Chapter 11 - Quality Assurance
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11-1 Chapter 11 - Quality Assurance
TABLE OF CONTENTS
11.1 Quality Assurance (QA) ................................... 11-2 Sec Subject Page 11.2 Concepts of Quality Assurance ............................ 11-2 11.3 Responsibility for Quality in Maintenance ................ 11-4 11.4 Quality Assurance Responsibilities ....................... 11-4 11.5 Quality Assurance Inspectors (QAIs) ...................... 11-9 11.6 Collateral Duty Quality Assurance Inspectors (CDQAIs) ... 11-11 11.7 Collateral Duty Inspectors (CDIs) ....................... 11-11 11.8 Quality Assurance Programs .............................. 11-12 11.9 Quality Assurance Program Management .................... 11-13 11.10 ALRE Discrepancy Reporting Program ...................... 11-21 11.11 ALRE Hazardous Material Report (ALRE HMR) ............... 11-30 11.12 ALRE Engineering Investigation (ALRE EI) ................ 11-34 11.13 ALRE Product Quality Deficiency Report (ALRE PQDR) ...... 11-35 11.14 ALRE Technical Publication Deficiency Report (ALRE TPDR) 11-39 11.15 ALRE Discrepancy Report Preparation ..................... 11-41 11.16 Other Required Reports .................................. 11-49 11.17 Address Indicator Group ONE THREE EIGHT EIGHT FIVE ...... 11-50
TABLE OF FIGURES
11-1 ALRE Quality Assurance Organization ..................... 11-52 Fig Subject Page 11-2 Sample Maintenance Instruction .......................... 11-53 11-3 ALRE PQDR Process Flow .................................. 11-54 11-4 Sample ALRE Hazardous Material Report Message ........... 11-55 11-5 Sample ALRE Engineering Investigation Request Message ... 11-56 11-6 Sample ALRE Engineering Investigation Request Message (Environmental Impact) .................................. 11-57 11-7 Sample ALRE Hazardous Material Report and Engineering Investigation Request Message ........................... 11-58 11-8 Sample ALRE CAT I Product Quality Deficiency Report Message ................................................ 11-59 11-9 Sample ALRE CAT II Product Quality Deficiency Report Message ................................................ 11-60 11-10 Sample ALRE CAT I Technical Publications Deficiency Report Message ................................................ 11-61 11-11 ALRE Discrepancy Reports Matrix ......................... 11-62 11-12 ALRE Fleet Support Team Response Matrix ................. 11-63 11-13 ALRE EI, ALRE HMR, ALRE PQDR Message Template ........... 11-64
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11-2 Chapter 11
Quality Assurance
11.1 Quality Assurance (QA)
11.1.1 QA is a planned and systematic pattern of actions necessary to provide confidence that an item or product conforms to established technical requirements.
11.1.2 The QA W/C is organized with a relatively small group of highly skilled personnel. These permanently assigned personnel, under the ALRE maintenance officer, are responsible for conducting and managing the QA program of the division. The maintenance personnel assigned to QA are known as QAIs. Additionally, personnel assigned to other W/Cs may be designated to perform certain inspection functions. Figure 11-1 depicts the standard ALRE QA W/C organization.
11.2 Concepts of Quality Assurance
11.2.1 The QA concept is fundamentally that of the prevention of the occurrence of defects. The concept embraces all events from the start of the maintenance operation to its completion and is the responsibility of all personnel. The achievement of QA depends on prevention, knowledge, and special skills. These factors are described as follows:
a. Prevention relies on the principle that it is necessary to preclude maintenance failure. This principle extends to safety of personnel, maintenance of equipment, and virtually every aspect of the total maintenance effort. Prevention is concerned with regulating events rather than being regulated by them.
b. Knowledge is derived from factual information. Data collection and analysis are a means of acquiring this knowledge.
c. Special skills, not normally possessed by production personnel, are required of a staff of trained personnel for the analysis of data and supervision of the QA program.
11.2.2 The terms inspection and audit, as used in this instruction have separate and distinct meanings and should be used accordingly. The following definitions are provided to clarify the conceptual differences in these terms:
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11-3 a. Inspection is the examination and testing of supplies (including raw materials, documents, data, components, and assemblies) and services to determine whether they conform to technical requirements.
b. Audit, as it applies to the QA program, is a periodic or special evaluation of details, plans, policies, procedures, products, directives, and records.
11.2.3 The QA program provides a systematic and efficient method for gathering, analyzing, and maintaining information on product quality and on the source and nature of defects and their impact on the current operation. It permits decisions to be based on facts rather than intuition or memory. It provides comparative data that will be useful long after the details of the particular time or events have passed. Its objective is to readily pinpoint problem areas in which management can:
a. Improve the quality, uniformity, safety, and reliability of the total maintenance effort.
b. Improve the work environment, tools, and equipment used in the maintenance effort.
c. Eliminate unnecessary man-hour and dollar expenditures.
d. Improve training, work habits, and procedures of maintenance personnel.
e. Increase the accuracy and value of reports and correspondence originated by maintenance personnel.
f. More effectively disseminate pertinent technical information.
g. Establish realistic material and equipment requirements in support of the maintenance effort.
h. Support the FOD prevention and other special programs.
11.2.4 Teamwork must be achieved before benefits can be obtained from a QA program. Individuals in the organization must use critical judgment in the course of their daily work. Judgment plays a vital part in the quality of the work performed. QA techniques supply each person, from the worker to the commanding
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11-4 officer, with information on actual quality standards, goals, and achievements. The resultant recorded knowledge can encourage the best efforts of all personnel. 11.3 Responsibility for Quality in Maintenance 11.3.1 The commanding officer is ultimately responsible for the inspection and quality of material under his or her COG. Command policy and emphasis will establish high standards of quality in a maintenance organization.
11.3.2 Attaining quality in maintenance and the prevention of maintenance errors is an all hands task that can only be accomplished through positive leadership, proper organization, and a complete understanding of responsibilities by each individual in the division. The QA program requirements, as well as QA functions and responsibilities stipulated in this instruction, provide a sound basis for conducting an effective ALRE QA program.
11.3.3 QA is a staff function, which requires both authority and assumption of responsibility. Direct liaison between QA and the W/C is a necessity and must be energetically exercised. Although the QA supervisor is responsible to the ALRE maintenance officer for the overall quality of maintenance within the division, W/C supervisors are responsible for ensuring that required inspections are conducted and that quality workmanship is attained. The foremost responsibility of the ALRE QA program is the assurance of proper maintenance actions.
11.3.4 The QA supervisor shall be designated in writing by the commanding officer. 11.4 Quality Assurance Responsibilities 11.4.1 Specific program responsibilities assigned to the QA supervisor are to:
a. Maintain the central TPL for the division, including TDs; control classified technical publications for the division and ensure that each W/C receives all publications that are applicable and that they are kept current and complete.
b. Establish QAI qualifications and requirements for QAIs, CDQAIs and CDIs; review the qualifications of personnel nominated for these positions, and endorse nominations to the commanding
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11-5 officer and air officer via the chain of command. A current list of all QAIs and CDQAIs and CDIs will be issued to all W/Cs and include the type of equipment each may inspect.
c. Recheck qualifications of CDIs by monitoring them at a minimum quarterly during scheduled or unscheduled maintenance tasks. Documentation of monitoring must be retained for a period of 2 years within the QA branch.
d. Ensure all work guides, check-off lists, check sheets, MRCs, etc., used to define and control maintenance, are complete and current prior to issuing to crews and individuals. Verify ships equipment file MIP pages for ALRE W/C are accurate and by NAVAIRWARCENACDIV equipment MAPL and TYCOM directives. Recommendations for additional MIP and MRC coverage’s for non- NAVAIRWARCENACDIV MIP's shall be submitted to TYCOM and NAVAIRWARCENACDIV using the OPNAVINST 4790.4E and NAVSEAINST 4790.8B guidelines for consideration and possible inclusion into NAVAIRWARCENACDIV ALRE MIPs.
e. QA shall monitor and review all requests for departures from specifications, REIs, HMRs, TPDRs, PQDRs, EI requests, PMS fleet feedback reports, fleet COSAL feedback reports and MSC problem worksheets, to ensure that they are accurate, clear, concise, and comprehensive prior to submission.
f. Monitor use of PME to ensure compliance with calibration intervals and safety instructions.
g. Perform inspection of all maintenance equipment and facilities to ensure compliance with fire and safety regulations and existence of satisfactory environmental conditions. Additionally, monitor proper training, qualification, and licensing of equipment operators and drivers.
h. Provide a continuous training program in techniques and procedures pertaining to the conduct of QA inspections. When directed or required, provide technical task forces to study trouble areas and submit recommendations for corrective action.
i. Use information from the ALRE MAF in developing discrepancy trends to identify failure areas or other maintenance problems.
j. Review periodic inspection records, and note recurring discrepancies requiring special action.
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11-6 k. Maintain liaison with TYCOMs, NAVAIRWARCENACDIV Lakehurst, carrier and CAFSU, and other available field technical services. Establish and maintain liaison with other maintenance and rework activities to obtain information on ways for improving maintenance techniques, quality of workmanship, and QA procedures.
l. Ensure personnel performing QA functions use inspection equipment such as mirrors, magnifying glasses, comparators, tensiometers, pressure gauges, etc., as required. Ensure that maintenance personnel have such equipment available, in operating condition and calibrated.
m. Ensure that established standard procedures are observed for conducting PMS actions.
n. Ensure that the configuration of equipment and components is such that all essential modifications have been incorporated. This requires checking equipment records with the current service bulletin and service change zero bulletin, SEF, which provides required configuration information.
o. Ensure an inspection is conducted on all equipment received for use, returned for repair, or held awaiting repair to verify its material condition, identification, packaging, preservation, and configuration are satisfactory; and when applicable, that shelf- life limits are not exceeded.
p. Ensure that prior to the installation of an ALRE component, part and contract numbers are validated against the DPL database to ensure the installation of non-discrepant parts. Ensure contractor, VRT personnel, and all repair activities are briefed on and utilize the ALRE DPL Program. Ensure maintenance documentation (e.g., OPNAV 4790/160) procedures support the program objective.
