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CHAPTER 6

WORK CENTER MANAGEMENT AND QUALITY


ASSURANCE

To most personnel, an assignment to a supervisory A supervisor sets in motion the plans, schedules,
position is a welcome challenge. They like the feeling and policies of his superiors. When you become a
of the added prestige, authority, and the responsibility supervisor, you are primarily concerned with seeing
that accompanies the assignment. However, when you that the job is done correctly, safely, and efficiently
do reach this level, you may soon realize that the with no waste of materials. You will not necessarily
position of Work Center Supervisor is not as easy as perform the work yourself. You must know your
it may have seemed when viewed from another personnel, know their limitations, assign them the
position. work to be done, train them to do the best job possible,
and, if necessary, direct them through the performance
Each day you may be confronted with many new of the work. YOU assume the responsibility for seeing
problems and situations that require immediate action. that the job is done, and done right. This role demands
If you know the duties, responsibilities, personnel, skill, common sense, and mutual respect.
equipment, tools, and job priorities, it will be easier to
function in a supervisory capacity. However, if you OBJECTIVES OF THE WORK
don’t possess this knowledge, your troubles may CENTER SUPERVISOR
multiply at an alarming rate.
The first part of this chapter will discuss some of A specific list of duties and responsibilities can
the general duties and responsibilities of a supervisor be made concerning only a specific position.
and a few ways to prevent some problems before they However, listed below are some typical duties and
are problems. responsibilities common to all work center supervisors:
Get the right person on the job at the right time
THE WORK CENTER SUPERVISOR
Use and place materials economically
LEARNING OBJECTIVES: Describe the Ensure personnel and equipment safety
primary concerns of the work center supervisor.
Promote high morale
Describe how the work center layout affects
efficiency and safety. Maintain quality work
Keep accurate records and reports
To be a supervisor, you must clearly understand
Maintain discipline within the work center
the terms supervision and supervisor. SUPERVISION
can be defined as the act of guiding, directing, Plan and schedule work
overseeing, evaluating, and controlling the activities Train personnel
of others in the accomplishment of an objective. A
SUPERVISOR can be defined as the one who is Procure the proper tools and equipment to do the
responsible for and directs the work of others. work
Inspect, preserve, and protect tools and
THE SUPERVISORY POSITION equipment
Give clear orders and directions
The job of supervising your personnel in a work
center is a many sided task. Some of the techniques are Maintain liaison with other work centers
learned through past experience; others will be learned Check and inspect jobs and workmanship
during actual supervision. Still other techniques may
Promote teamwork
be learned from self-study courses and technical
publications. Maintain good housekeeping

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By analyzing the typical duties and responsi- A good supervisor anticipates the eventual loss of
bilities listed above, you will find that they can be experienced personnel through transfers, separations,
grouped into three broad objectives. etc. These things can be offset by establishing an
effective and continuing training program. Use the
1. Operate with maximum efficiency and safety Naval Aviation Maintenance Program, OPNAVINST
2. Operate with minimum expense and waste 4790.2, manual as a guideline for this program. In
addition to raising the skill level of the work center,
3. Operate free from interruption and difficulty the training program ensures that personnel otherwise
While these are the primary objectives of a work qualified will be prepared for the next Navy-wide
center supervisor, it is important for you to keep in advancement examination.
mind that it also affords you the opportunity to gain
practical experience toward eventual promotion to A work center safety program must be organized
Chief Petty Officer. and administered if the work center is to function
efficiently. Current Navy directives and local policies
Q1. What is the primary concern of a work center are quite specific as to the establishment of safety
supervisor? training programs.
Q2. The typical duties and responsibilities of the
supervisor can be grouped into broad objectives. Accurate, complete, and up-to-date records are the
List these three objectives. primary factors in the efficient operation of a work
center. This includes records of usage data, work
OPERATING WITH MAXIMUM accomplishments, and personnel qualifications. The
EFFICIENCY AND SAFETY most efficient record keeper is one who has enough
information without having records and files bulging
The operational efficiency of a work center is with useless and outdated materials.
dependent to a large extent upon how conveniently the
work spaces and equipment are arranged. As As supervisor, you should schedule your workload
equipment in your work center becomes obsolete, new in such a way that planned absences of key workers do
equipment and new models are phased into the not interrupt the daily routine. When scheduling the
inventory. With this occurrence, efficiency naturally workload, keep in mind the skill level required for
increases. This happens even in a poorly arranged various tasks, and assign jobs to individuals in such a
work center, but the full work center potential may not way that the work may still progress if any worker is
be realized. It may not be economically feasible to unexpectedly absent.
make drastic changes in the work center spaces and
equipment. However, if drastic changes result in
improved use of equipment, personnel safety, and in The discussion thus far indicates that an efficient
and safe work center is one in which the supervisor
generally improved working conditions, then the
practices balanced supervision. Balanced supervision
change should be made. The supervisor should make
an assessment of the existing work center layout to means applying sufficient attention to each phase of
ensure the most efficient arrangement possible. the supervisor’s responsibilities. Do not emphasize
production at the expense of safety or training. Also,
The supervisor, by virtue of the position, has do not become so concerned with the human element
authority over other individuals. The supervisor tells that production is neglected. Keep paperwork current
them what to do, when to do it, and if necessary, how and updated to prevent having to spend long periods
to do it. This authority alone is not enough to gain catching up at the expense of other important interests.
maximum effectiveness performance from the crew. Always strive to place the proper emphasis on each
A good supervisor must know the limitations and phase of responsibility to promote work center
capabilities of subordinates to obtain the most efficient efficiency and harmony.
performance from them. The capabilities of the crew
Q3. How does work center efficiency naturally
should be exploited. If at all possible, a well qualified
person should be assigned to each job. Individuals that increase?
are less qualified but who are ready for advanced Q4. How can an effective supervisor offset the loss of
on-the-job training should be assigned to assist. experienced personnel?

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OPERATING WITH MINIMUM PLANNING WORK CENTER
EXPENSE AND WASTE ARRANGEMENT

LEARNING OBJECTIVE: Describe the LEARNING OBJECTIVES: Identify the two


supervisor's responsibility to operate with types of maintenance that concern the
minimum expense and waste. supervisor. Describe the purpose of the daily
maintenance meeting.
As a work center supervisor, you don’t actually
handle money, but you still must be aware of expenses.
Remember that not only will such things as a It is entirely possible that you may never have the
misdirected effort, broken tool, wasted time, wasted opportunity to plan or assist in planning a work center
material, and injuries actually add to your expenses, in a new facility. In almost every case, the supervisor
they also cut down on efficiency. You have the takes charge of an existing functional work center. If
responsibility for properly ordering and accounting for your unit is moved to a new base or facility, you are
spare parts and material. Impress upon your personnel usually assigned to spaces already equipped or laid out
the need for thrift in the use of these materials. Train for your specific needs. In either case, as the
your less experienced personnel to become supervisor, you should evaluate the work center’s
cost-conscious without sacrificing efficiency. layout. This reevaluation of the work center’s layout
should include researching applicable allowance lists
OPERATING FREE FROM to determine if the work center equipment allowances
INTERRUPTION AND have been updated or changed in any way. If changes
DIFFICULTY have been made and the equipment is not available,
you should initiate efforts to procure it immediately.
LEARNING OBJECTIVE: Describe the There is no use in relocating work center equipment if
effects of judicious delegation of authorty. there are lighting, wiring, ventilation, or plumbing
changes to be made if improved replacement models
The success of this objective depends largely upon are authorized and available.
the extent to which the work center, files, test
equipment and tools are maintained. Also, the skill Purpose of the Work Center
level and training of assigned personnel must be
considered in meeting this objective. Accurate
A basic consideration in planning a work center
tracking of test equipment requiring calibration,
layout is the purpose of the work center. When more
ensuring tools are in safe working condition, and
than one working space is available, the supervisor
up-to-date files and publications are also important
must decide which space is best suited for a particular
factors. They contribute to an efficient job completion
with minimal interruption or difficulty. job. For example, if two spaces are identical in size,
one may be completely unacceptable for performing
Smooth functioning of the work center may be hydraulic sample patch tests, yet may be perfectly
further enhanced if you delegate authority to other suited for a drill press, vise, and workbench.
responsible petty officers. Delegation of authority
does not relieve you, as supervisor, of the overall The general function of the work center must be
responsibility for work accomplishment. It is considered in the allocation of space and equipment.
primarily a means of relieving you of details. If you The ideal arrangement contains enough space to have
become too involved with details, you can lose you workbenches, special tools, parts and tool stowage
effectiveness as a supervisor. If your work center can space, technical publication stowage, and ample space
run smoothly and efficiently under normal conditions for the workers. Since this is not always possible,
without your personal directions and efforts, (for a especially aboard ship, the supervisor must decide
reasonable period of time) your delegation of authority which of these is most important and what can be
to other members of the crew has been successful. sacrificed. It may be decided that all of the toolboxes
and special tools should be located in a central
Q5. Which of the three broad objectives are affected
toolroom. At the intermediate level, the supervisor
by wasted materials?
may simply have to decide which work centers are to
Q6. Describe the primary purpose of delegation of be combined. However, the decision to combine
authority. different maintenance functions should be based on

