status Codes

Table 3.2. System Capability Codes

Table 3.3. Deviation Cause Codes

3.8. Aircraft Section

3.9. Specialist Section

3.10. Weapons Section

3.11. Support Section

3.12. AMU Decentralized Materiel Support (DMS)

Chapter 4—MAINTENANCE SQUADRON (MXS) 53

4.1. General

4.2. Maintenance Supervision Responsibilities

4.3. MXS Production Superintendent (Pro Super)

4.4. Accessories Flight

4.5. Aerospace Ground Equipment (AGE) Flight

4.6. Armament Flight

4.7. Avionics Flight

Figure 4.1. Example Index Numbers

4 AFI21-101 21 MAY 2015

4.8. Fabrication Flight

4.9. Maintenance Flight

4.10. Munitions Flight

4.11. Propulsion Flight

4.12. Test, Measurement, and Diagnostic Equipment (TMDE) Flight (N/A to the ARC).

Chapter 5—MAINTENANCE OPERATIONS 83

5.1. General

5.2. Maintenance Operations (MO)

5.3. Maintenance Training (MT)

5.4. Programs and Resources (P&R)

Chapter 6—QUALITY ASSURANCE (QA) 94

6.1. General

6.2. Responsibilities

6.3. QA Superintendent Responsibilities

6.4. Chief Inspector Responsibilities

6.5. Quality Assurance Inspector Responsibilities

6.6. Quality Assurance Inspector Training

6.7. Maintenance Standardization and Evaluation Program (MSEP)

6.8. MAJCOM-approved QA database

6.9. QA Product Improvement Programs (PIP)

6.10. Configuration Management (CM) and Modification Management

6.11. Technical Order Distribution Office (TODO)

6.12. One-Time Inspections (OTI) program

6.13. Functional Check Flights (FCFs) to include Operational Check Flights (OCFs). . 113

6.14. Inflight Operational Checks

6.15. High Speed Taxi Checks

6.16. Weight and Balance (W&B) Program

Chapter 7—IMPOUNDMENT PROCEDURES 118

7.1. Aircraft and Equipment Impoundment

7.2. Specific Guidance

7.3. Impoundment Authorities

7.4. Impoundment Official Responsibilities

AFI21-101 21 MAY 2015 5

7.5. Mandatory Impoundments

7.6. Impoundment Procedures

7.7. Rules of Impoundment Specifically for Explosive-Related Events/Mishaps

Chapter 8—TOOL AND EQUIPMENT MANAGEMENT 123

8.1. Tool and Equipment Management

8.2. Guidelines for Program Management

8.3. General Program Guidelines

8.4. TMDE Management Guidelines

8.5. Tool Accountability

8.6. Tool and Equipment Marking and Identification

8.7. Locally Manufactured, Developed, or Modified Tools and Equipment

8.8. Tool Room Operations and Security

8.9. Lost Item/Tool Procedures

Chapter 9—MATERIEL MANAGEMENT SUPPORT 136

9.1. General

9.2. Decentralized Materiel Support

9.3. Supply Discipline

9.4. Parts ordering

9.5. Backorder review and validation

9.6. Parts processing

9.7. Readiness Spares Package (RSP) Review

9.8. Bench Stock

9.9. Consumable Readiness Spares Package (CRSP)

9.10. Shop Stock

9.11. Operating Stock

9.12. Work Order Residue

9.13. Adjusted Stock Levels

9.14. Shelf-life Items

9.15. Equipment Items

9.16. Special Purpose Recoverable Authorized Maintenance (SPRAM)

9.17. Supply Assets Requiring Functional Check, Calibration, or Operational Flight

Programming

9.18. Time Compliance Technical Order (TCTO) Kit Procedures

6 AFI21-101 21 MAY 2015

9.19. Supply Points

9.20. Local Manufacture

9.21. DIFM Management

9.22. Tail Number Bins (TNB)

9.23. CANN actions

9.24. Bench Check and Repair Policy

9.25. Maintenance Turn-Around (TRN) Record Update Processing

9.26. Buildup Items

9.27. Deficiency Report (DR) Exhibits

9.28. Destruction of TOP SECRET Material

9.29. Certifying Items Associated With Explosives

Chapter 10—MUNITIONS POLICY AND WEAPONS LOAD CREW PROGRAM 146

10.1. AF Munitions Policy

10.2. Unit Committed Munitions List (UCML), Test/Training Munitions List (TTML).

10.3. Weapons Load Crew Training Program (WLCTP)

10.4. Loading Standardization Crew (LSC)

10.5. Weapons Academic Instructor

10.6. Lead Crews

10.7. Training Facilities/Aircraft

10.8. Weapons Academics

10.9. Practical Training

10.10. Task Assignment List (TAL)

10.11. Munitions Aircraft Loading Certification/Decertification

10.12. Proficiency Review Period

10.13. Minimum Required Proficiency Load

10.14. Load Crew Semi-Annual Evaluations (SAE)

10.15. Documenting Load Crew Certification/Decertification/Qualification

10.16. Weapons Task Qualification

10.17. Munitions Load Time Standards

Table 10.1. Fighter Aircraft Munitions Family Group and Munition Load Time Standards (in minutes)

Table 10.2. Bomber Aircraft Munitions Family Group and Munition Load Time Standards. . 162

AFI21-101 21 MAY 2015 7

Table 10.3. Remote Piloted/Special Mission Aircraft Munitions Family Group and Munition

Load Time Standards

Chapter 11—ADDITIONAL MAINTENANCE REQUIREMENTS AND PROGRAMS 164

11.1. Facility Housekeeping and Contamination Control

11.2. Personal Wireless Communications Systems (PWCS) Management

11.3. Special Certification Roster (SCR)

Table 11.1. Mandatory Special Certification Roster (SCR) and Prerequisites (T-1)