NOTE Ensure contract numbers of parts installed are annotated on the OPNAV 4790/160 when it is completed. The ALRE maintenance officer and maintenance chief shall initial contract number block of OPNAV 4790/160 for all UNKNOWN contract number entries.
q. Review all incoming technical publications and directives to determine their applicability to the division.
r. Prepare or assist in the preparation of maintenance instructions (MIs) to ensure that QA requirements are included.
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11-7 s. Develop and administer appropriate tests for QA nominees. Ensure currency and integrity of all testing materials.
t. The QA supervisor is assigned the overall responsibility for the division safety program as outlined in paragraph 11.9.3.1.
11.4.2 To comply with assigned responsibilities, QA will perform the inspections identified in the following paragraphs:
11.4.2.1 Mandatory QA inspections as specified in the MRCs, TDs, and MIs.
11.4.2.2 Those inspections required to be conducted by QA personnel during and upon the completion of a maintenance action.
11.4.2.3 ALRE QA cards are provided for certain preventive and corrective maintenance tasks that, if improperly performed, could cause equipment failure or jeopardize the safety of personnel. They contain guidelines for conducting QA inspections. QAI level inspections are performed during and after task performance, using the following criteria:
a. If the proper performance of a task cannot be determined after the task is completed, a QA inspection shall be required while the task is being performed. Work shall not proceed past the inspection point indicated on the task MRC until the QA inspection has been completed. For these inspections, the notation QA REQUIRED appears on the MRC containing the task.
b. If the proper performance of a task can be determined by a visual inspection after the task is completed, a QA inspection is required after the task completion.
11.4.2.3.1 QA cards shall be maintained and used by QA personnel. Upon receipt of a new QA card, the enclosed feedback form shall be filled out and forwarded to NAVAIRWARCENACDIV Lakehurst to acknowledge receipt of the card(s). Additionally, fleet units shall send a feedback report, indicating receipt, to their respective TYCOM.
11.4.2.3.2 Recommended changes and corrections shall be reported by ALRE category (CAT) I or CAT II TPDR under paragraphs 11.10.5.2 and 11.14.1.3.
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11-8 11.4.2.3.3 NAVAIRWARCENACDIV Lakehurst Technical Data Branch (Code 6.8.5.1) will manage the ALRE QA MRC program and issue cards annually and as they are updated.
11.4.3 Procedures shall be established within each W/C to ensure that the QA inspection requirements are complied with during all maintenance evolutions. In developing procedures, inspections normally fall into one of the following categories:
a. Receiving or screening inspections apply to material, components, parts, equipment, logs and records, and documents. These inspections are normally conducted by CDIs to determine the condition of material, proper identification, MRs, disposition, and correctness of accompanying records, documents, etc.
b. In-process inspections are specific QA functions that are required during the performance of MRs and actions in cases where satisfactory task performance cannot be determined after the task has been completed. These inspections, when designated, include witnessing application of torque, functional testing, adjusting, assembly, servicing, installing, etc.
c. Final inspections are specific QA functions performed following the completion of a task or series of tasks.
d. In-process and final inspections are normally conducted by CDIs, however, QAIs shall conduct in-process and final inspections of all tasks on all which require the equipment to have a functional check. Additionally, QAIs will perform inspections of any other tasks as determined by the ALRE maintenance officer. It must be emphasized that only those personnel designated as QAI and CDQAIs and CDIs are authorized to sign as inspector for a QA inspection requirement. While not all QA inspections conducted during the various phases of maintenance require a signature, all specified QA inspections are conducted, witnessed or verified by designated QA personnel.
11.4.4 The INSPECTED BY block on all MAFs are signed by QA inspectors. Only the QA inspector(s) actually inspecting the work for proper standards will sign inspection documents.
11.4.5 Billet descriptions shall be prepared for QA personnel to ensure that all QA functions and responsibilities are assigned. Billet descriptions shall assign specific programs that are managed and monitored by each QA.
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11-9 11.5 Quality Assurance Inspectors (QAIs) 11.5.1 QAIs perform the following functions:
a. Review incoming technical publications and directives to determine their application to the division.
b. Prepare or assist in the preparation of MIs to ensure QA objectives and requirements are defined.
c. Participate as members of technical task forces to investigate trouble areas and provide recommendations for corrective action.
d. Verify the certification of maintenance personnel; i.e., welder, tow tractor, or forklift.
e. Review qualifications of personnel nominated to become CDIs (or CDQAIs) and provide recommendations as appropriate.
f. Assist in the preparation of ALRE discrepancy reports (see paragraph 11.10.3), PMS feedback reports, and change recommendations to technical manuals. Review all report entries for adequacy and correctness prior to distribution.
g. Provide technical assistance to CDIs and maintenance personnel who are required to make decisions concerning QA.
h. Review ALRE discrepancy reports, PMS feedback reports, and change recommendations to technical manuals to determine discrepancy trends and specific problem areas relative to their areas of responsibility.
i. Conduct in-process and final inspections of tasks that require certification by QAIs and CDQAIs (e.g., functional check of A/G). Ensure that each QA inspection includes an examination of the work area for sources of potential FOD.
j. Monitor calibration status of equipment and tools in W/C.
k. Develop discrepancy trends and such charts and graphs that are necessary to depict quality performance.
l. Maintain liaison with TYCOM, NAVAIRWARCENACDIV Lakehurst, CAFSU and other field technical services. Establish and maintain
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11-10 liaison with other maintenance and rework activities to obtain information for improving the maintenance techniques, quality of workmanship, and QA procedures.
m. Develop checklists for auditing W/C, specific maintenance programs, and processes that require monitoring by QA.
NOTE No QAI may inspect his or her own work and sign as an inspector.
11.5.2 All personnel being considered for selection as QAIs should meet the following qualifications:
a. Be senior in grade and experience, at pay grade E-6 or above, with a well-rounded maintenance background. See paragraph 11.6.2 for additional information.
b. Have fully developed skills and experience and be technically qualified in fields under their COG.
c. Be able to research, read and interpret; drawings, technical manuals and directives, configuration records and APLs.
d. Be able to write with clarity and technical accuracy.
e. Be stable and excellent in performance.
f. Be motivated and have personal desire to acquire greater knowledge of their technical specialty.
g. Be observant, alert, and inquisitive.
h. Ability to work with others.
i. Successfully qualify by passing a test administered by the QA branch.
11.5.3 The QA supervisor shall ensure that personnel assigned to perform QA functions receive continuous training in inspecting, testing, and quality control methods specifically applicable to their area of assignment. They will also ensure that QAIs receive cross training to perform those QA functions not in their assigned area. This training should include local training courses, OJT, rotation of assignments, and PQS. QAIs shall have successfully completed the CNATTU (Norfolk and San Diego) ALRE QA Administration course (C-670-2017).
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11-11 11.5.4 QAIs shall be designated in writing by the commanding officer. The OPNAV 4790/162 ALRE QAI Recommendation and a maintenance instruction (figure 11-2) shall be used for this purpose. 11.6 Collateral Duty Quality Assurance Inspectors (CDQAIs) 11.6.1 When shortages of skills or manpower preclude the assignment of a QAI, a qualified individual within an appropriate W/C may be designated a CDQAI. CDQAIs must meet the same criteria as QAIs, including designation in writing by the commanding officer, and will have the same authority as QAIs, but remain part of the W/C organization. CDQAIs are primarily assigned to meet duty and or in-port workload requirements, and are not assigned specific responsibility for programs monitored and managed by QA. CDQAIs shall perform QAI-level inspections only when tasked to do so by the ALRE maintenance officer, M/C supervisor or QA supervisor. Tasking shall be limited to specific maintenance events.
NOTE No CDQAI may inspect his or her own work and sign as an inspector. No CDQAI may perform in a QA capacity and also sign as the W/C supervisor on the same job.
11.6.2 Should it become necessary to assign an individual below the grade of E-6 as a CDQAI to cover given skills or manpower shortfall a letter shall be submitted to the respective TYCOM requesting approval. Comprehensive information surrounding the shortfall and complete justification must be provided. Assignment of an individual below the grade of E-6 as a CDQAI shall not normally exceed a period of 90 days, however, TYCOMs may, at their discretion, approve greater time periods. These occurrences might be necessary to coincide with availabilities that exceed 90 days. The authorized period will commence on the date of the official correspondence response from the TYCOM, unless otherwise stated in said correspondence. In no case shall an individual below the grade of E-5 be appointed as a CDQAI. 11.7 Collateral Duty Inspectors (CDIs) 11.7.1 CDIs assigned to the W/Cs are to inspect all work and comply with the QA inspections required during all maintenance actions (with the exception of pre and post operation inspections) performed by their respective W/Cs. They will be responsible to the QA supervisor when performing these functions. CDIs will check
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11-12 all work in progress, and will be familiar with the provisions and responsibilities in the various programs managed and monitored by QA.
NOTE No CDI may inspect his or her own work and sign as an inspector. No CDI may perform in a QA capacity and also sign as the W/C supervisor on the same job.
11.7.2 QA will establish minimum qualifications for personnel selected for CDI. W/C supervisors are responsible for ensuring that sufficient qualified personnel are nominated for CDI to comply with QA inspections required during all maintenance actions. Due to the critical role of the CDI, it is imperative that branch officers, group and W/C supervisors carefully screen all candidates for these assignments. CDIs will be required to be PQS qualified and to demonstrate their knowledge and ability on the particular type equipment by successfully passing a test that is locally prepared and administered by QA.
11.7.3 CDIs shall be designated in writing by the air officer. The OPNAV 4790/162 and a maintenance instruction (figure 11-2) shall be used for this purpose. 11.8 Quality Assurance Programs 11.8.1 The QA management program includes continuous collection and distribution to cognizant personnel of all messages, letters, instructions, and other information concerning programs being managed. Programs assigned to QA for management include, but are not limited to:
a. QA audit Program.
b. TPL.
c. Safety Programs including electrical safety.
d. FOD.
e. Tag-Out Program.
f. Calibration Program.
g. TCP (including electrical tool issue).
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11-13 h. QA Standards and Qualification Program.
i. Configuration Validation Program.
j. Government Support Equipment Licensing Program.
k. Maintenance logs.
l. Monthly maintenance plan (MMP).