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safety, economy, functional compatibility, and Scheduling and Assignment of
convenience. Workload

Arrangement Your most important concern as a supervisor is the


assignment and accomplishment of the scheduled and
The arrangement of the furnishings should be unscheduled workload.
made on the basis of use rather that appearance.
Moving shop-installed equipment into an Scheduled maintenance can be defined as
out-of-the-way corner may improve the appearance of maintenance that is required by hours, calendar
the space but greatly reduces the efficiency of the periods (days or weeks), and starts. This type of
personnel using the equipment. It may also create a maintenance is always anticipated and planned. By
safety hazard. A good rule to follow is to locate the tracking flight or operating hours, maintenance control
equipment where it can be safely used by the greatest knows exactly when a particular aircraft is due for a
number of authorized persons with minimum effort in phase inspection. It is also easy to determine when an
the least amount of time. aircraft or piece of equipment is due for a 28-day
inspection.
Work tables and benches should be positioned
with respect to fixed equipment so that the equipment Unscheduled maintenance is defined as
most often used is most quickly and easily reached. maintenance that occurs on aircraft or equipment other
Electrical and compressed air outlets should be readily than scheduled. For example, an aircraft develops a
available to workbenches. Needless delays are caused hydraulic fluid leak on preflight, or perhaps while
by having to rig unnecessarily long connections from performing scheduled maintenance on an aircraft
poorly located outlets. engine, a worker discovers a cracked or chaffed line.
The repair or replacement of that line is unscheduled
You should give special considerations to the
maintenance.
installation of special lighting, such as explosionproof,
vaporproof, or interference-free lights, near As the work center supervisor, you should attempt
workbenches where specific or intricate work is to be to coordinate the installation of technical directives
performed. Another special consideration is that of (TDs) and correct minor discrepancies to coincide
ventilation. All work spaces should have adequate with scheduled maintenance. You may not be
ventilation under all conditions that are expected to authorized to wait until the next scheduled
exist in that work space. maintenance period for the installation of a TD; the
The use of paint in various colors to emphasize assigned category (priority) determines the maximum
portions of intricate machinery for safety and allowable time period for compliance with the
reflective purposes is known as dynamic painting. directive. A directive classified IMMEDIATE
Painting in this category should be kept in an efficient ACTION may be issued with instructions to be
state for maximum effectiveness; however, this type completed "prior to further use of equipment" or "prior
of paint should not be used for normal building to next flight"; a directive classified ROUTINE
maintenance. ACTION must be accomplished within 18 months of
the date of issue.
The work center layout plan should have a
provision for an information or bulletin board. Safety The supervisors objective is the satisfactory
posters, maintenance posters, instructions, notices, completion of assigned tasks in a reasonable amount
plan of the day (POD), and such other information as of time, using available personnel and materials as
appropriate should be placed on this board. This board efficiently as possible. To achieve this objective, the
should be located in a prominent place in the work supervisor must become skilled in estimating the
center, preferably near the entrance where everyone amount of time required for each task and the number
assigned must pass at sometime during the day. ofworkers required. To be able to estimate effectively,
Material on the bulletin board should be kept current, you, as the supervisor, must be familiar with the task
expired notices removed promptly, the current POD and know the capabilities of your personnel. You must
posted early, and safety posters rotated periodically. If realize the importance of assigning qualified and
the same material is presented in the same format day unqualified persons to the same job, when possible.
after day, personnel begin to ignore the board. A new Allow for planned interruptions, and yet do not operate
arrangement will arouse curiosity and interest. on so tight a schedule that minor, unplanned

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interruptions completely disrupt the maintenance 6. WHEN is the job to be started and what are the
effort. time constraints?
Q7. Describe scheduled and unscheduled It is not necessary to have an answer to all of these
maintenance. questions; however, the more you can answer, the
better plan you will have. As supervisor, start each new
Estimating Time and Personnel shift by checking over the work to be done; plan for
Requirements maximum use of manpower, equipment, and material.
Also, ensure that you attend the maintenance meeting
Estimating times for completion of maintenance with other work center supervisors. Periodically
tasks will be one of the supervisors responsibilities. during the shift, make checks to ensure that work is
The quality and quantity of personnel assigned to progressing as planned.
perform these tasks directly affect the time required
for completion. Other items that affect time are the Daily Maintenance Meeting
type and complexity of maintenance, the availability
and condition of materials, work center tools and The daily maintenance meeting is one of the best
equipment, and working conditions or job site tools for ensuring a smooth flow of information about
(in-shop, cold flight deck, etc.). maintenance between shifts and other supervisors.
This meeting allows all the supervisors within your
Probably the most important single aid in department or division to brief the maintenance chief
estimating time and personnel requirements for on the status of equipment, components, or aircraft that
maintenance tasks is a JOB PLAN. Within an office, currently have ongoing work or are scheduled to have
a work center, or on the line, job planning is one of the maintenance performed. It also allows supervisors to
most important functions of the supervisor. The person coordinate time frames for sharing certain facilities,
who allows an organization to run haphazardly, who equipment, or electrical power requirements. In
never thinks ahead, who is never ready for an addition, these maintenance meetings may bring to the
emergency or extra workload, and who does not attention of the maintenance chief items of material
delegate work or trust subordinates is not a good that may be difficult to obtain. It may identify certain
supervisor. document numbers that require "hand massaging" by
Proper planning saves time, reduces cost, and the supply chief.
makes the work easier, safer, and more pleasant for Q8. What is the most effective tool for ensuring a
everyone. Proper planning can eliminate friction and smooth flow of information regarding
confusion, as well as make better use of in-port periods maintenance between shifts, other work centers,
for tasks that cannot be performed underway; it also and maintenance control?
frees the supervisor from petty details. Planning
expedites the work, eliminates "bottlenecks," and Personnel Work Assignments
makes the supervisor's job easier.
Rotate work assignments so that each person in
The following hints can help you as a supervisor. you work center can develop skills in all phases of
In planning a job, use the BIG SIX—WHAT, WHY, maintenance. Personnel in lower paygrades should be
WHERE, HOW, WHO, and WHEN. encouraged to get involved in many different types of
1. WHAT is the task? What does it involve and maintenance. A worker who understands a system or
what special tools may be required? aircraft will be a better troubleshooter. Additionally,
when you rotate work assignments and encourage a
2. WHY is the work to be done? (This helps to wide range of maintenance skills, the work becomes
establish priorities.) more interesting to the worker. More interest, more
3. WHERE can the job be done? (In-shop, hanger quality! If one highly skilled mechanic performs all of
bay, etc.) the work of a certain type, the supervisor and the work
center would suffer if that technician were to transfer,
4. HOW is the job done? (Electrical or air be assigned TAD, or even take a period of well earned
requirements, etc.) leave; this is another reason for rotating work
5. WHO is affected? (Are there other work centers assignments. Assign less experienced workers to work
involved? Who is the best qualified?) with the skilled mechanics so they can become