11.4. Aircraft Grounding

11.5. Ramp Inspection Program

11.6. Red Ball Maintenance

11.7. Maintenance Recovery Team (MRT):

11.8. Foreign Object Damage (FOD) Prevention Program

11.9. Dropped Object Prevention (DOP) Program

11.10. Aircraft Structural Integrity Program (ASIP)

11.11. Identification Friend or Foe (IFF) Program

11.12. Radar Warning Receiver (RWR)/Radar Threat Warning (RTHW) Testing

11.13. Cannibalization Program

11.14. Hangar Queen Aircraft

11.15. Ground Instructional Trainer Aircraft (GITA)

11.16. Aircraft Inlet/Intake/Exhaust Certification

11.17. Engine Run Training and Certification Program

11.18. Engine Blade Blending Training and Certification Program

11.19. Engine Flexible Borescope Inspection Training and Certification Program

11.20. Flying Crew Chief (FCC) Program

11.21. Maintenance of Flash Blindness Protective Devices

11.22. WRM External Nestable Fuel Tank Build-Up (NFTBU)

11.23. Protective Aircraft Shelters (PAS)

11.24. Combat Sortie Generation

11.25. Hot Refueling Procedures

11.26. Aircraft Rapid/Hot Defueling

11.27. 406 MHz Emergency Locator Transmitter (ELT) Systems

11.28. Crash Damaged or Disabled Aircraft Recovery (CDDAR) Program

11.29. Aircraft Battle Damage Repair (ABDR) (N/A to ARC)

8 AFI21-101 21 MAY 2015

11.30. Egress/Cockpit Familiarization Training

11.31. Aircraft Defensive Systems Loading Program

11.32. Aircraft and Equipment Decontamination

11.33. Senior Leader Mission Generation (SLMG) Course

Chapter 12—MAINTAINING COMMERCIAL DERIVATIVE AIRCRAFT (CDA) 220

12.1. Background Information and Objective

12.2. AF/A4L will:

12.3. The Program Manager (PM) will:

12.4. Lead Commands will:

12.5. Units will:

12.6. Maintenance Personnel Requirements

12.7. Deviations/Changes to Inspection Requirements, Time Change Intervals, and

Component/Aircraft Overhaul

12.8. Air Force Modifications to CDA and Components

12.9. Certification Basis for CDA

Chapter 13—CENTRALIZED REPAIR FACILITIES (CRF) 223

13.1. Introduction

13.2. Organization

13.3. CRF Production Requirements

13.4. Maintenance Squadron (EMS, CMS, MXS) Operations Officer/MX SUPT will: 223

13.5. CRF Enterprise Information Management

13.6. Mission Generation Network Support

13.7. Documentation

13.8. Metrics

13.9. Agile Combat Support (ACS)

Chapter 14—AIRCRAFT AND EQUIPMENT MAINTENANCE CONTRACT

SURVEILLANCE 225

14.1. Contract Surveillance

14.2. Responsibilities

14.3. Training Requirements

14.4. Quality Assurance Surveillance Plan (QASP)

14.5. COR Inspections

14.6. Surveillance Schedule

AFI21-101 21 MAY 2015 9

Table 14.1. Proposed QASP Layout

Chapter 15—MAINTENANCE PLANS, SCHEDULING AND DOCUMENTATION

(PS&D) 235

15.1. Responsibilities:

15.2. Data Documentation

15.3. Configuration, TCTO, SI and TCI Management

15.4. ENGINE MANAGEMENT (EM)

15.5. Maintenance and FHP Planning Cycle

15.6. Contingency and Expeditionary Responsibilities

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 271