11.8.2 MIs shall be prepared to carry out internal procedures and methods of administering specific programs and processes assigned for management. MIs are used to issue technical information and local policy of a sustaining nature. They direct efforts of QAIs, CDQAIs, CDIs, and other maintenance personnel. MIs shall be prepared in standard Navy directives format as prescribed in OPNAVINST 5215.17. A sample of the format is in figure 11-2.
11.8.3 QA shall prepare an audit MI, which describes the specific functions, required to monitor each of the QA managed programs. Checklists used to monitor and audit W/Cs and maintenance programs shall be included as part of the MI governing that program. The QA supervisor is responsible for ensuring that all appropriate QA elements are included in these instructions, including the applicable audit checklist. Audits are one of the tools used in program; however, continuous attention is required to effectively manage program performance.
11.8.4 The originals of all MIs will be maintained in the central technical publication library (CTPL). A numbering system shall be established to provide file control (e.g., 1-01, 2-01). A master MI list shall be prepared and maintained by the central TPL. It shall include the MI number, title, effective date, and latest change date (if any). A copy of this list shall be held by each W/C, and updated every 90 days.
11.8.5 MIs shall be reviewed for currency and validity on the MI anniversary date. The review shall be conducted jointly by the cognizant W/C and QA. 11.9 Quality Assurance Program Management 11.9.1 QA Audits. QA audits are essential elements of an effective QA program. Audits provide an evaluation of performance and program compliance throughout the division. They serve as an orderly method of identifying, investigating, and correcting
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11-14 deficiencies on a scheduled and unscheduled basis. Audits are also used to monitor those specific maintenance programs and processes assigned to QA for management.
11.9.1.1 Audits fall into the following three categories:
a. W/C audit.
b. Special audit.
c. TYCOM audit.
11.9.1.2 W/C audits are conducted quarterly to evaluate the overall quality performance of each W/C. As a minimum, the following applicable items are evaluated:
a. Personnel and skills.
b. Technical publications.
c. MIs.
d. Adherence to directives, procedures, and inspections.
e. Adequacy and availability of process, test, and inspection procedures.
f. Availability and calibration status of PME.
g. Proper use of PME.
h. Certification of personnel performing special processes such as welding, etc.
i. Handling, packaging, protection, and storage of material.
j. Cleanliness and condition of spaces.
k. Compliance with fire, safety and electrical safety regulations.
l. Configuration of components, equipment, and accuracy of associated logs and records.
m. Equipment logs and records.
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11-15 n. Material condition and corrosion control of equipment.
o. FOD Prevention Program compliance.
p. TCP compliance.
q. Tag Out Program compliance.
11.9.1.3 Special audits are conducted to evaluate specific maintenance tasks, processes, procedures, and programs. These audits provide a systematic, coordinated method of investigating known deficiencies, evaluating the quality of workmanship, and determining the adequacy of and adherence to applicable technical publications and instructions. The ALRE maintenance officer or QA supervisor on an as required basis normally directs conducting special audits.
11.9.1.4 Audit forms for each W/C, with appropriate checklists, are developed by QA.
11.9.1.5 Upon completion of an audit, the findings are reviewed with the W/C involved and reports of the findings, with recommendations when required, are submitted to the ALRE maintenance officer.
11.9.1.6 Adequate follow up procedures shall be established to ensure that discrepancies found during a QA audit are resolved and documented. Attention from all levels within the V-2 division organization is essential.
11.9.1.7 TYCOM AMMTs will visit each ship at least once during the work-up cycle and will audit the ALRE QA program prior to deployment.
11.9.2 TPL. The TPL serves two important functions. It provides a central source of up-to-date information for the use of all personnel in the performance of their work, and it is an excellent source of reference information to facilitate personnel training and individual improvement. To perform these functions properly, the TPL must contain at least one paper copy of all publications affecting the assigned equipment.
11.9.2.1 Management of the TPL is a function of QA. This function includes the determination of technical manuals, IRACs, RACs, repair procedures, TDs, etc., required to support the division, receipt and distribution control of these manuals, as well as the
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11-16 responsibility for ensuring manuals are updated throughout the division. Detailed information for establishing and operating a TPL are contained in NAVAIR (NA) 00-25-100 (NOTAL).
11.9.2.2 Each activity that has established a TPL shall designate a CTPL. Personnel assigned as the CTPL must receive indoctrination and continuous training in library operation and successfully complete the Aeronautical Technical Publications Librarian Course (D-555-0007) under NA 00-25-100 (NOTAL), and be designated in writing by the air officer.
11.9.2.3 In order to ensure the most up-to-date technical publications are being used during maintenance procedures, technical publication work packages shall be printed from the Joint Knowledge Caching Server (JKCS) server or Naval Air Technical Data and Engineering Service Command (NATEC) Web site (https://mynatec.navair.navy.mil) and are the only authorized source for reference when performing corrective maintenance. Electronic copies from any other source are not permitted.
NOTE
Divisional personnel may use copies of technical manuals from others sources for training only. Only work packages issued by QA shall be used to perform maintenance.
The technical publication checkout process shall be controlled by the QA branch. Work packages from technical manuals must be verified, printed, stamped, and issued to the W/C CDI by the QA branch. The process is as follows:
a. Once a corrective action has been identified and an OPNAV 4790/180 is generated, the W/C CDI will notify QA and request copy or copies of the appropriate work package(s) needed to perform the MR(s).
b. The CTPL and QA will access the JKCS server or NATEC Web site and download the current publication that contains the needed work package(s) to be issued.
NOTE
If the work package includes drawings that do not fit on stock 8.5” x 11” paper, the affected pages must be produced at the nearest print shop facility.
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11-17 c. After printing the applicable work package(s), the CTPL and QA will issue the work package(s) by stamping each page with a locally prepared stamp containing W/C, number of pages, current date and time, expiration date of material, and signature block for the CTPL and QA. The CTPL will also make a log entry with the same information. The work package(s) can now be used by the W/C to perform the maintenance action.
NOTE
Work packages issued are valid for 7 days. If MR exceeds 7 days, the work package shall be returned to QA to be validated and reissued.
d. Once the maintenance action is complete, the CDI will return the issued work package(s) to the QA branch. The CTPL and QA will verify that all pages of the work package(s) have been returned; enter the date and time returned in the log, and destroy the documents per local guidance. In addition, the CTPL and QA will initial block 35 of the ALRE MAF that the work package(s) have been returned and all pages have been accounted for.
11.9.2.4 Each W/C that contains a dispersed library shall assign a dispersed technical publication custodian (DTPC) who will be responsible for the storage, update and user availability of the publications issued to them. The training of DTPCs is a responsibility of the CTPL and the W/C supervisor and division officer. Each DTPC shall be recommended jointly by the appropriate W/C supervisor and division officer and designated in writing by the ALRE maintenance officer.
11.9.2.5 For continuity, effective operation and adequate training, personnel assigned to the CTPL should be retained in the billet a minimum of 1 year. Additionally, personnel assigned as a DTPC should be retained for a minimum of 6 months.
11.9.2.6 When an activity is unable to locate the applicable COMNAVAIRSYSCOM approved technical publication, or concludes that such a publication does not exist, that activity shall send an assistance request letter, via the chain of command, to: Commanding Officer, Naval Air Technical Data and Engineering Service Command (NATEC), Code 685.3, San Diego, CA 92135-7031, with a copy to PEO(T) (PMA 251) and NAVAIRWARCENACDIV Lakehurst (Code 6.8.5.1). In addition to a brief explanation of the problem, previous resolution attempts, a point of contact, and the following information shall be included, if applicable:
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11-18 a. Item nomenclature.
b. P/N.
c. NSN.
d. Applicable ALRE system application.
e. Serial number.
f. Manufacturer's name or the contractor and government entity (CAGE) code.
g. Identification of the next higher assembly (for example, nomenclature, P/N, NSN).
11.9.2.7 NATEC shall respond directly to the originator, with copies to other involved commands, within 30 calendar days of receiving the request for assistance.
11.9.2.8 TDs provide information on the proper administration, technical and or operational use of equipment. TDs also provide technical alteration specifications to install, remove, reconfigure, and repair equipment. The applicable zero dash bulletins provide a complete numerical index and current status of the TDs.
11.9.2.9 Detailed information concerning the ordering of technical publications and TDs is contained in NA 00-25-100 (NOTAL). Requisitions are submitted to the appropriate ICP listed in NAVSUP P-2008, Navy Stock List of Publications and Forms (NOTAL).
11.9.3 Division Safety Program. This program seeks to identify and eliminate hazards wherever and whenever they are found. Effectiveness and safety result when properly trained personnel use properly designed equipment per established procedures under competent and persistent supervision. It requires active daily participation by all personnel to obtain desired results. Any safety program must address the aviation, shipboard, and industrial aspects of safety.
The QA supervisor is assigned the overall responsibility for the V- 2 division safety program. The intent of this program is not to conflict with any portion of the ship's overall safety program but to assist in the coordination of the total safety effort. The following responsibilities are included:
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11-19 a. Disseminating appropriate safety posters and literature.
b. Reporting any hazards, mishaps, and unsafe practices in the division.
c. Conducting training and safety meetings within the W/Cs.
d. Coordinating with the ship's safety officer.
e. Participating in the ship's safety surveys and stand-downs.
11.9.4 FOD Program. QA will ensure that:
a. There is compliance with all instructions pertaining to FOD prevention issued by the FOD prevention officer.
b. All W/Cs have instituted procedures that comply with applicable instructions and the FOD prevention and safety relationship is adequately addressed. Evaluation of FOD prevention measures shall be included in all special and planned W/C audits.
c. Maintenance methods and procedures support the FOD prevention program.
d. The ship's FOD prevention officer, the aircraft handling officer is made aware of FOD related problems.
e. Contractor and field maintenance teams are briefed regarding the command's FOD prevention program requirements and that discrepancies are to be reported to the FOD prevention officer.
11.9.5 Tag-out Program. QA will ensure that:
a. Tag-out procedures are verified under current directives.
b. All W/Cs have instituted procedures that comply with OPNAVINST 3120.32C and other applicable instructions are adequately addressed.
11.9.6 Calibration Program. During daily walk-through, routine audits, and while conducting inspections of all maintenance actions, QA will verify that all equipment and components are in calibration and are in safe working condition. QA will ensure that cognizant W/Cs comply with procedures established for the induction of equipment and components that require calibration.