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proficient at a particular skill. This also permits each CONCEPTS OF QUALITY
person to broaden his/her knowledge. ASSURANCE

Allowing for Planned The QA concept is fundamentally the prevention


Interruptions of the occurrence of defects. This includes all events
from the start of maintenance operations until their
During an average workday, personnel will need completion. Quality is the responsibility of all
to leave their work center for various personal reasons; maintenance personnel. Achievement of quality
this may easily interrupt the scheduled workload. assurance depends on prevention, knowledge and
Some reasons can be anticipated and some cannot. special skills.
Among those that can be anticipated are training Prevention of the occurrence of defects relies on
lectures, inspections, immunization schedules, rating the principle of eliminating maintenance failures
examinations, meals, watches, and other military before they happen. This principle extends to safety of
duties. personnel, maintenance of equipment, and virtually
Before assigning a task, the supervisor should every aspect of the total maintenance effort.
determine what delays can be anticipated. It may be Prevention is concerned with regulating events rather
possible to arrange assignments so that work than being regulated by them.
interruptions are held to a minimum. It is much easier Knowledge is obtained from factual information.
for the same technician to complete a task that he This knowledge is acquired through the proper use of
started than for another to pick up where the first data collection and analysis programs. The
worker left off. If interruptions cannot be avoided, the maintenance data collection system provides
supervisor should allow for these predictable delays maintenance managers limitless quantities of factual
when estimating completion times. information. Correct use of this information gives
management the knowledge needed to achieve
QUALITY ASSURANCE maximum readiness of aircraft and weapons systems.
LEARNING OBJECTIVE: State the purpose Special skills, normally not possessed by
and concept of Quality Assurance. production personnel, are required by a staff oftrained
personnel for the analysis of data and supervision of
When you progress up the ladder of responsibility QA.
in aviation maintenance, you become more involved The terms inspection, quality assurance, and audit
in quality assurance (QA). You may be assigned as a (as used in this context) have distinct meanings and
QA representative or a collateral duty inspector. should be used accordingly. The following definitions
Therefore, you must become quality conscious. are provided to clarify the differences in these terms.
The quality assurance (QA) division determines Inspection is the examination (including testing)
deficiencies, analyzes discrepancy trends, prescribes of supplies and services, including raw material,
inspection procedures, and determines the quality of documents, data, components, and assemblies.
maintenance accomplished. The division also Inspection is done to determine if the supplies and
provides follow-up action and functional guidance to services conform to technical requirements.
stimulate QA at the departmental level.
Quality assurance is a planned and systematic
NOTE: At the time of publication of this training pattern of actions necessary to provide confidence that
manual, the NAMP Policy Committee has determined the product will perform satisfactorily in service. QA
that Naval Aviation Maintenance Program Standard is also the monitoring/analyzing of data to verify the
Operating Procedures (NAMPSOP) will take the place validity of these actions.
of Maintenance Instructions (MIs) throughout naval An audit (as it applies to QA) is a periodic or
aviation. MIs are mentioned frequently throughout
special evaluation of details, plans, policies,
this chapter as they are still referred to in the NAMP.
procedures, products, directives, and records.
The next update of the NAMP may reflect the use of
NAMPSOP rather than local MIs. Refer to OPNAV QA provides an efficient method for gathering,
NOTICE 4790 for further information regarding analyzing and maintaining information on the quality
NAMPSOP. characteristics of products, on the source and nature of

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defects, and their impact on the current operation. It RESPONSIBILITIES FOR QUALITY
permits decisions to be based on facts rather than OF MAINTENANCE
intuition or memory. It provides comparative data that
will be useful long after the details of the particular The commanding officer is responsible for the
times or events have been forgotten. QA requires both inspection and quality of material within a command
authority and assumption of responsibility for action. and the full cooperation of all hands to meet this
responsibility. The responsibility for establishing a
A properly functioning QA points out problem successful program to attain high standards of quality
areas to maintenance managers so they can act to workmanship cannot be discharged by merely creating
accomplish the following: a QA division within a maintenance organization. To
operate effectively, this division requires the full
Improve the quality, uniformity, and reliability support of everyone in the organization. It is not the
of the total maintenance effort. instruments, instructions, and other facilities for
Improve the work environment, tools, and inspection that determine the success or failure in
equipment used in the performance of achieving high standards of quality; it is the frame of
maintenance. mind of all personnel.

Eliminate unnecessary man-hour and dollar Quality maintenance is the objective. The
expenditures. supervisor must know that high quality work is vital
to the effective operation of any maintenance
Improve the training, work habits, and organization. To achieve this high quality work, each
procedures of maintenance personnel. person must know not only a set of specification limits,
Increase the quality and value of reports and but also the purpose for those limits.
correspondence originated by the maintenance
activity. The person with the most direct concern for
quality workmanship is the production supervisor.
Distribute technical information more This concern stems from the supervisor’s
effectively. responsibility for the proper professional performance
of assigned personnel. A production supervisor is
Establish realistic material and equipment responsible for the assignment of a collateral duty
requirements in support of the maintenance inspector (CDI) at the time work is assigned. This
effort. procedure allows the inspector to conduct the
Support the Naval Aviation Maintenance progressive inspection required so the inspector is not
Discrepancy Reporting Program. then confronted with a job already completed,
functionally tested, and buttoned up. The completion
Support the Foreign Object Damage (FOD) of production work is not a function of the QA
Prevention and Reporting Program. division. Production personnel in the added role of
inspector cannot certify inspection of their own work.
QA serves both management and production
equally. Management is served when QA monitors the Direct liaison between the QA division and
complete maintenance effort of the department and production divisions is a necessity and must be
furnishes the factual feedback of discrepancies and energetically pursued. Although the QA officer is
deficiencies. In addition, it acts to improve the quality, responsible to the aircraft maintenance officer (AMO)
reliability, and safety of maintenance. Production is for the overall quality of maintenance within the
served by having the benefit of collateral duty department, division officers and work center
inspectors who are formally trained in inspection supervisors are responsible for ensuring that required
procedures; it is also served by receiving technical inspections are conducted and that high quality
assistance in resolving production problems. The workmanship is attained.
introduction of QA to the maintenance function does
not relieve production personnel of the basic Q9. What is the purpose of the quality assurance
responsibility for quality work; instead, that division?
responsibility is increased by adding accountability. Q10. The prevention of the occurence of defects relies
This accountability is the essence of QA. on what principle?