Attachment 2—AIRCRAFT COMMANDER FEEDBACK ON FCC 311

Attachment 3—QUARTERLY FCC REPORT FORMAT 312

Attachment 4—ANNUAL FCC REPORT 313

Attachment 5—FCC SDAP REQUEST 314

Attachment 6—FOREIGN OBJECT DAMAGE (FOD) REPORT 315

10 AFI21-101 21 MAY 2015

Chapter 1

MANAGEMENT PHILOSOPHY AND POLICY

1.1. Introduction. This instruction prescribes basic aircraft and equipment maintenance management policy implementation and procedures used throughout the USAF to perform

Mission Generation (MG) functions.

1.2. Organization. AF organizations are structured according to AFI 38-101, Air Force

Organization, or as authorized by AF/A1M. Contracted maintenance functions are not required to organize IAW AFI 38-101, but will implement the organization as outlined in their proposal as accepted by the government. The term “Lead Command” is used to describe the technical advocacy and product support provided to individual weapon systems across the using

MAJCOMs as described in AFPD 10-9, Lead Command Designation and Responsibilities for

Weapon Systems.

1.3. Maintenance Concept. Per AFPD 21-1, organizational, intermediate and depot maintenance capabilities for operational readiness shall be maintained to ensure effective and timely response to peacetime operations, mobilizations, national defense contingencies and other emergencies.

1.3.1. As a minimum each capability will be able to:

1.3.1.1. Organizational: launch and recover sorties, maintain and repair material coded for organizational level repair.

1.3.1.2. Intermediate: repair materiel coded for organizational and intermediate level repair in back shops and/or centralized repair facilities.

1.3.1.3. Depot: repair materiel coded for organizational, intermediate and depot;

overhaul; rebuild; modify and manufacture.

1.3.2. Organizational and intermediate-level maintenance is organized into two mutally supporting networks, the Mission Generation Network (MGN) and the Repair Network (RN).

The MGN is optimized for mission generation at the wing level and consists of authorized

“on-equipment” and “off-equipment” maintenance capabilities required to launch, recover, configure, inspect and repair AF systems and equipment. The RN supports the MGN by providing maintenance required to fulfill operational needs outside the capability and/or capacity of MGN activities. The interface between the two networks takes place when the

MGN activity relinquishes control of reparable assets to the RN activity (e.g. supply counter turn-in) or changing an end item possession code from an operational activity to a repair network activity (e.g. depot maintenance).1.3.1. Most MGN units possess a complement of equipment and supplies to perform on-equipment and off-equipment maintenance.

1.3.2.1. RN units may reside at bases that perform mission generation. RN requirements and processes are identified in AFI 20-117, Repair Network Integration (RNI) and when published, AFMAN 20-118, Repair Network Integration (RNI) Operations.