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11-20 11.9.7 TCP. QA will ensure that:
a. Tool procedures are verified as directed by the ALRE maintenance officer and during W/C audits.
b. When work is to be performed by contractor and field maintenance teams, the division's tool control standard is maintained. A QAI will brief them upon their arrival regarding tool control responsibilities.
11.9.8 QA Standards and Qualification Program. To maintain proper quality inspections of maintenance, inspectors must be trained, tested and indoctrinated with the highest of standards. All personnel nominated to perform inspection of ALRE maintenance must meet the requirements specified in paragraphs 11.5.2, 11.5.3, and 11.7.3.
The TYCOM standardized ALRE job qualification requirements (JQR) for QAI, CDQAI and CDI will be utilized to assist in the effective and proper qualification of ALRE inspectors. Quality inspections require an aggressive continuous training program to ensure inspectors maintain quality in maintenance and prevention of maintenance errors.
11.9.9 MMP. The MMP is a comprehensive tool used by V-2 division to organize and track various qualifications, publications, training requirements and other pertinent maintenance and training related information. It is prepared by the V-2 QA branch on a monthly basis and reviewed by the V-2 QA supervisor, ALRE maintenance officer and V-2 division officer. At a minimum, the MMP will include the following appendixes:
a. Key personnel.
b. Collateral duties.
c. QAI, CDQAI, CDI qualified personnel list.
d. Special qualifications.
e. PQS qualifiers list.
f. MI index.
g. QA monitor program and QA audit schedule.
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11-21 h. ALREMP reports tickler.
i. Active, standing and safety required reading.
j. V-2 tag out authorizing officers.
k. ALREMP training schedule. 11.10 ALRE Discrepancy Reporting Program 11.10.1 Introduction
a. This program is the method by which hazardous deficiencies in material and publications, substandard workmanship, and improper QA procedures are reported.
b. COMNAVAIRSYSCOM has provided a Naval Aviation Maintenance Discrepancy Reporting (NAMDRP) Web site enabled capability to organizational level and intermediate level maintenance activities to create, transmit, and track EI requests, hazardous material EI requests and PQDRs. Requests will be routed to the assigned FSTs and automatically routed to other concerned activities. The NAMDRP Web site enabled capability also permits maintenance activities to receive reports and other information, conduct technical dialog with the FST technical representative, and verify status of an EI or PQDR. This Web site is accessible at http://www.jdrs.mil by all organizations with a role in the EI or PQDR process.
c. COMNAVAIRSYSCOM has also established a NAMDRP clearinghouse to oversee the EI and PQDR processes and interface between the requesting activity and the FSTs for all COMNAVAIRSYSCOM activities. The function of the NAMDRP clearinghouse is to monitor the performance of the EI and PQDR processes, and assist fleet activities resolve problems with specific discrepancy report requests. The NAMDRP clearinghouse will operate up to 16 hours each working day to respond to or expedite solutions to fleet problems or concerns. NAMDRP clearinghouse personnel can be contacted through the NAMDRP Web site at http://www.jdrs.mil.
d. It is the policy of this program to expeditiously resolve reported discrepancies relating to ALRE equipment. By utilizing prepaid commercial express shipping (e.g., FedEx) integrated on the NAMDRP Web site, EI and PQDR exhibits can usually be delivered to the investigation activity within 3 days continental United States (CONUS) and 7 days non-CONUS.
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11-22 11.10.2 Exceptions to the ALRE discrepancy reports are:
a. Changes or corrections to carrier Naval Air Training and Operating Procedures Standardization (NATOPS) or tactical manuals are reported per OPNAVINST 3710.7U using OPNAV 3710/6 NATOPS Tactical Change Recommendation.
b. Deficiencies resulting from incorrect packaging, preservation, marking, handling (as reported by supply activities), or deficiencies in shipment which are the result of overage, shortage, expired shelf life, or misidentified material, are reported per SECNAVINST 4355.18A.
c. Locally procured material found to be deficient by the procuring activity or station is reported under SECNAVINST 4855.3B.
d. Deficiencies in letter type instructions and notices are reported by letter to the sponsor.
e. Recommendations for improvements in procedures which are not a result of incorrect information contained in publications are reported by NATEC. Provide an info copy to NAVAIRWARCENACDIV Lakehurst, Code 6.8.5.1.
11.10.3 Program Management
11.10.3.1 QA is responsible for managing the ALRE Discrepancy Reporting Program. Reports covered by this program are the ALRE PQDR, ALRE HMR, ALRE EI request, and ALRE TPDR. QA will assist the W/Cs in determining if one or more reports are needed for any maintenance problem or situation occurring in the activity. They will also review all discrepancy reports to ensure they are accurate, clear, concise, and comprehensive prior to submission.
11.10.3.2 The ship's safety officer shall review all correspondence pertaining to ALRE-related aircraft, ground, flight, and flight related mishaps.
11.10.3.3 Correspondence, reports, or requests involving the management of ALRE discrepancy reports shall be reviewed by the ALRE maintenance officer.
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11-23 11.10.4 Safety
11.10.4.1 All hands have a responsibility to be alert for defects and discrepancies having an adverse effect on safety and to properly report them via their chain of command.
11.10.4.2 Safety shall be the primary consideration when submitting the reports outlined in this chapter. If an incident meets the criteria for an ALRE HMR and an ALRE EI, the hazard and the EI request should be reported in a single priority request on the NAMDRP Web site or a single priority message in the format shown in figure 11-4. Submission through the NAMDRP Web site is preferred and should be utilized when accessible. If a TPDR meets the criteria for a CAT I TPDR, it should be reported via priority message.
11.10.5 Reporting Procedures
11.10.5.1 Submit ALRE PQDRs, ALRE HMRs, ALRE EI requests and all combination ALRE discrepancy reports via the NAMDRP Web site to NAVAIRWARCENACDIV, Lakehurst, FST for ALRE. If submitting by naval message, use the message format shown in figure 11-13 and submit to Address Indicator Group (AIG) ONE THREE EIGHT EIGHT FIVE. In the remarks section of the message state, “THIS MSG ACTION FOR NAVAIRWARCENADLKE. INFO ALL OTHERS.” AIG ONE THREE EIGHT EIGHT FIVE shall not be used in the info addressee line of the message.
NOTE Submission of an ALRE discrepancy report is mandatory when the criteria of paragraph 11.11.2.1, 11.12.3.1, 11.13.3, or 11.14.1.1 is met. A CASREP may be required in addition to, but not in lieu of, an ALRE discrepancy report.
11.10.5.2 Submit CAT I ALRE TPDR messages to AIG ONE THREE EIGHT EIGHT FIVE and NATEC (Code 685.3) for dual action. AIG ONE THREE EIGHT EIGHT FIVE shall not be used in the info addressee line of the message. Submit OPNAV 4790/66 Technical Publications Deficiency Report (TPDR) CAT II to the NATEC (Code 685.3) and with an info copies to the originator's TYCOM and the FST.
NOTE For ALRE TPDRs involving ALRE QA cards, NATEC will not be a recipient of the report. The report action addressee will be NAVAIRWARCENACDIV Lakehurst (Code 6.8.5.1).
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11-24 11.10.5.3 A report control number (RCN) will be assigned to each ALRE discrepancy report. RCNs will be assigned sequentially throughout the calendar year, without regard for the type of report: for example, 8001 is the first report and is an ALRE HMR; 8002 is the second report and is a CAT I ALRE PQDR; 8003 is the third report and is an ALRE TPDR; and 8004 is the fourth report and is another ALRE HMR. The RCN shall not contain any spaces but will contain hyphens; for example, V03300-01-8001. The RCN is composed of the following elements:
a. Element (1) is the service designator code applicable to the originating activity, either R or V. These codes are the only correct service designator codes for ALRE discrepancy reports. V is for Navy and Marine Corps aviation Atlantic Fleet operating forces, and R is for Navy and Marine Corps aviation Pacific Fleet operating forces.
b. Elements (2) through (6) are the UIC of the originating activity; for example, 03300.
c. Elements (7) and (8) are a two-character identification of the calendar year; for example, 01. There will be a hyphen directly preceding and following the two-character year.
d. Elements (9) through (12) are the locally assigned control number. These numbers are sequential beginning with 8001 each calendar year.
11.10.5.4 Reference the RCN and message date-time-group of the originating activity on all supplemental correspondence. Include shipping information and the investigation control number (ICN) assigned by the FST.
NOTE ALRE HMRs, ALRE TPDRs, ALRE PQDRs, ALRE EI requests and combined reports prepared as a result of an aircraft mishap are not privileged. Exercise extreme care to ensure that these reports and requests do not contain privileged information. Refer to OPNAVINST 3750.6R.
11.10.5.6 ALRE discrepancy report submission criteria, precedence, and time limits are summarized in figure 11-11.
11.10.6 Handling and preparation of ALRE PQDR, HMR, and EI material
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11-25 11.10.6.1 The V-2 (ALRE) material control W/C will hold the defective material until disposition instructions are received from the FST or directing authority. When disposition instructions are received from the FST, V-2 (ALRE) material control shall take the defective material to the supporting supply department for shipping.
NOTE Defective material investigations are often closed without reaching a conclusion about why the component failed because the exhibit is lost prior to shipment or damaged due to improper handling or packaging. NOTE Any material directed by the FST to be released to an authorized contractor's representative or shipped directly to a contractor's plant shall be processed through the supporting supply department. Supply can issue the material on a custody basis, only after receiving authority from the FST.
a. Maintain material in an AS IS condition, ensuring the ALRE ICN assigned by the FST appears on all documents, exhibits, and packaging. Whenever a hazardous condition is evident, request shipping instructions from the FST.
b. Take special care to cap and package material immediately upon removal from the system in such a manner as to prevent corrosion, contamination, or other damage that may contribute to confusion or loss of possible cause factors. Do not attempt any adjustments, disassembly, or perform any type of cleaning, externally or otherwise. If any adjustment, disassembly, or cleaning was done during a local investigation, a list of particulars describing the local investigation must accompany the material to the FST.
c. Forward samples of the fluid in clean, sealed, authorized containers. If contamination is suspected, annotate sample bottles accordingly.