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Q11. What are the three factors that ensure the Monitor inspections of precision measuring
achievement of quality assurance? equipment (PME) to ensure compliance with calibration
intervals and safety instructions.
Q12. State the definition of a Q/A audit.
Perform inspections of all maintenance
Q13. What does the frame of mind of all personnel
equipment and facilities to ensure compliance with fire
assigned to a department determine?
and safety regulations; that satisfactory environmental
Q14. When must the production supervisor assign a conditions exist; that equipment operators and drivers
collateral duty inspector to a task? are properly trained, qualified, and licensed; and that
equipment is maintained in a safe operating condition.
QUALITY ASSURANCE Provide a continuous training program in
DIVISION RESPONSIBILITIES techniques and procedures pertaining to the conduct of
AND ORGANIZATION inspections. When directed or required, provide a
technical task force to study trouble areas and submit
recommendations for corrective action.
LEARNING OBJECTIVE: Describe the
quality assurance division’s responsibilities Use information from the maintenance data
and its organization. reports (MDRs) and NALCOMIS reports to develop
discrepancy trends, and to identify failure areas or other
maintenance problems.
The quality assurance responsibilities assigned to
the QA division include the following: Review source documents and periodic
inspection records, and note recurring discrepancies that
Maintain the central technical publications require special actions.
library for the department, including technical Maintain liaison with contractors via the
directives (TDs). Control classified technical contracting officer’s representative (COR), Naval
publications for the department. Ensure that each Aviation Engineering Services Unit (NAESU), Naval
division or branch receives all publications applicable Aviation Depot Operations Center (NAVAV-
to its respective work areas and that these are kept NDEPOTOPSCEN), and other available field technical
current and complete. services. Establish and maintain liaison with other
Establish qualification requirements for quality maintenance and rework activities to obtain information
assurance representatives (QARs), collateral duty on ways to improve maintenance techniques, quality of
quality assurance representatives (CDQARs), and workmanship, and QA procedures.
collateral duty inspectors (CDIs). Review the Obtain and use appropriate inspection
qualifications of personnel nominated for these equipment, such as lights, borescopes, mirrors,
positions, and endorse these nominations to the magnifying glasses, fluorescent inspection kits,
department head. tensiometers, pressure gauges, and carbon monoxide
Periodically accompany CDIs during scheduled testers. Ensure that production personnel have such
and unscheduled maintenance tasks to observe their equipment available, in operating condition, calibrated,
proficiency. if applicable, and in use.
Ensure that all work guides, checklists, check Ensure that established standard procedures are
sheets, maintenance requirements cards, etc., used to observed for conducting scheduled and unscheduled
define or control maintenance operations are complete inspections, ground tests and bench checks of
and current before they are issued to crews or components, including engines. Periodically (at a
individuals. minimum, once a quarter) accompany check crews or
plane captains during inspections. Check the
Review all engineering investigation (EI)
performance of their work to ensure that the desired
requests, quality deficiency reports (QDRs), technical
quality level is obtained.
publications deficiency reports (TPDRs), hazardous
material reports (HMRs), hazard reports (HRs), and Ensure check pilots and aircrew members are
aircraft discrepancy reports (ADRs) to ensure that they briefed before the post maintenance functional check
are accurate, clear, concise, and comprehensive before flight (FCF) so the purpose and objective of the flight
mailing. are clearly understood. After completion of the FCF,

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conduct a debrief with the check pilot, aircrew are discussed briefly in Chapter 1 and are outlined
members, a maintenance control representative, and specifically in OPNAVINST 4790.2.
applicable work center representatives for compliance The number of personnel assigned to the QA
with objectives outlined on the FCF checklist, and to division varies among activities, depending on the size
clarify discrepancies noted. The completed check flight of the unit and number of work shifts. When activities
checklists are retained in the aircraft maintenance files with four or less aircraft assigned or small OMDs elect
for a minimum of 6 months, or one phase cycle,
to organize a QA division, the QA officer and the QA
whichever is greater.
supervisor will be permanently assigned. Usually, in a
Ensure the configuration of aircraft, aeronautical small OMD under a one work center concept, qualified
components, and support equipment (SE) is such that personnel are designated as CDQARs to carry out the
all essential modifications have been incorporated. QA verification functions.
Ensure an inspection is conducted on all Q15. At a minimum, how often must plane captains
equipment received for use, returned for repair, or held have their qualifications monitored by Q/A?
awaiting repair to verify that its material condition,
Q16. Why must a QAR brief the check pilots and
identification, packaging, preservation, and
aircrew prior to a functional check flight (FCF)?
configuration are satisfactory; and, when applicable,
that shelf-life limits are not exceeded. Q17. What division is responsible for reviewing all
incoming technical publications and directives
Review all incoming technical publications and
to determine their application to the
directives to determine their application to the
maintenance department?
maintenance department.
Q18. In relation to the organization of a quality
Prepare or assist in the preparation of
assurance division, what determines the number
maintenance instructions to ensure that QA
of assigned personnel?
requirements are specified (until Naval Aviation
Maintenance Program Standard Operating QUALITY ASSURANCE
Procedures, NAMPSOP, Volume V, of OPNAVINST REPRESENTATIVES
4790.2 is issued).
Maintain current assignments of personnel LEARNING OBJECTIVE: Describe the
qualified for specific QA responsibilities. Activities functions and qualifications of QARs,
using Naval Aviation Logistics Command Management CDQARs, and CDIs.
Information System (NALCOMIS) should refer to the
User’s Manual for specific procedures. The need for quality control requires that only
highly skilled maintenance personnel be designated as
Be responsible for the effective monitoring of the QA representatives/inspectors. QARs and CDIs must
Enhanced Comprehensive Asset Management System be highly qualified personnel with the ability to ensure
(ECAMS). quality of maintenance within their technical areas.
Be responsible for effective monitoring of Under this concept, the personnel in the production
hazardous material and hazardous waste procedures divisions are ultimately responsible for the quality of
within the aircraft maintenance department. work performed in the department. The QA division
monitors the production and ensures that high quality
The QA division is organized with a small group workmanship is accomplished by maintenance
of highly skilled personnel. These permanently personnel and that specifications and quality standards
assigned personnel, under the QA officer, are are met. QA is concerned with the completeness and
responsible for conducting and managing the QA adequacy of inspections, and emphasis is placed on the
effort of the department. The maintenance personnel thoroughness of the inspection rather than the number
assigned to the QA division are known as QARs. To of units inspected.
obtain more efficient use of the information collected
by the aviation Maintenance Data System (MDS) and Quality Assurance Representatives
to increase the scope of QA for commands still Functions
operating under VIDS, a qualified data analyst is
assigned to the QA/A division. The primary duties of The nucleus of the QA division is a group of
the data analyst or NALCOMIS system administrator QARs. These permanently assigned representatives

6-9
are, in most activities, supplemented by designated If flight control malfunctions occur, comply with
CDIs. The QARs perform the following functions: the applicable type/model/series conditional
maintenance requirements cards.
Review incoming technical publications and
directives to determine their application to the Perform QA inspections, ensuring each
maintenance department. inspection includes an examination of the work area for
sources of potential FOD. Ensure contractor and field
Assist in the certification of production maintenance teams are briefed about the FOD
personnel. Prevention Program requirements and reporting
Participate as members of technical task forces procedures.
to investigate trouble areas and recommend corrective
actions. Quality Assurance Representative
Qualifications
Ensure QA objectives and requirements are
defined during MI preparation (until completely under All personnel considered for selection as a QAR
the NAMPSOP). should possess the following qualifications:
Review qualifications of personnel nominated to
Senior in grade and experience. This means a
become CDIs or CDQARs, and provide
petty officer (E-6 or above) with a well-rounded
recommendations as appropriate. maintenance background. Unusual circumstances may
Investigate Hazard Reports (HRs), as defined in temporarily require the use of other than E-6 or above
OPNAVINST 3750.6 (series), applicable to the unit that personnel. Under such circumstances, the most
are received from other activities. Assist in the experienced personnel available, as determined by the
preparation of NAMDRP reports. Review all report AMO, may be temporarily designated as a QAR.
entries for adequacy and correctness before distribution. Fully developed skills and experience related to
Provide technical assistance to CDIs and the technical-fields under their cognizance.
production personnel. Periodically accompany CDIs on The ability to research, read, and interpret
assigned inspections and evaluate their performance. drawings, technical manuals, and directives.
Review MDRs, NALCOMIS reports, The ability to write with clarity and technical
Maintenance Action Forms (MAFs), NAMDRP accuracy.
reports, and HRs to determine discrepancy trends and
specific problem areas in areas of responsibility. Stability and excellence in performance.