1.3.3. Requests for Assistance (RFA). If a maintenance activity requires assistance for evaluation and/or repair beyond unit capability, requests are made IAW AFI 21-103, Equipment Inventory, Status And Utilization Reporting; TO 00-25-107, Maintenance

AFI21-101 21 MAY 2015 11

Assistance; and TO 00-20-14, AF Metrology and Calibration Program, or automated process as approved by the Mission Design Series (MDS) Program Manager (PM) (e.g., C-130

AIRCATS, F-16 TAR). All requests for assistance must be coordinated through the originating MAJCOM and Lead Command as applicable. (T-2).

1.4. Aircraft Maintenance Tactics, Techniques and Procedures (TTP). TTPs are developed from lessons learned and best practices that provide valuable reference documents to improve maintenance processes and procedures. Maintenance leaders should utilize the maintenance fundamentals TTP volumes (Aircraft, Munitions/Missile) to effectively and efficiently support mission generation. Maintainers who attend the USAF Advanced Maintenance and Munitions

Operations School (AMMOS) are trained in advanced operational, expeditionary and tactical maintenance management concepts stemming from the alumni’s development and formalization of TTPs. MXG/CC’s should identify their AMMOS graduates and utilize them as advisors and instructors to enhance mission capability. TTP 3-3, Aircraft Maintenance, can be found at:

https://intelshare.intelink.gov/sites/561jts/3-3/default.aspx. For additional information on

AMMOS and TTP development see AFI 21-111, Advanced Maintenance and Munitions

Education Program.

1.5. Aircraft and Equipment Readiness. Aircraft and equipment readiness is the maintenance mission. The maintenance function ensures assigned aircraft and equipment are safe, serviceable, and properly configured to meet mission needs. Maintenance actions include, but are not limited to, inspection, repair, overhaul, modification, preservation, refurbishment, troubleshooting, testing, analyzing condition and performance and maintenance documentation.

All levels of supervision need to place emphasis on safety, quality, and timeliness in the performance of maintenance. The concept of quality maintenance must be fostered by each supervisor and technician to ensure the integrity and skill of each maintainer is not degraded. To the greatest extent possible, maintenance is accomplished on a preplanned scheduled basis.

Planning provides the most effective and efficient use of people, facilities, and equipment, reduces unscheduled maintenance, and allows for progressive actions toward maintaining and returning aircraft and equipment to safe operating condition. Exploiting repair network capability and maintaining visibility of repair cycle assets throughout the maintenance cycle are also critical elements of the equipment maintenance program.

1.5.1. Preventive Maintenance. AF units implement and manage the tasks specified in the scheduled recurring maintenance program for their assigned aircraft and associated support equipment (SE). Preventive maintenance is achieved through the inspection requirement concepts described in TO 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policy, and Procedures, and applicable weapon system -6 TO.

1.6. Maintenance Discipline. It is the responsibility of all maintenance personnel to comply with all written guidance to ensure required repairs, inspections, and documentation are completed in a compliant, safe, timely, and effective manner. Supervisors are responsible for enforcing and establishing a climate that promotes maintenance and supply discipline.

1.6.1. Compliance Terminology. For the purposes of this instruction, the following definitions apply:

1.6.1.1. Shall, Must, Will - Indicates mandatory requirements. Note: “Will” is also used to express a declaration of purpose for a future event.

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1.6.1.2. Should - Indicates a preferred method of accomplishment.

1.6.1.3. May - Indicates an acceptable or suggested means of accomplishment.

1.6.2. Use of Technical Orders (TO) and TO Supplements. Use of the prescribed technical data to maintain aircraft and equipment is mandatory and will be conducted and managed

IAW TO 00-5-1, Air Force Technical Order System. (T-1). All personnel will enforce compliance with technical data. (T-1).

1.7. Communications Security (COMSEC)/Controlled Cryptographic Item (CCI)

Accountability. The Air Force COMSEC/Central CCI Authority is the Cryptologic and Cyber

Systems Division, Joint Base San Antonio-Lackland, Texas.