NOTE Hazardous material should be handled and packaged under OPNAVINST 5100.23G. Contact the supporting supply department for assistance.
d. Do not attempt to reassemble fragments of failed material. Wrap each fragment separately to prevent damage caused by relative movement. When feasible, forward associated accessories,
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11-26 components, or material suspected of contributing to the malfunction or mishap. Do not touch failed surfaces as this could mask failure data.
e. Ensure DD 2332 Product Quality Deficiency Report Exhibit is attached to the exhibit. Also, provide a copy of the OPNAV 4790/160 (if applicable), appropriate copies of DD 1149 Requisition and Invoice/Shipping Document with a copy of the ALRE discrepancy report and all other supporting documents inside of the shipping container. QA shall ensure the OPNAV 4790/160 is marked with the ALRE ICN assigned by the FST and that ALRE PQDR, ALRE HMR or ALRE EI, as appropriate, appears in 3 inch red letters, in a manner not to obscure vital data.
NOTE Exhibits shall be held 60 days by the originating point or until disposition instructions are received from an appropriate screening or action point. If after 60 days, shipping or disposition instructions have not been received, the originator shall conduct a follow-up with the appropriate screening or action point. Exhibits shall not be repaired within the 60 day holding time unless critical mission requirements dictate. In such instances, action should be initiated to retain evidence of the deficiency through photographs, testing, etc., which can be included with the ALRE discrepancy report.
NOTE Within 45 days after receipt of an ALRE discrepancy report, the ALRE screening activity shall provide feedback to the originating activity concerning status of any possible exhibit request. Feedback shall delineate any requirement for the originator to hold the exhibit material for a period exceeding the initial 60 days.
11.10.7 Response to ALRE Discrepancy Reports
11.10.7.1 The originating point is an activity that finds a quality deficiency and reports it by ALRE PQDR, ALRE HMR, ALRE HMR/EI, or ALRE TPDR to the designated screening point. Figure 11- 3 depicts the process flow for ALRE PQDRs. Processing for other ALRE discrepancy reports is similar.
a. The originator shall respond to all requests from screening, action or support points for additional information that may be necessary in the investigation of any ALRE discrepancy reports.
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11-27 b. When a reply has not been received within the timeframes specified in paragraphs 11.11 through 11.14 for the applicable discrepancy report, the originating activity's ALRE QA will initiate follow-up action to the screening point via the NAMDRP Web site, priority message, routine message or naval letter, as appropriate. Submission through the NAMDRP Web site is preferred and should be utilized when accessible. At a minimum, information addressees and "copies to" for follow-up action will include PEO(T) (PMA 251), and COMNAVAIRFOR Pacific (Code N433), COMNAVAIRFOR Atlantic (Code N433).
11.10.7.2 The screening point is the activity that reviews the discrepancy report for proper category classification, validity, correctness of entries, accuracy, and completion of information addresses; determines and transmits the report to the cognizant action point; maintains an audit trail for each report; reviews PQDR closeout responses from action points; and collects, maintains, and exchanges report data. The primary screening point for ALRE equipment is the ALRE FST, NAVAIRWARCENACDIV Lakehurst, NJ. The screening point for NAVAIRSYSCOM publications is NATEC, Code 685.3. The screening point responsibilities are further broken down at NAVAIRWARCENACDIV, Lakehurst based on the type of report being submitted. These are outlined in the applicable report paragraphs, 11.11 through 11.14. Duties of the screening point for all type reports include the following:
a. The screening point shall forward an initial response, acknowledging receipt of the discrepancy report, to the originator within the time limits specified in paragraphs 11.11 through 11.14.
b. The screening point shall forward ALRE discrepancy reports to the appropriate action point within the time limits specified in paragraphs 11.11 through 11.14.
c. The screening points shall establish an audit trail for each ALRE Discrepancy Report forwarded to the action points for investigation.
d. Once the EI or HMR request or PQDR report has been screened and accepted, the screening point shall assign an ICN to the ALRE discrepancy report as follows:
(1) Request the deficient exhibit (if needed) from the originator (holding point) as soon as the need is determined, but
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11-28 not later than time prescribed for the particular report. The support point may be authorized to request the exhibit directly from the holding point.
(2) Use the EI request and PQDR investigation control system for deriving control numbers shown in the following paragraphs:
WAFEI - ALRE - 0012 - 03R | | | | | | Routine | | | | | | | | | | 2003 | | | | | | | | Control Number | | | | | | Type Equipment | | | | Type Report (e.g., EI, PQDR) | | NAVAIRWARCENACDIV Lakehurst
(3) The first three elements are the ORG code, as established in Navy MS Office or the Naval Aviation MS Office (NAMSO) 4790.A7065-01. The FRC identifier for NAVAIRWARCENACDIV Lakehurst is WAF.
(4) The next element, appended to the ORG code is "EI" or "PQDR," followed by a dash (-).
(5) The next four characters are the system identifier (type equipment). ALRE will be used for launch and recovery systems equipment. This element is followed by a dash (-).
(6) The next four elements comprise the serial number. This number will be assigned sequentially throughout the calendar year (beginning with 0001) without regard for the type of report. This element is followed by a dash (-).
(7) The next two elements are the calendar year identifier beginning with "00" for calendar year 2000, and continuing in arithmetic progression with changes in calendar year.
(8) The last element, appended to the calendar year, is a request urgency indicator, that is, "R" for routine, "S" for
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11-29 safety, and "M" for mishap related. This indicator will be based on the nature of the request as specified in the ALRE discrepancy report.
11.10.7.3 The action point is a focal point identified within each activity, responsible for resolution of a reported product deficiency including necessary collaboration with support points. For PQDR reports, the action point should be determined using material COG codes, i.e., 1H, 5R, 7E, 9G, etc. For EI, HMR and all combination requests, the action point is the applicable equipment FST engineer at NAVAIRWARCENACDIV, Lakehurst, NJ. For ALRE discrepancy reports, the action point shall:
a. Investigate the reported deficiency.
b. Ensure action is taken to provide disposition instructions for the deficient product.
c. Carefully evaluate the need to request an exhibit. If the exhibit is essential in the investigation, request it from the report originator as soon as the need is known but no later than the time limits specified in paragraphs 11.11 through 11.14.
d. In the case of ALRE PQDRs, determine if a contract warranty applies and initiate any additional special actions that are required.
e. Determine if the same deficiency is currently under investigation or has been resolved because of a previous report.
f. Forward an initial, interim or final response to the originator or screening point as applicable within the time limits specified in paragraphs 11.11 through 11.14.
g. Additional guidance for action points is provided in DLAR 4155.28 and SECNAVINST 4855.3B.
11.10.7.4 The support point is an activity that assists the action point, when requested, by conducting and providing results of a special analysis or investigation pertinent to the correction and prevention of a reported deficiency. The support point, when requested, shall:
a. Conduct an investigation to determine the root cause(s) of the reported deficiency and the corrective actions necessary.
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11-30 b. Evaluate the need to request an exhibit.
c. Provide an interim or final reply to the requesting action point within the time limits specified in paragraphs 11.11 through 11.14.
NOTE Failure to meet the specified time limits does not relieve the requirement to process the ALRE discrepancy report. Activities will provide progress reports or request status reports as necessary to ensure timely completion of required action.
11.10.7.5 NAVAIRWARCENACDIV Lakehurst shall prepare a monthly summary and status report listing all new, open, and resolved (that month) ALRE discrepancy reports by type and category, and forward copies to COMNAVAIRSYSCOM, COMNAVAIRFOR Atlantic, COMNAVAIRFOR Pacific, all aircraft carriers (CVNs), NAVICP Philadelphia, NAVICP Mechanicsburg, NAVSAFECEN, and other concerned activities. 11.11 ALRE Hazardous Material Report (ALRE HMR) 11.11.1 This report provides a standard method for reporting material deficiencies that, if not corrected, could result in death or injury to personnel, or damage to or loss of aircraft, equipment, or facilities. Such incidents are reportable regardless of how or when the discrepant condition was detected.
NOTE The ALRE HMR is not applicable for discrepancies related to new or newly reworked material. These discrepancies shall be reported using the ALRE PQDR (CAT I or CAT II, as applicable).
11.11.2 Reporting Criteria. Originating activities shall prepare and submit ALRE HMRs per this instruction. Submit an ALRE HMR or HMR and EI by priority request on the NAMDRP Web site or a priority precedence message (submission through the NAMDRP Web site is preferred and should be utilized when accessible) within 24 hours of the discovery under one or more of the following conditions:
NOTE In case of a naval aircraft mishap, the required reports will be submitted under OPNAVINST 3750.6R. In addition, a report of deviation from normal catapult launch and arrested landing will be filed, when applicable (refer to COMNAVAIRFORINST 13800.6A
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11-31 (NOTAL)). However, submission of the preceding reports does not negate the requirement to submit ALRE discrepancy reports as described in this instruction.
a. Malfunction or failure of a component part which, if not corrected, could result in death or injury to personnel, or damage to or loss of aircraft, equipment, or facilities.
b. A configuration deficiency, which constitutes a safety hazard, is discovered in ALRE or associated equipment.
c. Urgent action or assistance is required and corrective action must be completed at an early date because of an operational requirement.
d. A condition is detected wherein the design of a part is such that incorrect installation can be easily accomplished and system malfunction or failure may occur.
11.11.3 Screening Point Responsibilities. The primary screening point for ALRE equipment is the ALRE FST, NAVAIRWARCENACDIV Lakehurst, NJ. The functions of the screening point are described in paragraph 11.10.7.2, and for HMR and or EI requests the responsibilities are divided between the NAMDRP clearinghouse representative and the ALRE FST technical representative. The responsibilities of the NAMDRP clearinghouse and the FST technical representative are detailed below regarding HMR and or EI requests. Differences between the handling of an EI as opposed to an HMR are minor and are delineated in paragraph 11.12.
11.11.3.1 NAMDRP Clearinghouse. The function of the clearinghouse is to monitor the performance of the EI and PQDR processes, and assist fleet activities resolve problems with specific discrepancy report requests. This will include determining the cognizant action point when requested by the originating activity or FST technical point of contact, providing deficiency report status and metrics for process improvements and providing screening capability for reports submitted via the naval message system. Contact information for the NAMDRP clearinghouse is available on the NAMDRP Web site, http://www.jdrs.mil.