Upon completion of tasks that require The motivation and personal desire to develop
certification by QARs, conduct final inspections. greater knowledge of his or her technical specialty.
An observant, alert, and inquiring nature.
Monitor the calibration or certification status of
equipment, tools, and personnel used in each work The ability to work with others.
center.
Billet descriptions are prepared for QA division
Coordinate with the analyst in the development personnel to ensure that all QA functions and
of discrepancy trends and such charts and graphs that responsibilities, covered in the Naval Aviation
are necessary to depict quality performance. Maintenance Program (NAMP), are assigned.
Maintain liaison with contractors via the COR
NAESU, NAVAVNMAINTOFF, cognizant field COLLATERAL DUTY QUALITY
ASSURANCE REPRESENTATIVES
activities (CFAs), and other available field technical
services. Establish and maintain liaison with other
maintenance and rework activities to obtain information When CDQARs are assigned to work centers or
production divisions, they function in the same
for improving maintenance techniques, quality of
capacity as QARs and must meet the same minimum
workmanship, and QA procedures.
qualification requirements as their QA division
Develop checklists for auditing work centers, counterparts. When CDQARs are assigned to work
specific maintenance programs, and processes that centers or production divisions because of temporary
require monitoring by QA. shortages of skills, and these shortages have not been

6-10
alleviated within 90 days, a letter must be submitted for only as long as his or her qualifications are current,
to the aircraft controlling custodian (ACC), through as judged by the cognizant division officer.
the chain of command, advising of the personnel
NOTE: A CDI will NOT inspect his or her own
problems, action taken, and intent to continue the
work and sign as inspector.
assignments. ACCs will take action to authorize
activities to continue or to curtail the assignment. The
QUALITY ASSURANCE
letter will contain name, rate, Navy enlisted
REPRESENTATIVE TRAINING
classification (NEC), and functional area.
Permanent CDQARs may be assigned to The QA officer ensures that personnel assigned to
organizational maintenance activities that have perform QA functions receive continuous training in
minimal ordnance delivery in their assigned mission, inspecting, testing, and quality control methods
and where manning the armament billet would not be specifically applicable to their area of assignment. The
justified. An organizational activity may also QA officer also ensures that QARs receive cross
designate a p e r m a n e n t a i r c r e w p e r s o n a l training to perform those QA functions not in their
protective/survival equipment CDQAR and an assigned area. This training should include local
egress/environmental systems CDQAR when the training courses, on-the-job training (OJT), rotation of
activity’s aircraft are not equipped with ejection seats. assignments, personnel qualifications standards
Permanent CDQARs also may be designated to (PQS), and formal schools. According to
supplement multiple work shifts or detachments, OPNAVINST 4790.2, QARs should attend a Fleet
provided QA division billets are fully manned. Aviation Specialized Operational Training Group
Permanent CDQARs may also be assigned when the Detachment QA course.
activity maintains four or less aircraft and is organized
Division officers are responsible for establishing
according to guidelines set forth in the NAMP.
and maintaining training programs for production
personnel involved with QA functions. This
COLLATERAL DUTY
responsibility includes training in troubleshooting,
INSPECTORS
testing, and inspection techniques; ensuring that
operations requiring certified operators are
The CDIs assigned to the production or
accomplished; and that steps are taken to qualify and
maintenance training unit (MTU) work centers inspect
certify affected personnel.
all work and comply with the required QA inspections
during all maintenance actions performed by their QARs, CDQARs, and CDIs must be designated in
respective work centers. They are responsible to the writing by the AMO. The only deviation authorized
QA officer when performing these functions. CDIs allows the officer in charge (OIC) of a detachment to
spot check all work in progress. This requires them to designate QA personnel provided (1) the deployment
be familiar with the provisions and responsibilities of period is more than 90 days, and (2) all procedures and
the programs that QA manages and monitors. requirements for designating QA personnel are
accomplished by the detachment. See figure 6-1 for a
The QA division establishes minimum
sample of a Quality Assurance Representative/
qualifications for personnel selected for CDI. Division
Inspector Recommendation/Designation form.
officers are responsible for ensuring that sufficient
qualified personnel are nominated for CDI to comply
ISSUE AND CONTROL OF QUALITY
with QA inspections required during all maintenance ASSURANCE STAMPS
actions. Due to the importance and responsibility of
duties performed by CDIs, division officers and work
QA stamps may be used in place of a signature.
center supervisors must carefully screen all candidates They are required in an intermediate maintenance
for these assignments. CDIs must demonstrate their
activity/aircraft intermediate maintenance department
knowledge and experience on the particular type of
(IMA/AIMD), but are optional at organizational-level
equipment by successfully passing a locally prepared
maintenance. In an IMA/AIMD, all QARs, CDQARs,
written test administered by the QA division. In and CDIs receive QA stamps.
addition, a locally prepared oral or practical
examination may be administered. When a CDI is At the organizational level, QA stamps are to be
transferred from a production work center, his or her used by QARs and CDQARs only. These
designation as a CDI for that work center remains valid open-purchased, numbered, impression stamps, which

6-11
Figure 6-1.—Quality Assurance Representative/Inspector Recommendation/Designation (OPNAV 4790/12).

6-12
identify the inspector, are used in place of signatures whether a QAR, CDQAR, or CDI performs the QA
to certify completion of inspections on maintenance functions listed in the MRCs. QA inspections are
documents and in place of initials where use of initials performed during or after task performance.
is specifically authorized. The QA division closely
controls these stamps. Once a QA stamp is turned in If the proper performance of a task cannot be
by an inspector, either due to transfer or loss of determined after the task is completed, a QA inspection
qualifications, it may not be reassigned within a period is required while the task is being performed. Work
of 3 months. cannot proceed past the inspection point indicated on
the task MRC without the approval of the inspector.
Q19. Who has the responsibility to review MDRs, For these inspections, the notation "QA Required"
NALCOMIS reports, and VIDS/MAFS to appears on the MRC containing the task. If the proper
determine discrepancy trends and specific performance of a task can be determined by a visual
problem areas? inspection after the task was completed, a QA
Q20. Under normal circumstances, what paygrade is inspection is required after task completion.
usually assigned as a QAR? Each work center sets up procedures to ensure that
Q21. How long may a CDQAR be assigned to a work the QA inspection requirements are complied with
center without having to notify the aircraft during all maintenance evolutions. With these
controlling custodian? procedures developed, inspections normally fall into
one of the three following inspection areas.
Q22. When may a CDI inspect his own work and sign
as inspector? RECEIVING OR SCREENING INSPEC-
Q23. When a deployment period is more than 90 days TIONS. These inspections apply to material,
and all requirements for assigning QA personnel components, parts, equipment, logs and records, and
have been met by the detachment, who may documents. CDIs normally conduct these inspections to
designate QA personnel? determine the condition of material, proper
identification, maintenance requirements, disposition,
Q24. What is used to annotate an inspection on a and accuracy of accompanying records and documents.
VIDS/MAF in place of a signature at an AIMD?
IN-PROCESS INSPECTIONS. These
QUALITY ASSURANCE inspections are specific QA functions that are required
INSPECTIONS during the performance of maintenance requirements
and actions when satisfactory task performance cannot
LEARNING OBJECTIVE: Identify the types be determined after the task has been completed. When
of quality assurance inspections. designated, these inspections include witnessing
application of torque, functional testing, adjusting,
QA inspections are essential elements of an assembling, servicing, installation, and similar tasks.
effective QA program. To comply with assigned FINAL INSPECTIONS. These inspections
responsibilities, QA personnel perform the following comprise specific QA functions performed following
QA inspections: the completion of a task or series of tasks. QA inspection
Mandatory QA inspections specified in of work areas following task accomplishment by several
maintenance instruction manuals (MIMs), TDs, and different personnel is an example of a final inspection.
local MIs.
In-process and Final Inspections
Those inspections required to be conducted by
QA personnel during and/or upon the completion of a
CDIs normally conduct these inspections;
maintenance action.
however, QARs and CDQARs must conduct
QA maintenance requirements cards (MRCs) in-process and final inspections of all tasks that require
provided for all maintenance tasks that, if improperly the aircraft to have a functional check flight (FCF) in
performed, could cause equipment failure or jeopardize an O-level maintenance activity. QARs and CDQARs
the safety of personnel. The "QA" appearing on MRCs also must perform inspections of maintenance tasks
signifies that a QA function is required. Local involving egress systems, personnel parachutes, and
commands must determine and designate, in writing, by flotation devices when the affected mechanism or
annotating the master and the work center decks, function of that equipment is not reinspected or