1.7.1. COMSEC/CCI accountability will be accomplished IAW AFMAN 33-283, Communications Security (COMSEC) Operations and AFI 23-101, Air Force Materiel

Management. (T-1). Questions concerning COMSEC/CCI accountability can be directed to the Cryptologic and Cyber Systems Division’s COMSEC Policy Office (AFLCMC/HNCLS) at DSN 969-3886.

1.8. Environmental Compliance. It is the responsibility of all maintenance personnel to comply with all written guidance to ensure compliance with hazardous material, hazardous waste management and air emissions record keeping as required for environmental compliance IAW

AFI 90- 803, Environmental, Safety, and Occupational Health Compliance Assessment and

Management Program, installation ESOHMS/EMS policy/guidance and applicable environmental requirements and guidance. (T-0).

1.9. Publications. Units may tailor procedures to the unique aspects of their own maintenance operation and publish directives, instructions, supplements, addendums, and, for functional areas, Operating Instructions (OI) IAW AFI 33-360.

1.9.1. Develop, control, and maintain functional checklists, at a minimum, each functional checklist is titled and dated. Functional checklists are not be used in place of or to circumvent technical data for operation, servicing, inspection or maintenance of aircraft, aircraft systems, munitions, and all other equipment supporting aircraft and munitions maintenance.

1.10. Maintenance Training. Maintenance training provides initial, recurring and advanced proficiency, qualification, or certification skills needed by a technician to perform duties in their primary AF Specialty Code (AFSC)/Civilian Job Series. Maintenance training includes combat and sortie generation skills not normally integrated into peacetime operations (e.g., munitions handling, and external fuel tank build-up, hot refueling). Maintenance training carries an equal priority with the operational training mission. For maintenance training policy and guidance, refer to AFI 36-2650, Maintenance Training and MAJCOM supplements.

1.11. Modification Management. A modification proposal is a recommendation to change the operation, use, or appearance of AF equipment. Modifications (temporary, permanent, or safety) to AF aircraft or equipment are expressly prohibited without PM approval. Note: PM is used in this publication as defined in DODD 5000.01. Refer to AFI 63-131, Modification Management, for modification management procedures.

1.11.1. Modifications to Munitions. All proposed modifications to aircraft-carried munitions include SEEK EAGLE certification IAW AFI 63-104, The SEEK EAGLE Program. All

AFI21-101 21 MAY 2015 13

modifications to AF nuclear munitions or their associated support/training equipment are nuclear certified IAW AFI 91-103, Air Force Nuclear Safety Design Certification Program and AFI 63-125, Nuclear Certification Program. All modifications to AF conventional munitions or their associated support/training equipment are certified IAW AFI 91-205, Non-

Nuclear Munitions Safety Board.

1.12. Maintenance Information Systems (MIS). MIS refers to automated maintenance information systems that support and enable maintenance business processes. MIS is used to document maintenance actions and track fleet health. The information entered into the MIS is accomplished IAW TO 00-20-2, Maintenance Data Documentation and match the content of the aircraft forms. MIS data entries do not have to be accomplished by the same individual who documented the aircraft forms, but employee numbers/man numbers/USERIDs of individuals accomplishing the actual work are entered into the MIS. Red Ball maintenance is documented

IAW Chapter 11 of this instruction.

1.12.1. Units use the approved MIS for their assigned weapon system.

1.13. General Safety Guidance. Maintenance personnel are exposed to a large variety of hazardous situations, machinery, equipment, and chemicals. Most hazardous situations can be avoided by following approved procedures, asking for help when needed, and using personal protective equipment (PPE).

1.13.1. Safety “Knock It Off” and Risk Management. Due to the inherent danger to life, limb, and property associated with maintenance operations, personnel are empowered to terminate an operation or situation which they perceive is unsafe or too dangerous. When supervisors/crew leaders become task-focused, junior personnel are often better able to assess the danger; however, deferring to the experience and judgment of the crew leader, they may choose to remain silent, missing an opportunity to break the mishap sequence chain.