11.11.3.2 FST Technical Representative(s) Responsibilities. For HMR and or EI reports the FST technical representative(s) acts as both screening point and action point. Response times are summarized in figure 11-12. The responsibilities include:
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11-32 a. Reviews the discrepancy report for proper FST technical representative routing and will readdress to the correct representative if required. Reviews for proper category classification, validity, correctness of entries, accuracy, and completion of information addresses. Conducts liaison with the request originator as required to obtain amplifying and clarifying information on the reported discrepancy and failure. “Accepts” receipt of the HMR and or EI request via the NAMDRP Web site within 1 working day.
b. Study the history of failures and utilize FST engineer (TOOL KIT) to determine the need for and value of an investigation on the equipment and material in question. The determination to proceed or not to proceed with the HMR and or EI shall be completed and an initial response forwarded to the originator, under paragraphs 11.11.3.2c and 11.11.3.2d below, within 3 working days of the request.
c. When engineering analysis, technical dialog, or other factors indicate that an HMR and or EI is not required, the FST engineer will inform the originator, as well as other required addressees through the NAMDRP Web site or by naval message. The FST engineer will summarize the factors that led to a decision to deny the HMR and or EI request.
d. When it is determined an HMR and or EI is required, the FST technical representative will provide an initial response to include an assigned ICN, (assigned over the NAMDRP Web site per paragraph 11.10.7.2), and provide shipping instructions for the discrepant equipment and material or describe the arrangements for an on-site investigation. All HMR and or EI exhibits will be shipped as directed in the shipping instructions received from the FST.
e. The FST technical representative in cooperation with the applicable support points shall develop an EI exhibit examination plan and post it on the NAMDRP Web site. He or she will ensure the examination plan is provided to the support points and the investigating activity if exhibit is to be examined off-site. He or she will notify the local investigating activity-receiving personnel (customer service representative) of the request for the equipment and material exhibit, so the exhibit can be properly identified and routed when received.
f. Follow-up on exhibit non-receipt. Under normal circumstances, follow-up shall be made within 4 days for CONUS
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11-33 shipping or 8 days for non-CONUS shipping, after the initial response, but the period may be extended if it is known that shipment will take longer. Follow-up shall include a NAMDRP Web site report or message to the HMR and or EI request originator, after first checking with the local supply activity and investigating activity-receiving area, as a minimum. All possible follow-up actions shall be taken, particularly on equipment and material related to HMRs.
g. Acknowledge receipt of HMR and or EI exhibit via the NAMDRP Web site or naval message system within 1 working day of exhibit receipt.
h. The FST technical representative conducts the investigation by documented standard operating procedures. Immediate corrective action required to resolve life-threatening conditions shall be transmitted by telephone or message within 24 hours. An interim response for the HMR will be provided via the NAMDRP Web site or naval message system within 10 working days of the initial response (if exhibit was not required) or material receipt (if exhibit was required). A final HMR response will be provided via the NAMDRP Web site or naval message system within 30 working days of the initial response (if exhibit was not required) or material receipt (if exhibit was required). An interim response shall be provided every 30 working days until a final response is provided. Interim responses shall include status to date and a projected final response date. The final response shall include at a minimum, background, description of findings, conclusions, recommendations, related information, pending action and exhibit disposition information.
11.11.4 Action Point Responsibilities. As described above the action point for ALRE HMR and or EI requests is the equipment technical representative at FST, NAVAIRWARCENACDIV Lakehurst and their responsibilities are listed above.
11.11.5 Support Point Responsibilities. The responsibilities of the support point are delineated in paragraph 11.10.7.4. Using information provided by the action point, the support point will complete the requested service or analysis specified in the examination plan in order to meet the action point’s reporting timeframes listed above.
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11-34 11.12 ALRE Engineering Investigation (ALRE EI)
11.12.1 ALRE EIs are applicable to all ALRE systems, their subsystems, equipment, components, related SE, special tools, and fluids and materials used in the operation of the equipment. ALRE EIs:
a. Provide an investigation process to determine the cause and depth of fleet reported material failures.
b. Support the investigation of material associated with aircraft mishaps.
c. Support the scheduled removal component and equipment history record programs by providing for the investigation of high time and on-condition components and assemblies to confirm, revise, or initiate component or assembly operating times.
d. Provide for engineering assistance relating to any fleet ALRE material problem.
11.12.2 Types of ALRE EIs conducted are disassembly and inspection, material analysis, and engineering assistance.
11.12.3 Reporting Criteria. Originating activities shall prepare and submit ALRE EIs per this instruction.
11.12.3.1 Submit an ALRE EI request under one or more of the following conditions:
a. Safety is involved. This includes ALRE EI requests prepared in conjunction with aircraft mishaps and ALRE HMRs when it is evident that an unsafe condition exists.
b. Additional technical or engineering information is required to complete an aircraft mishap investigation.
c. Launch and recovery systems readiness is seriously impaired due to poor material reliability.
d. When environmental issues force material or process changes that conflict with existing publications or TDs.
e. When directed by higher authority.
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11-35 11.12.3.2 Originating activities shall prepare and submit ALRE EIs per this instruction. They shall:
a. Submit an ALRE EI request by routine request on the NAMDRP Web site or routine precedence message (submission through the NAMDRP Web site is preferred and should be used when accessible) within 3 calendar days after discovery of deficiency, unless combined with an ALRE HMR.
b. A combined ALRE HMR and EI shall be sent by priority request on the NAMDRP Web site or priority precedence message within 24 hours of discovery, see the submission guidance under HMR.
c. Hold defective or environmentally sensitive material in V-2 (ALRE) material control for a minimum of 60 days or until receipt of disposition instructions from the Lakehurst FST.
11.12.4 The screening point, action point and support point functions and responsibilities, the combined handling of the EI request by the NAMDRP clearinghouse and FST technical representative, are nearly identical to those of the HMR. The only difference lies in the time of the interim response by the FST technical representative. An interim or final response for the EI will be provided via the NAMDRP Web site or naval message system within 30 working days of the initial response (if exhibit was not required) or material receipt (if exhibit was required). It shall be the goal of the FST technical representative to complete the investigation within the specified 30 working days and provide the final report response. If circumstances will not allow the completion of the investigation within this timeframe, interim responses are required every 30 working days until a final response is provided.
11.13 ALRE Product Quality Deficiency Report (ALRE PQDR)
11.13.1 An ALRE PQDR provides maintenance activities with a method for reporting deficiencies in new or newly-reworked material which may be attributable to nonconformance with contractual or specification requirements or substandard workmanship. Failures must have occurred at zero operating time, during initial installation, operation, test, or check. Discrepancies discovered after the initial use do not qualify for ALRE PQDR reporting, and shall be reported as ALRE HMRs and ALRE EIs, as appropriate. ALRE PQDRs are targeted toward reporting possible deficiencies in QA during the manufacturing or rework process. The goal is to improve
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11-36 the quality of work done by FRC, NAVSHIPYDs, contractors, and subcontractors returning reworked material to supply stock. The process flow for ALRE PQDRs is depicted in figure 11-3. Processing for other ALRE discrepancy reports is similar.
11.13.2 Definition of Terms
11.13.2.1 New Material. Material procured under contract from commercial or government sources or manufactured by an in-house facility. Such material will be considered new until it has been proven in actual system operation.
11.13.2.2 Reworked Material. Material that has been overhauled, rebuilt, repaired, reworked, or modified by an outside military or commercial facility and unproven during actual system operation, will be considered newly reworked until it has been proven during actual system operation.
11.13.3 Types of ALRE PQDRs
11.13.3.1 CAT I. A quality deficiency in new or newly reworked material which may or will affect safety of personnel including causing injury or death; cause loss or major damage to a weapon system; or impair the combat efficiency of an individual or organization, or jeopardize mission accomplishment.
11.13.3.2 CAT II. A report of a quality deficiency in new or newly reworked material that does not meet the criteria set forth in CAT I.
11.13.4 Reporting Criteria
11.13.4.1 Originating activities shall prepare and submit ALRE PQDRs per this instruction.
11.13.4.1.1 ALRE CAT I PQDR Submission. ALRE CAT I PQDRs shall be submitted by a priority request on the NAMDRP Web site or a priority precedence message (the NAMDRP Web site is preferred and should be utilized when accessible) within 24 hours after discovery of the deficiency.
NOTE Do not combine ALRE PQDRs and ALRE EIs or HMRs.
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11-37 11.13.4.1.2 ALRE CAT II PQDR Submission
a. ALRE CAT II PQDRs shall be submitted by a routine request via the NAMDRP Web site or a routine precedence message to the FST, “INFO FOR” the originator's TYCOM. The FST for ALRE is NAVAIRWARCENACDIV Lakehurst.
b. Submit ALRE CAT II PQDRs by routine precedence message within 3 calendar days after discovery of the deficiency if, in the opinion of a QAI, a quality deficiency requires attention. Originating activities should evaluate the administrative costs involved to determine if such costs will exceed the benefits, giving less consideration to administrative costs when the deficiency is recurring or chronic in nature.
c. Units reporting ALRE CAT II PQDR should follow submission instructions on the NAMDRP Web site when using the Web site or use the general format contained in paragraph 11.15.1.1 when using the naval message system.
d. ALRE CAT II PQDRs must, as a minimum, include the FST as the action addressee and the originator’s TYCOM as an information addressee.
e. Send copies of all supporting documents, such as, DD 1348- 1A Issue Release/Receipt Document; DD 1155 Order for Supplies or Services; photographs; test reports; and other pertinent data to the FST order for supplies or services in order to facilitate processing. Include the ALRE CAT II PQDR RCN on all documents.
f. ALRE CAT II PQDRs on deficiencies in common or general type material, for example, tools, lubricants, corrosion preventative material, received bad from supply but not installed will be submitted to the Fleet Material Support Office. NAVAIRWARCENACDIV Lakehurst remains the FST for ALRE special tools.
NOTE Exhibits shall be held 60 days by the originating point or until disposition instructions are received from an appropriate screening or action point.
11.13.4.2 All originating activities shall turn in defective ALRE discrepancy report material exhibits to the ALRE material control W/C to hold until receipt of exhibit disposition instructions from the FST or directing authority (see paragraph 11.10.6). When
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OPNAVINST 4790.15E 29 Jul 2011
11-38 disposition instructions are received from the FST, the ALRE material control W/C shall take the defective material to the supporting supply department for shipping.