6-13
functionally tested before flight. Aircraft maintenance and that the areas where maintenance was performed
officers determine which additional maintenance tasks are free from foreign objects. If the discrepancy
require QAR or CDQAR level in-process and final involves safety of flight, a QAR reinspects the repairs
inspections. Only those personnel designated as upon return to home base.
QARs, CDQARs, and CDIs are authorized to sign as Q25. What person or activity decides if a CDI,
inspector for QA inspection requirements. While not CDQAR, or QAR is to perform inspections
all QA inspections conducted during the various required by "QA " annotated on an MRC?
phases of maintenance require a signature, all
specified QA inspections are conducted, witnessed, Q26. During a maintenance evolution, inspections
and/or verified by designated QA personnel. normally fall into three categories. What are the
three categories?
Quality Assurance Inspection Q27. QAR and CDQAR are required to conduct
Sign-offs in-process and final inspections of all
maintenance tasks that require what actions?
The QA inspector who actually performs the
inspection of the standards of the work signs the Q28. When must a QAR reinspect in-flight
"INSPECTED BY" block on all VIDS/MAFs. The maintenance sign-offs?
sign-off on documents that do not involve an actual
inspection (for example, a control document for a QUALITY ASSURANCE PROGRAMS
phase inspection) is a certification that all QA
functions associated with the inspection have been LEARNING OBJECTIVE: Describe the
performed and that the designated QA inspectors programs that are managed and monitored by
received and accepted all necessary documentation. In quality assurance.
activities using NALCOMIS, refer to the NALCOMIS
User’s Manual for specific details and procedures The QA division manages or monitors many
related to QA inspection sign-offs. different types of programs. Until Volume V of the
NOTE: Do not be tempted by operational tempo NAMP, OPNAVINST 4790.2 (NAMPSOP), is
or commitment to sign off any maintenance task distributed, local MIS should be prepared by your
without physically inspecting the job. activity for each program

In-flight Maintenance Sign-offs QUALITY ASSURANCE


MANAGEMENT
In the absence of designated QA personnel during
in-flight maintenance, the senior aircrew maintenance Currently local maintenance instructions contain
person is authorized to sign as inspector. He or she procedures for implementing management programs
inspects the work performed from a technical that contain information, techniques, local policy
standpoint to ensure that sound maintenance procedures, and methods to manage each program.
procedures were followed and that areas where Soon NAMPSOP will replace these MIs. The
maintenance was performed are free of foreign programs managed by QA are covered in the following
objects. If the discrepancy involves safety of flight, a paragraphs.
QAR inspects the repairs upon return to home base.
This is in addition to the inspection already performed
by the in-flight personnel. Quality Assurance Audits

Transient Maintenance Sign-offs Audits are essential elements of an effective QA


program. Audits provide an evaluation of performance
In the absence of designated QA expertise during throughout the department and serve as an orderly
transient maintenance, the pilot in command is method of identifying, investigating, and correcting
authorized to either sign as inspector or designate a deficiencies. They also evaluate various maintenance
qualified member of the aircrew to function in this tasks and procedures. Audits monitor those specific
capacity. The pilot or person designated inspects the maintenance programs assigned to QA for monitoring.
work performed from a technical standpoint, ensures Audits fall into two categories—work center audits
that sound maintenance procedures were followed, and special audits.

6-14
THE WORK CENTER AUDIT.—QA conducts QA uses special audits to monitor maintenance
these audits quarterly to evaluate the overall quality programs and processes specifically assigned to QA
performance of each work center. As a minimum, QA for monitoring. In addition, QA conducts special
evaluates the following items: audits of periodic inspections, testing, and servicing of
Personnel and skills aircraft by organizational maintenance activities. The
QA officer normally directs special audits.
Technical publications
Quality assurance develops audit forms with
Compliance with NAMP programs and MIs (or checklists for each work center. The QA division also
NAMPSOP) prepares an audit MI and includes the audit checklists
Adherence to directives, procedures, as enclosures to the MI.
inspections, and applicable end-to-end testing
Upon completion of an audit, QA reviews the
Adequacy and availability of written process, findings with the work centers involved. QA submits
test, and inspection procedures a report of the findings, with recommendations when
Availability, calibration status, and proper use of required, to the AMO with a copy to the cognizant
test and measuring devices division(s). Records of audits are maintained for 1
year. Follow-up procedures ensure that discrepancies
Accuracy and proper use of the Maintenance found during a QA audit are resolved in a timely
Data System (MDS) fashion.
Certification of personnel performing special
processes, such as nondestructive inspection Maintenance Department or
(NDI) and welding Division Safety
Designation of plane captains, if applicable
The QA division is assigned the overall
Licensing of personnel for taxi, turnup, and responsibility for the maintenance department safety.
operation of SE The intent of this program is to assist in the
Handling, packaging, protection, and storage of coordination of the total safety effort.
aeronautical material The maintenance department safety program helps
Cleanliness and condition of working spaces to identify and eliminate hazards. Effectiveness and
Compliance with fire and safety regulations safety result when properly trained personnel use
properly designed equipment and follow procedures
Configuration of aircraft, components, and SE under competent supervision. It is an all hands effort.
Accuracy of equipment logs and records Any safety effort must address aviation and
Material condition of aircraft and SE industrial safety. OPNAVINST 3750.6 contains the
Validation of VIDS boards and VIDS operating instructions for maintenance personnel participation
procedures if operating using VIDS. If operating in command aviation safety programs. It also contains
NALCOMIS OMA, review and verify newly the instructions for investigating and reporting naval
initiated. MAFs by using the work center aviation hazards that are not reportable under the
workload report; if NALCOMIS IMA, NAMP. Even though OPNAVINST 3750.6 calls for
validation of current job status specific reports, you still have to follow reporting
procedures called for in the NAMP.
Compliance with the FOD prevention program
Other references you may use in relation to
Industrial Radiation Safety Program
maintenance department safety are as follows:
SPECIAL AUDITS.—In addition to scheduled
work center audits, QA conducts special audits to Navy Occupational Safety and Health Programs
evaluate specific maintenance tasks, processes, for Forces Afloat, OPNAVINST 5100.19, which
procedures, and programs. These audits provide a contains safety precautions to be followed while aboard
systematic, coordinated method of investigating ship.
known deficiencies, evaluating the quality of Standard Organization and Regulations of the U.
workmanship, and determining the adequacy of and S. Navy, OPNAVINST 3120.32, which contains the
adherence to technical publications and instructions. standards for organizing a ship/station/squadron’s

6-15
safety department and information on billet descriptions or occurrence within the activity. They are also
and responsibilities. responsible to review all HMRs, EI requests, QDRs,
and TPDRs to ensure they are accurate, clear, concise,
NAVAIROSH Requirements for the Shore
and comprehensive. The work center supervisor
Establishment, NAVAIR A1-NAOSH-SAF-000/
provides assistance to the QA representative with
P-5100-1, which contains safety precautions to be
information needed to complete the message request.
followed while ashore.
QA’s responsibilities to the maintenance The QA division also initiates and maintains a
department safety program are as follows: report log and assigns a report control number (RCN)
to each NAMDRP report. RCNs are assigned
Disseminate safety posters and literature. sequentially throughout the calendar year, regardless
Report all hazards, mishaps, and unsafe practices of the type of report.
in the department. The RCN is composed of 12 elements as follows:
Conduct safety meetings within the department,
at least monthly. Element (1) is the Service Designator code of the
originating activity. Refer to the OPNAVINST
Coordinate aspects of safety with the aviation 4790.2 for Service Designator codes.
safety officer.
Elements (2) through (6) are the Unit
Participate in the activity’s safety surveys and Identification Code (UIC) of the originating
stand downs. activity, followed by a dash (-).
When a report is required by OPNAVINST Elements (7) and (8) are a two-character
3750.6, the QA division collects and provides identification of the calendar year, followed by
maintenance and material data necessary for a dash (-).
preparation of required reports.
Elements (9) through (12) are the locally
Q29. What programs are managed by quality assigned "control numbers." These numbers are
assurance? sequential, beginning with 0001 each calendar
year.
Q30. What are the two categories of audits performed
by Q/A? The various reports required under the NAMDRP
Q31. Upon completion of an audit, the findings are are as follows:
forwarded to the AMO, with a copy going where? Hazardous Material Report (HMR)
Q32. How long are past audits maintained by Q/A? Engineering Investigation (EI) request
Q33. In addition to reporting naval aviation hazards Quality Deficiency Report (QDR)
in accordance with OPNAVINST 3750.6, you
still must follow reporting procedures called for Technical Publication Deficiency Report
in what manual? (TPDR)
Q34. With regard to maintenance department safety, Aircraft Discrepancy Report (ADR)
what does the Q/A division have a responsibility The aviation safety officer, with assistance from
to do at least monthly? QA, reviews all correspondence concerning aircraft,
ground, flight, flight-related, and explosive mishaps.
The Naval Aviation Maintenance
Discrepancy Reporting Program All hands have a responsibility to be alert for
(NAMDRP) safety-related defects or discrepancies, which is the
primary reason for submitting each report.
NAMDRP is the method for reporting hazardous
deficiencies in material, publications, substandard If a report meets the criteria for an HMR and
workmanship, and improper QA procedures. warrants an EI Request, a Category (CAT) I QDR, or
TPDR, is sent as a dual message report.
The QA division manages the program and assists
the various work centers in determining if one or more Exceptions to the NAMDRP and its reporting
of these reports are needed for a maintenance problem procedures are as follows:

6-16
Changes or corrections to the Naval Air Training Malfunction or failure of a component that, if not
and Operating Procedures Standardization (NATOPS) corrected, could result in death or injury to personnel,
manuals or tactical manuals are reported by using or damage to or loss of aircraft, equipment, or facilities.
procedures found in OPNAVINST 3710.7 and In case of a naval aircraft mishap, as defined in
NAVAIRINST 3710.10 using OPNAV 3710/6. OPNAVINST 3750.6, submit required reports
according to that instruction. The submission of reports
Deficiencies resulting from incorrect
required by OPNAVINST 3750.6 does not eliminate
preservation, packaging, marking and/or handling
any of the requirements for submission of reports
(when reported by supply activities) or deficiencies in
required by the NAMP.
shipment that are the result of overage, shortage, expired
shelf life, or misidentified material are reported A configuration deficiency discovered in
according to instructions found in NAVSUPINST aeronautical equipment (aircraft, SE, components, etc.)
4440.179. that constitutes a safety hazard.
Locally procured material found to be deficient An urgent action or assistance required and a
by the procuring activity is reported according to corrective action completed at an early date because of
instructions contained in NAVSUPINST 4440.189. an operational requirement.
Deficiencies in letter-type instructions and A system malfunction or failure may occur
notices are reported by letter to the sponsor. because of a part design, which might allow the part to
Discrepancies in OPNAVINST 4790.2 are reported by be installed improperly.
naval letter to Naval Aviation Maintenance Office A potential or experienced in-flight or
(NAMO) (Code 46), via the chain of command. on-the-ground loss of aircraft parts in which
Incorrect source, maintenance, and recover- maintenance or material factors are involved. Use the
ability (SM&R) codes are reported according to term things falling off aircraft (TFOA) when referring
NAVAIRINST 4423.11. to such incidents. TFOA includes incidents generally
categorized in other areas, such as a foreign object
Recommendations for improvements in
damaged engine, which sheds parts, or a helicopter rotor
procedures that do not result from incorrect information
blade pocket failure.
contained in publications are reported by letter to Naval
Air Technical Services Facility (NAVAIRTECH-
SERVFAC). ENGINEERING INVESTIGATION.—EIs
apply to all aircraft and weapons systems, their
Explosive incidents, dangerous defects, and subsystems, equipment, components, related SE,
malfunctions or failures involving explosive systems, special tools, fluids, and materials used in operating
launch devices, and armament weapons support the equipment. The three types of EIs are (1)
equipment are reported under OPNAVINST 8600.2 as disassembly and inspection, (2) material analysis, and
an Explosive Mishap Report (EMR) or a Conventional (3) engineering assistance.
Ordnance Deficiency Report (CODR). These reports
still fall under the NAMDRP for accounting and
monitoring purposes. Submit EI requests under one or more of the
following conditions:
A brief description of each of the programs of the
NAMDRP is contained in the following paragraphs. Safety is involved. This includes EI requests
prepared in conjunction with aircraft mishaps, and
HMRs when it is evident that an unsafe condition exists.
HAZARDOUS MATERIAL REPORT.—This Additional technical or engineering information
report provides a standard method for reporting is required to complete an aircraft mishap investigation.
material deficiencies that, if not corrected, could result
Aircraft readiness is seriously impaired due to
in death or injury to personnel, or damage to or loss of
poor material reliability (including SE).
aircraft, equipment, or facilities. Report such incidents
regardless of how or when the discrepant condition A component is rejected through the Joint Oil
was detected. Submit an HMR priority precedence Analysis Program (JOAP) after authorized repairs are
message within 24 hours of discovery under one or attempted and exhausted at the O and I levels of
more of the following conditions: maintenance.

6-17
When environmental issues force material or aircraft weapons system or item being reported. If the
process changes that conflict with existing publications CFA for the weapons systems or material cannot be
or TDs. determined, the action addressee is NAVAIR-
TECHSERVFAC. This report is a CAT I TPDR and
When directed by higher authority.
must be submitted within 24 hours of the discovered
Submit the EI request by routine precedence deficiency.
message within 5 working days after discovery of the
A CAT II TPDR is a simplified procedure for
deficiency unless combined with the HMR, in which
reporting technical publication deficiencies.
case the combined report is to follow HMR reporting
Publication deficiencies include technical errors,
criteria. The supporting supply department and the
wrong measurement values, incorrect use of support
CFA supply department are information addressees on
equipment, wrong sequence of adjustments, part
the EI message.
number errors or omissions, and microfilm
QUALITY DEFICIENCY REPORT.—This deficiencies, such as poor film quality.
report provides maintenance activities with a method
Technical publications include MRCs, checklists,
for reporting deficiencies in new or newly reworked
Work Unit Code (WUC) manuals, MIMs, illustrated
material. Unless the materials are under warranty,
parts breakdowns (IPBs), and other technical manuals.
failures must have occurred at zero operating time,
The TPDR program does not apply when deficiencies
during initial installation, operation, test, check,
in instructions or notices are reported. Submit
turnup, or first flight. It differs from the EI program in
improvement procedures that do not result from
that it reports on possible deficiencies in quality
incorrect information contained in the publication but
assurance during the manufacturing or rework
are recommendations by letter to NAVAIR-
process. The goal is to improve the quality of work
TECHSERVFAC.
done by naval aviation depots (NAVAVNDEPOTs),
contractors, and subcontractors returning reworked AIRCRAFT DISCREPANCY REPORT.—The
material to supply stock. ADR is a method for reporting defects discovered in
newly manufactured, modified, or reworked aircraft
There are two types of QDRs.
that require immediate attention to ensure acceptable
CAT I. A quality deficiency which will, or may, standards of quality in aircraft maintenance and
affect safety of personnel, impair the combat efficiency rework procedures. The cognizant defense plant
of an individual or organization, or jeopardize mission representative office, administrative contracting
accomplishment. office, or NAVAVNDEPOT will enclose sufficient
copies of the ADR form (Standard Form 368) with
CAT II. All quality deficiencies that are assessed
envelopes preaddressed, in each aircraft logbook for
to have significant and widespread material or human
delivery with the aircraft. Additionally, they ensure
resource impact and do not affect the conditions of a
that a copy of the previous reporting custodian’s work
CAT I.
request is furnished to the ferry pilot and functional
CAT I QDRs are reported by routine precedence wing. Naval Aviation Depot Operations Center
message within 1 working day after the discovery of (NAVAVNDEPOTOPSCEN) is the ADR screening
the deficiency unless combined with an HMR. A point on aircraft commercially reworked under the
combined HMR CAT I QDR follows HMR reporting procuring contract office.
guidelines.
An acceptance inspection is performed and a
CAT II QDRs are submitted on an SF 368 to the functional check flight flown as soon as possible after
CFA within 5 working days of the discovered the aircraft is delivered and prior to maintenance
deficiency. (other than required to complete the acceptance
inspection) or further flight. Only those discrepancies
TECHNICAL PUBLICATION DEFICIENCY noted by the ferry pilot or crew and those found during
REPORT.—This report applies when a technical the acceptance inspection and check flight are
publication deficiency is detected that, if not reported.
corrected, could result in death or injury to personnel,
or damage to or loss of aircraft, equipment, or In reporting the initial acceptance of an aircraft,
facilities. The action addressees for the message report use "Initial Acceptance Inspection of Aircraft" as the
is NAVAIRTECHSERVFAC and the CFA for the subject of the Standard Form 368. Submit this initial