Maintenance commanders and supervisors are responsible to foster a culture in their units so that a simple, but recognizable “audible” from anyone can prevent a potential mishap. Note:

See AFI 90-802, Risk Management, and AFPAM 90-803, Risk Management (RM) Guidelines and Tools for additional information.

1.13.2. Visitors. Units will not permit visitors to operate any AF equipment unless they are qualified to operate such equipment and are doing so in the performance of their assigned official duties. (T-1). Visitors will not be allowed in the flightline area if munitions operations are present IAW AFMAN 91-201, Explosive Safety Standards. (T-1).

1.14. Duty Shifts and Rest Periods. Maintenance personnel duty hours are aligned to provide optimal mission support.

1.14.1. Supervision at all levels will be equitably distributed to cover all duty periods. (T-2).

1.14.2. Personnel will not be scheduled for more than 12 hours of continuous duty time. (T-

1). Duty time begins when personnel report for duty and ends when their supervisor releases them. Time spent in exercise/contingency deployment processing lines and in-transit counts toward the total duty day. Exception: MXG/CCs are final approval authority for duty time extensions exceeding 12-hour limit up to a maximum of 16 hours. Aircraft/Detachment CCs assume this responsibility in deployed/travel status.

14 AFI21-101 21 MAY 2015

1.14.3. Commanders and supervisors will provide a rest period after each shift. (T-1). A rest period is a block of time that gives a person the opportunity for 8 hours of uninterrupted sleep in a 24-hour period. Note: This rest period also applies during exercises or inspections.

1.14.4. Personnel will not handle, load or perform maintenance on nuclear weapons, conventional munitions and/or egress explosives beyond a 12-hour continuous duty period.

(T-1). This requirement may not be waived for exercises or inspections; however, the 12-hour continuous duty period may be exceeded for shift turnover/administrative actions only and will be avoided to the maximum extent possible. The MXG/CC or equivalent may waive this requirement during advance defense readiness conditions, actual emergencies as defined in DOD Directive 3150.02, DOD Nuclear Weapons Surety Program, or to resolve an unexpected event (e.g. disabled vehicle, WS3 fault, hoist failure, etc…).

1.14.5. In alert force or standby duty situations where facilities are available for resting, established norms may be exceeded. Adjust rest periods to allow for 8 hours of uninterrupted sleep.

1.14.6. Commanders and supervisors will ensure individuals are afforded adequate duty rest periods and breaks to prevent fatigue or thermal injury. (T-1). Stop anyone if fatigue may jeopardize safety. In all cases, Aircraft Commanders (AC)/supervisors ensure aircraft maintenance personnel are not required to perform duty when they have reached the point of physical or mental fatigue rendering them incapable of performing their assigned duties safely and reliably.

1.15. Communications. Effective maintenance accomplishment requires the ability to efficiently and effectively communicate across all facets of the maintenance operation.

Communication technology (radios, cell phones, wireless internet, etc.) must be available to expedite personnel, equipment, material, and maintenance data throughout the maintenance complex. (T-2). Commanders shall develop communication plans according to mission requirements. (T-2). See Chapter 11 for detailed communication requirements.

1.15.1. MAJCOMs will develop guidance on the use and control of personal electronic and communication devices on the flightline, in munitions areas, hangars, and/or other industrial work areas.

1.16. Maintenance Repair Priorities. Maintenance repair priorities are listed in Table 1.1

This does not prohibit the Production Superintendent (Pro Super), in coordination with the

Maintenance Operations Center (MOC), from changing the maintenance repair priority when warranted. During tasked Operational Plan (OPLAN) or operational exercise, the preplanned maintenance flow determines job sequence. The maintenance repair priority and the Logistics

Readiness Squadron (LRS) delivery priorities (listed in AFI 23-123V1, Materiel Management

Reference Information) are normally identical. Raising or lowering maintenance repair priorities does not necessarily require a corresponding change in the LRS delivery priority. However, the

Pro Super may authorize the use of a less responsive LRS delivery priority.