NOTE Any material directed by the FST to be released to an authorized contractor's representative or shipped directly to a contractor's plant shall be processed through the supporting supply department. Supply can issue the material on a custody basis, only after receiving authority from the FST.
11.13.5 Screening Point Responsibilities. The screening point for ALRE PQDRs is FST, NAVAIRWARCENACDIV Lakehurst, NJ. The functions of the screening point are summarized in figure 11-11 and described in paragraph 11.10.7.2. In addition to those responsibilities, the screening point shall:
a. Forward an initial response to the originator within 1 working day after receipt of an ALRE CAT I PQDR, or within 3 working days after receipt of an ALRE CAT II PQDR.
b. Forward the PQDR to the appropriate action point within 1 working day after receipt of an ALRE CAT I PQDR or within 10 working days after receipt of an ALRE CAT II PQDR.
11.13.6 Action Point Responsibilities. For ALRE PQDRs, the action point is often the particular exhibit’s applicable government procuring activity or the applicable contractor. Action point responsibilities are described in paragraph 11.10.7.3. In addition to those responsibilities, the action point shall:
a. Request the exhibit from the originator, if required, as soon as the need is known but no later than 5 working days after receipt of an ALRE CAT I PQDR or within 10 working days after receipt of an ALRE CAT II PQDR.
b. For CAT I PQDRs, forward an interim or final reply to the screening point within 20 working days after CAT I PQDR receipt (if exhibit was not required) or material receipt (if exhibit was required). If an interim or follow-up interim reply is sent, include status to date and a projected final reply date. Immediate corrective action required to resolve life-threatening conditions shall be transmitted by telephone or message within 24 hours.
c. For CAT II PQDRs, forward an interim or final reply to the screening point within 30 working days after CAT II PQDR receipt
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OPNAVINST 4790.15E 29 Jul 2011
11-39 (if exhibit was not required) or material receipt (if exhibit was required). If an interim reply or follow-up interim reply is sent, include status to date and a projected final reply date.
11.13.7 Support Point Responsibilities. The support point responsibilities are described in paragraph 11.10.7.4. In addition to those responsibilities the support point will complete the requested service or analysis specified by the action point in order to meet the action point’s reporting timeframes listed above. 11.14 ALRE Technical Publication Deficiency Report (ALRE TPDR) 11.14.1 This report provides a simplified procedure for reporting technical publication safety hazards and routine deficiencies.
11.14.1.1 A CAT I ALRE TPDR message is required when a technical publication deficiency is detected which, if not corrected, could result in death or injury to personnel or damage to or loss of aircraft, equipment, or facilities. These are to be reported using the priority precedence CAT I ALRE TPDR message format. The importance of submitting a message for the CAT I ALRE TPDR for safety related deficiencies are emphasized.
11.14.1.2 CAT II publication deficiencies are those that do not meet the criteria of a CAT I ALRE TPDR. They may include technical errors, wrong sequence of adjustments, P/N errors or omissions, and microfilm deficiencies, such as poor aperture card film quality. These are to be reported using OPNAV 4790/66 or on the NATEC Web site, https://mynatec.navair.navy.mil.
11.14.1.3 Technical publications include MRCs, maintenance and overhaul manuals, operation manuals, IPBs, TDs, service bulletins, and other technical manuals. The ALRE TPDR is not applicable when reporting deficiencies in instructions or notices.
11.14.1.4 For NAVSEASYSCOM publication deficiencies refer to paragraph 11.16.4.
11.14.2 Reporting Criteria
11.14.2.1 Originating activities shall prepare and submit ALRE TPDRs per this instruction.
11.14.2.2 CAT I ALRE TPDR
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11-40 11.14.2.2.1 All activities shall prepare and submit a CAT I ALRE TPDR priority message within 24 hours of discovery of a deficiency under paragraph 11.15.2. The action addressee for the message report will be NAVAIRWARCENACDIV Lakehurst (Code 6.8.5.1) and NATEC (Code 685.3).
NOTE For CAT I ALRE TPDRs involving ALRE QA and ALRE C cards, NATEC will not be a recipient of the report. The message report action addressee will be AIG ONE THREE EIGHT EIGHT FIVE. In the remarks section of the message state, “THIS MSG ACTION FOR AVAIRWARCENACDIVLKE. INFO FOR ALL OTHERS.” AIG ONE THREE EIGHT EIGHT FIVE shall not be used in the info addressee line of the message.
11.14.2.2.2 When urgency dictates, CAT I ALRE TPDRs may be reported by the most expeditious means available, for example, telephone, facsimile (FAX) or local visit. The NAVAIRWARCENACDIV Lakehurst FAX numbers are (732) 323-7232/7233.
NOTE Oral or FAX communication shall be promptly confirmed by message.
11.14.2.3 ALRE CAT II TPDR
All activities shall use the OPNAV 4790/66 or on the NATEC Web site https://mynatec.navair.navy.mil within 10 working days for reporting routine technical publication deficiencies (CAT II). The original and one copy shall be sent to NATEC (Code 685.3), one copy shall be sent to NAVAIRWARCENACDIV Lakehurst (Code 6.8.5.1), and one copy shall be sent to the originator's TYCOM COMNAVAIRFOR Atlantic or COMNAVAIRFOR Pacific.
NOTE For CAT II ALRE TPDRs involving ALRE QA and ALRE C cards, NATEC will not be a recipient of the report. The report will be sent to NAVAIRWARCENACDIV Lakehurst (Code 6.8.5.1).
11.14.3 NATEC will serve as the central manager for all NAVAIRSYSCOM technical publications and shall:
a. Maintain a record of all technical manual deficiencies.
b. Acknowledge receipt of each ALRE TPDR to the originator and assign FST action for ALRE TPDRs as required. This will be
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11-41 accomplished within 1 working day after receipt of CAT I ALRE TPDRs, and within 10 working days after receipt of CAT II ALRE TPDRs.
c. Coordinate action with FST and contractor to ensure correction of technical publications.
d. Follow-up on each ALRE TPDR to ensure corrective action is accomplished.
e. Provide ALRE TPDR status as required to the applicable TYCOM.
11.14.3.1 FSTs will coordinate with the NATEC and take the appropriate action necessary to ensure the deficiency is resolved, for example, correctness of technical publication, appropriate printing assignment, or preparation and initiation of change for corrective action.
11.14.3.2 NATEC will report action taken on all ALRE TPDRs in a timely manner.
11.14.3.3 FSTs will notify NATEC and the ALRE TPDR originator of final disposition of each ALRE TPDR. FSTs shall also ensure that all addressees of the original report are included in all correspondence related to that report. 11.15 ALRE Discrepancy Report Preparation 11.15.1 ALRE HMR, ALRE EI and ALRE PQDR Preparation.
11.15.1.1 Whenever possible, ALRE HMRs, ALRE EIs, ALRE PQDRs and combined discrepancy reports should be reported through the NAMDRP Web site. Report submission instructions are posted on the Web site and are very similar to submission through the naval message system. When circumstances will not permit reporting through the Web site, the following format and content apply to ALRE HMR, ALRE EI, ALRE PQDR, and combined ALRE discrepancy message reports. (Examples are provided in figures 11-4 through 11-10 and a convenient message template is provided in figure 11-13).
NOTE Use of MINIMIZE CONSIDERED shall be under the NTP-3 (NOTAL).
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11-42 Precedence: Priority and Routine (as applicable) From: Message Originator To: NAVAIRWARCENACDIV LAKEHURST NJ AIG ONE THREE EIGHT EIGHT FIVE
NOTE AIG ONE THREE EIGHT EIGHT FIVE shall not be used in the info addressee line of the message.
Info: NAVICP Mechanicsburg PA//05632// (all 1H or 7E COG material)
NOTE Security classifications are defined in the DON Security Classification Guides (OPNAVINST 5513.1F); however, every attempt should be made to employ unclassified to expedite routing.
Subj: List applicable subject or combination of subjects, for example ALRE Catapult HMR and EI, or ALRE VLA CAT I PQDR
Ref: A. OPNAVINST 4790.15E
NOTE Reference other applicable instructions and any related mishap or investigation reports submitted under OPNAVINST 3750.6R and mishap classification and serial number. Include only instructions and references applicable to the occurrence. When a technical manual is referenced, include issue date and latest change date.
1. Reporting custodian and UIC. Example: USS SHIP (CV-00)/03300.
2. FST for failed item. Example: NAVAIRWARCENACDIV LAKEHURST, NJ.
3. Report Control Number (RCN): A number assigned by the originating activity under paragraph 11.10.5.3. Example: R00123-02-8003
4. The five digit Julian date and location that deficiency was discovered. Example: 03125/Deployed.
5. NSN information of discrepant item. Enter COG symbol, national stock number and special material identification code (SMIC) of the
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11-43 unsatisfactory material. Example: 7RH, 1234-00-123-1234, EY. Enter not applicable (N/A) or unknown (UNK) for these elements if not applicable or unknown.
NOTE Do not leave the NSN blank without ALRE maintenance officer’s approval.
6. Discrepant Item Nomenclature. Annotate as officially described on drawings or in manuals.
7A. For new material, indicate manufacturer's five digit CAGE code, name, city and state. Example: 12345, Vandeley Industries, Springfield, MO. Enter N/A or UNK for these elements if not applicable or unknown.
7B. For reworked material, indicate the last rework activity’s five digit CAGE code, name, city, and state. Example: 54321, Overhaul Experts Inc., Columbus, OH. Enter N/A or UNK for these elements if not applicable or unknown.
7C. Enter Shipper’s name, city and state. Example: 00012, Shipping Expeditors, Las Vegas, NV. Enter N/A or UNK for these elements if not applicable or unknown.
8. P/N of Discrepant Item. Enter the manufacturer’s P/N and the NAVAIRWARCENACDIV Lakehurst P/N. Enter N/A or UNK for these elements if not applicable or unknown.
9. Serial, lot, or batch number (indicates number used). Enter N/A or UNK for these elements if not applicable or unknown.