6-18
report within 5 working days of the acceptance check The division of the individual originating the
flight. A supplemental report, if needed, must be report retains a copy of the SE Misuse/Abuse report.
submitted not later than 30 days after completion of The report is sent to the organization that has
the check flight. Individual Material Readiness List (IMRL) reporting
responsibility for the SE. A copy of the report is sent
Support Equipment Misuse/Abuse to the CO of the command to which the offender is
attached and/or the CO of the command that held
SE Misuse/Abuse forms can be submitted by custody of the item where the misuse or abuse occurred
anyone witnessing misuse or abuse (fig. 6-2). for appropriate action. As a minimum, the QA division

Figure 6-2.—SE Misuse/Abuse Form (OPNAV 4790/108).

6-19
of the command receiving the report conducts an QUALITY ASSURANCE
investigation. Also, QA performs an analysis to MONITORING
provide appropriate recommendations for corrective
action. The QA division monitoring includes the
continuous collection and distribution to cognizant
Aviation Gas Free Engineering personnel of all messages, letters, instructions, and
other information concerning the programs or
(AVGFE)
processes being monitored.
The purpose of the AVGFE program is to ensure The QA division does not manage any of these
a safe environment when aeronautical fuel systems are programs and processes. However, they are
worked on. NAVAIR 01-1A-35 outlines requirements responsible for overall surveillance of these programs
for the AVGFE program. Technicians certified under and processes to identify problems and to verify
the AVGFE program must be qualified QARs or compliance. Audits are one of the tools used in
CDQARs and have graduated from an approved monitoring these programs and processes. QA gives
AVGFE program course. O-level activities normally continuous attention to program performance. They
prepare checklists that describe the specific functions
provide their own AVGFE technicians; however,
needed to effectively monitor each assigned program
those activities with less than three gas free and process. These checklists are the same for O- and
engineering (GFE) requirements in a 6-month period I-level maintenance with a few exceptions.
may request the services of the supporting I-level
AVGFE technician. QA monitors the programs and processes listed
below:
Q35. What is the Naval Aviation Maintenance
FOD
Discrepancy Reporting Program?
Fuel surveillance
Q36. What division assists the aviation safety officer
in reviewing all correspondence about aircraft, Joint Oil Analysis Program (JOAP)
ground, flight, or flight-related mishaps and Aviators’ breathing oxygen (ABO)
explosive mishaps?
Hydraulic contamination control
Q37. Who has the responsibility to be alert for safety
SE Operator Training/Licensing and SE Planned
related defects or discrepancies? Maintenance Systems (PMS)
Q38. OPNAVINST 3710.7 contains procedures to SE testing
report discrepancies in what type of publication?
Calibration
Q39. If a system failure or malfunction occurs because
of a part design, which could allow improper Nondestructive inspection (NDI)
installation of the part, an HMR priority Tool Control Program
precedence message must be submitted within Corrosion prevention and control
what time frame?
Plane captain qualification
Q40. What term should be used in conjunction with an
Tire and Wheel Maintenance Safety
HMR when an aircraft part is lost in flight?
Individual Component Repair List (ICRL)
Q41. What are the three types of engineering
investigations (Els)? Egress system checkout
Q42. What type of report provides activities with a Explosives Handling Personnel Qualification
means of reporting deficiencies in new or newly and Certification Program
reworked material? Electrostatic Discharge (ESD) Control/
Q33. How long does the accepting activity have to Prevention Program
submit a supplemental ADR? Miniature/microminiature (2M)
Q44. Where is the original misuse/abuse report sent? Laser hazard control

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Aeronautical Equipment Welder Certification MIS will be discarded. Refer to the NAMP for further
and Recertification information on NAMPSOP.
Vibration analysis SUMMARY
Aircraft battle damage repair (ABDR)
Enhanced Comprehensive Asset Management Throughout this chapter, we have discussed the
System (ECAMS) numerous responsibilities of the work center
supervisor as well as many of the programs and
Under the NAMP, local MIs must show the responsibilities of the QA division. This is by no
responsibilities of personnel concerning these means all inclusive. To ensure mission accomplish-
programs and processes. The QA division should use ment, both positions require dedication, diligence,
the MI with the checklists to monitor each of these and, most of all, experience. So when you become the
programs and processes. These programs and work center supervisor, remember you are ultimately
processes are covered in detail in the NAMP. Some of responsible for the work performed by your personnel,
these programs and processes that are included in the so take the initiative to stay involved in every aspect.
NAMPSOP do not require additional instructions When you become a quality assurance representative,
or maintenance instructions (MIs). As new remember that you are there to assist, train, and
instructions are included in the NAMPSOP, existing monitor, not just to be a policeman.

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ANSWERS TO REVIEW QUESTIONS

A1. Seeing that the job is done correctly, safely, and efficiently with no waste of
materials.
A2. Operate with maximum efficiency and safety, operate with minimum waste
an expense, and operate free from interruption and difficulty.
A3. Update equipment as old models become obsolete.
A4. Through an effective and continuing training program.
A5 Operating with minimum expense and waste.
A6. A means of relieving the work center supervisor of the details of a task.
A7. Scheduled maintenance is maintenance required by hours, calender periods
(days or weeks), and starts. Unscheduled maintenance is maintenance that
occurs on aircraft other than scheduled.
A8. The daily maintenance meeting.
A9. Determine deficiencies, analyze discrepancy trends, prescribe inspection
procedures, and determine the quality of maintenance.
A10. Eliminating maintenance failures before they happen.
A11. Prevention, knowledge, and special skills.
Al2. A periodic or special evaluation of details, plans, policies, procedures,
products, directives, and records.
A13. The success or failure in achieving high standards of quality.
A14. At the time the task is assigned.
A15. Quarterly.
A16 To ensure the purpose and objective of the check flight are clearly
understood.
A17. Quality assurance division.
A18. The size of the unit and the number of work shifts.
A19. Quality assurance representatives.
A20. Normally, an E-6 or above is assigned as a QAR.
A21. 90 days.
A22. Never.
A23. The officer in charge.
A24. A Q/A stamp.
A25. Local commands make the decision and annotate the master and work center
MRC decks.
A26. Receiving or screening inspection, in-process inspection, and final
inspection.
A27. Functional check flights.
A28. When the discrepancy involves safety of flight.

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A29. a. QA audits.
b. CTPL.
c. Department/division safety.
d. NAMDRP.
e. SE misuse/abuse.
f. Aviation gas free engineering (AVGFE).
A30. Work center audits and special audits.
A31. The cognizant division.
A32. One year.
A33. NAMP, OPNAVINST 4790.2.
A34. Conduct maintenance department safety meetings.
A35. The NAMDRP is a method for reporting hazardous deficiencies in material,
publications, substandard workmanship, and improper Q/A procedures.
A36 Quality assurance division.
A37. All Hands.
A38. Naval Air Training and Operating Procedures Standardization (NATOPS)
manuals.
A39. Within 24 hours of discovery.
A40. TFOA (Things falling off aircraft).
A41. Disassembly and inspection, material analysis, and engineering assistance.
A42. Quality deficiency report (QDR).
A43. Within 30 days after completion of the check flight.
A44. The report is forwarded to the organization that has IMRL reporting
responsibility for the item abused.

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