AFI21-101 21 MAY 2015 15

Table 1.1. Maintenance Repair Priority Designators.

PRIORITY APPLICATION

1 Aircraft on alert status, war plan or national emergency missions, including related Aerospace Ground Equipment (AGE), munitions and munitions support equipment (MSE).

2 - Primary mission aircraft, related AGE, munitions, and munitions support equipment, for the first 8 work hours after landing or start of recovery or within

6 work hours of a scheduled launch, alert or test flight and during simulated generation/Operational Readiness Exercises (ORE).

- Air evacuation, rescue, Weather (WX) mission aircraft, related AGE, munitions, and munitions support equipment.

- All transient support, and FAA aircraft. Flight or missile crew training simulator, other training equipment or related AGE required repair, which is impacting the mission by preventing or delaying student training.

3 - Primary mission aircraft, engines, air launched missiles and related AGE, munitions and munitions equipment, and equipment undergoing scheduled or unscheduled maintenance, if not performed or repaired will prevent or delay mission accomplishment. Transient air vehicles not otherwise listed.

- Administrative aircraft within 8 hours of scheduled flight or on alert status with standby crews.

- Time change requirements for nuclear weapons.

- Repair cycle assets to satisfy a Mission Capable (MICAP) condition.

- Spares not available in supply.

- Critical end items and spares not available in supply.

- Routine maintenance of aircrew or missile-training simulator, or other training devices or related AGE or sites and aircraft or equipment used for maintenance training.

- Avionics shop electronic AGE and automated test stations.

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PRIORITY APPLICATION

4 - Routine or extensive repair of primary air mission and related AGE and repair cycle assets.

- Administrative aircraft undergoing scheduled or unscheduled maintenance.

- Routine maintenance of AGE, not otherwise listed above.

- War Reserve Materiel (WRM) items due maintenance or inspection.

- Inspection, maintenance, and Time Compliance Technical Order (TCTO) compliance of Mission Support Kit (MSK) or Mobility Readiness Spares

Package (MRSP) materiel.

- Extensive repair of aircrew or missile training simulators, other training devices, or related AGE.

- Inspection, maintenance, and TCTO compliance of munitions and munitions equipment, excluding spares excess to base requirements not listed above.

- Scheduled calibration and unscheduled repairs on Precision Measurement

Equipment (PME) not listed above.

- Scheduled maintenance to include periodic inspections, routine TCTO, Master

Configuration Lists (MCL) Grounding, and Time Change Items (TCIs).

- Primary mission Comprehensive Engine Management System (CEMS) or equipment including associated AGE undergoing extensive repair or modification.

5 - Non-tactical or non-primary-mission aircraft undergoing extensive repair.

- Fabrication and repair of aeronautical items not carrying a higher priority.

- Bench stock requirements.

- Extensive repair of aircrew training devices.

- Time change requirements not listed above.

- Routine repair of AGE and repair cycle assets.

- Alternate and other CEMS or equipment, including associated AGE undergoing extensive repair or modification.

- Clearing routine delayed discrepancies on training equipment or AGE, and routine maintenance which will not impair or affect mission accomplishment.

- Equipment requirements.

6 - Fabrication and repair of non-aeronautical items.

- Repair cycle asset shortages required to fill a peacetime operating stock authorization

7 - Spares/repair cycle assets excess to base requirements.

1.17. Associate Unit Program/Total Force Integration (TFI). The USAF employs the

Associate Unit/TFI program in some locations where active and/or Air Reserve Component

(ARC) units are collocated and share aircraft, equipment, facilities, and other resources IAW AFI

90-1001, Responsibilities for Total Force Integration, and MAJCOM supplements. For the purpose of this instruction, in an Active Association, the ANG/AFRC owns the aircraft, and

Regular AF (RegAF) personnel will follow ANG/AFRC maintenance policy. (T-1). In an ARC association, AFRC owns the aircraft, and ANG personnel will follow AFRC guidance, or vice versa. (T-1). In a classic association, RegAF owns the aircraft, and ANG/AFRC personnel will follow RegAF maintenance policy. (T-1). Type of association is determined by the Program of

Record for the associated unit.

AFI21-101 21 MAY 2015 17

1.18. Performance-Based Activities. MAJCOMs may publish the basic responsibilities for managing performance-based activities. Additional guidance may be found in AFI 38-203, Commercial Activities Program. Note: A contractor, Most Efficient Organization (MEO), or

High Performance Organization (HPO) are referred to as a service provider.

1.18.1. MAJCOMs will:

1.18.1.1. Designate focal points for organizational, functional, and technical questions pertaining to each performance-based activity program.

1.18.1.2. Specify measurement areas and performance levels required for aircraft, systems, and equipment operated or maintained by performance-based activities.

1.18.1.3. Specify the forms, methods of documentation, and frequency of reporting used to assess performance-based activities and ensures these requirements are included in the

Quality Assurance Surveillance Plan (QASP).

1.18.1.4. Approve base-level requests that would permit a single Federal Aviation

Administration (FAA) certified Airframe/Powerplant (A/P) contractor technician maintaining contracted logistics support (CLS) aircraft to repair and sign off their own

Red X’s when sent to recover aircraft off-station.

1.18.1.5. Ensure units with assigned Contracting Officer Representative (COR) personnel meet requirements in Chapter 14 of this instruction and applicable 63-series

AFI requirements.

1.18.1.6. Ensure aircraft depot maintenance contracts, Statements of Work (SOW), and

Performance Work Statements (PWS) are coordinated with the MAJCOM Munitions

Functional to ensure munitions handling, accountability and disposition requirements are adhered to.

1.18.2. Units will:

1.18.2.1. Designate a focal point for all functional, technical, and COR matters pertaining to performance-based activities. (T-1).

1.18.2.2. In coordination with the contracting officer and the MXG/CC (or equivalent), provide specific guidance to the performance-based activity to ensure proper maintenance discipline and flight worthiness of aircraft and subsystems. (T-2).

1.18.2.3. Develop and publish contingency procedures for support of continuing operations in the event of disruption, termination, or default of contracts. (T-1).

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Chapter 2

GENERAL RESPONSIBILITIES FOR COMMANDERS AND KEY LEADERS

2.1. General. This chapter outlines responsibilities for commanders and key leaders involved in maintenance activities. For the purpose of this instruction, in units where there is not a military commander responsible for maintenance, the applicable civilian Director of Maintenance (DOM) will ensure compliance with all responsibilities in this instruction. (T-1). For organizations without all commanders and key leaders assigned, MAJCOMs will identify equivalent positions of authority commensurate with the responsibilities of the leadership positions identified in this chapter in a MAJCOM supplement to this instruction. Note: For the purpose of this instruction, contractor equivalents are as follows: A1C—aircraft servicer or apprentice/journeyman; SrA (1 year time-in-grade)—aircraft worker or field maintenance worker or higher; SSgt—aircraft mechanic or field maintenance mechanic or higher; TSgt—senior mechanic or craftsman;

MSgt—lead mechanic; SMSgt/CMSgt/maintenance officer—foreman, branch chief or higher.

MAJCOMs may determine grade/skill level equivalents for civilians.

2.2. Wing Commander (WG/CC) Responsibilities. The WG/CC allocates resources to meet all mission requirements. The WG/CC will:

2.2.1. Ensure that maintenance organizations are not overtasked with augmentation duties outside maintenance functional areas. (T-1).

2.2.2. Conduct a daily "Wing Standup" meeting. (T-1). The meeting will include, at a minimum, a review of previous, current, and future activities, focused on identifying and resolving issues with executing the established flying and maintenance schedule. (T-2).

2.2.3. Ensure a coordinated wing/base instruction is developed to control tools, equipment, and electronic devices applicable to all wing/base agencies dispatching to aircraft runway/taxi/parking and maintenance areas. (T-1).

2.2.4. Ensure maintenance and operations develop a joint annual maintenance and Flying

Hour Program (FHP) that establishes a balance between the requirement for sorties and maintenance…