10. Contract number, purchase order number, re-order requisition number (turn-in document number, government bill of lading (GBL) number. Separate information by commas. Enter N/A or UNK for these elements if not applicable or unknown.
a. Contract No: Enter the contract number, if applicable. Contract numbers are especially important and should be entered when available. Enter total contract number (13 to 17 characters), if available. For a 13-digit contract number, the first six characters identify buying activity (N68335 is NAVAIRWARCENACDIV Lakehurst, N00383 is NAVICP Philadelphia, N00140 is Naval Regional Contracting Center, etc). Next two digits identify year contract was awarded, next letter digit identifies contracting method, and
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11-44 last four digits identify the contract serial number. Contract numbers are especially important and must be entered when available.
NOTE The ALRE maintenance officer must approve an entry of "UNK" for the contract number.
b. Purchase Order No: Enter the purchase order number, if applicable.
c. Re-order Requisition No/Turn-in Document No: Enter the re- order requisition number (turn-in document number) of depot level repairable items to receive charge reversal credit. Enter UNK or N/A if unknown or not applicable.
d. GBL: Enter the GBL number, if known or applicable.
11. New or newly reworked, if known. Enter the word "NEW" for items received through the supply system (unless known to have been refurbished) or direct shipments from a manufacturer. Enter the word "REWORKED" for items received via the supply system that are known to have been refurbished or those items from an authorized rework activity (i.e., VRT and RMC). If the DD 1574-1 Serviceable Materiel (2 PART TAG), commonly known as the ready for issue (RFI) tag is still available, indicate REPAIRED, REWORKED, OVERHAULED or UPKEEP as indicated on the RFI tag. If status is unknown, enter "UNK" (unknown). If not applicable (ALRE HMR and ALRE EI), enter "N/A".
12. Date manufactured, reworked, or overhauled, when available. If unknown, enter "UNK".
13. Operating time at failure or events. Indicate units (such as hours, arrestments, catapult shots, etc.). If unknown, enter "UNK".
14. Government-furnished material (YES, NO, N/A or UNK). Government- furnished material includes SC kits, interim spares, and initial outfitting items.
15. Quantity: Quantity shall be a count of each individual item, disregarding unit of issue. If problem does not relate to a quantity, enter "N/A".
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11-45 a. Received: Enter the total number of items received in the lot or batch in which the unsatisfactory material condition was found, if known.
b. Inspected: Enter the number of items that were inspected for the deficiency.
c. Deficient: Enter the number of items that were determined to be deficient as a result of the inspection.
d. In Stock: Enter the number of items remaining in stock locally.
16. Deficient item works on or with: Indicate the name and P/N of the equipment the problem is part of, adding MK and MOD where applicable.
a. End item nomenclature (A/G engine, jet blast detector (JBD), etc.), end item serial number (enter N/A if not applicable).
b. Next higher assembly NSN, nomenclature, P/N, serial number (if applicable.)
17. Dollar value of deficient material, man-hours to repair, estimated repair cost (if known or applicable, do not use commas). Example: 25000 DOLLARS, 150 MHRS, 300.00 DOLLARS.
18. If hazardous material or procedure, include military specification (MILSPEC), type, class and or grade, or NONE of no MILSPEC is available; if the report does not concern environmentally sensitive material or procedures, enter "N/A".
19. Item under warranty and expiration date. Enter YES, NO, N/A or UNK. (Enter UNK for ALRE material).
20. EIC: Enter the most specific code available.
21. Exhibit Disposition. Exhibits are important to determine the root cause of a problem, to return to a contractor for corrective- action purposes, or to precipitate a stock system purge action.
a. Identify the supply unit that may ship the exhibit. This will enable the identified supply unit to ship the exhibit using commercial premium shipping on the NAMDRP Web site.
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11-46 b. Action and Disposition Narrative. Material shall be handled as per paragraph 11.10.6. Enter "EXHIBIT HELD" to indicate that problem item is available for examination. Identify the location where the deficient material is being held, if applicable. If an exhibit is being held, indicate the number of days (minimum of 60 calendar days) the exhibit will be held.
NOTE Material shall be shipped within 3 days of receipt of disposition instructions from the FST.
22. Details
a. Narrative description. As precisely as possible, describe the type, scope and extent of the problem, known or probable causes, pertinent SCs incorporated, environmental issue listing references and regulatory agency, comments and recommendations to reduce or eliminate the source of the problem (if any). Indicate urgency, assistance needed, etc.
b. How safety of personnel or activity mission is affected.
c. Number of similar deficiencies in like items reported by the originating activity, for example, five in the past 4 months.
d. How deficiency was detected or confirmed, such as, visually or functional operation. Where deficiency was discovered, for example, maintenance and operational test.
e. Storage and handling information, if applicable. (If it appears these factors have contributed to the deficient material condition.)
f. Indicate if supporting documents will be supplied. Photographs to follow, are available upon request, are not available (as applicable). When photographs are taken, place a ruler alongside the object so as to appear in each photograph. Measurements should also appear on sketches. Write the report control number from block 3 on the back of photographs.
g. Description of incorrectly identified new material, if applicable.
h. Recommendations (PQDR Requisition Doc Number). Enter N/A for ALRE EIs and ALRE HMRs. For ALRE PQDRs use this field to identify or assign a requisition document number. In order to
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OPNAVINST 4790.15E 29 Jul 2011
11-47 receive credit for defective 9 COG and ships parts control center COG (1H,7E,7G,7H) material, list the original MILSTRIP requisition document number, "BILL TO" DoD Activity Address Code (DODAAC) (if different from requisitioned DODAAC), and the applicable fund and signal codes. When the original document number cannot be determined, a MILSTRIP document number must be assigned as follows:
NOTE Following closing action on discrepant NAVICP managed material (any remaining 1H, 3H, 4R, 5R, 7E, 7G, 7H, 7R and OM COG), NAVAIRWARCENACDIV Lakehurst will request credit to the end user by submitting a letter to NAVICP Philadelphia and Mechanicsburg (Material Returns Program Code 015), as appropriate. The letter must contain the complete document number under which the discrepant item was issued, and must be accompanied by a copy of the original CAT I/II PQDR message with closing action. This procedure requires that the originating activity provide the original MILSTRIP requisition document number as detailed above.
(1) The originating point DODAAC will comprise the first six characters (the DODAAC will receive credit unless otherwise specified).
(2) The current Julian calendar date for the next four characters - the ending four-digit serial number beginning with "U" will complete the constructed document number.
(3) Example: N63124-4286-U001
i. Name, rank, and Defense Switch Network (DSN) number of ALRE maintenance officer. (If deployed, delete phone number and insert the word DEPLOYED).
j. W/C code (example: VB01 for Catapult No. 1.)
k. N/A.
l. N/A.
11.15.2 CAT I ALRE TPDR Preparation.
11.15.2.1 The following format and content apply to CAT I ALRE TPDR message reports. (An example is provided in figure 11-10.)
NOTE Use of MINIMIZE CONSIDERED shall be under the NTP-3 (NOTAL).
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OPNAVINST 4790.15E 29 Jul 2011
11-48 Precedence: Priority From: Message Originator To: AIG ONE THREE EIGHT EIGHT FIVE NATEC SAN DIEGO CA//685.3//
NOTE AIG ONE THREE EIGHT EIGHT FIVE shall not be used in the info address line of the message.
NOTE Security classifications are defined in the DON Security Classification Guidance (OPNAVINST 5513.1F); however, every attempt should be made to employ UNCLAS to expedite routing.
UNCLASS//13800// MSGID/GENADMIN/V-2// SUBJ/CAT I ALRE TECHNICAL PUBLICATION DEFICIENCY REPORT REF/A/DOC/OPNAV/01FEB97// AMPN/OPNAVINST 4790.15E RMKS/THIS MSG DUAL ACTION FOR NATEC SAN DIEGO AND NAVAIRWARCENACDIV LKE. INFO FOR ALL OTHERS.
1. Reporting custodian and UIC.
2. Equipment FST.
3. Report control number.
4. Julian date deficiency discovered.
5. NSN of publication. **
6. through 21: N/A.
22. Details.
a. Technical manual number.
b. Equipment model number. **
c. Basic date of technical manual.
d. Change date and change number.
e. Work Package Number. **
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11-49 f. Page number.
g. Paragraph number.
h. Figure number and table number.
i. Aperture card number. **
j. Aperture card date. **
k. Aperture card revision number and date. **
l. Deficiency (be specific).
m. Recommendations (be specific).
n. Name, rank, and DSN number of ALRE maintenance officer. (If deployed, delete phone number and insert the word DEPLOYED).
NOTE ** Indicates these information blocks are not applicable for CAT I ALRE TPDRs concerning ALRE QA cards.
11.15.3 CAT II ALRE TPDR Preparation.
The format and content for submission of CAT II ALRE TPDR reports are contained on the reverse of the OPNAV 4790/66.
NOTE For CAT II ALRE TPDRs involving ALRE QA cards, refer to paragraph 11.14.2.3. 11.16 Other Required Reports 11.16.1 Familiarity with reports and compliance with reporting procedures such as Departures from Specifications, PMS feedback reports, and technical manual deficiency and evaluation reports (TMDERs) are necessary to an effective QA program.
11.16.2 A departure from specifications is a lack of compliance with any authoritative document, plans, procedure, instruction or notice. Specifications include:
a. ALRE numerical drawing list, detail specifications.
b. MIL Standard and MIL Specification series.
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11-50 c. PEO(T) (PMA 251) technical manuals, instructions, bulletins, letters, notices, repair procedures, etc.
d. COMNAVAIRFOR instructions and notices.
e. OPNAV instructions and notices.
11.16.2.1 Whenever a departure from ALRE specifications (material and or installation) is necessary, a message request for departure from specifications will be submitted to the TYCOM (info PEO(T) (PMA 251) and NAVAIRWARCENACDIV Lakehurst). COMFLTFORCOMINST 4790.3B (NOTAL) gives a complete description of this procedure.
11.16.2.2 Departures from ALRE specification will be categorized as follows:
a. Minor departure - A departure from ALRE specification in a system and subsystem that poses no threat to safety of flight, injury to personnel or damage to equipment. Commanding officers have authority to approve such departure to place equipment in operational status but must follow up with a message to the TYCOM.
b. Major departure - A departure from ALRE specification in a system and subsystem that could jeopardize safety of flight, cause injury to personnel or damage to equipment. Such a departure must be granted by the TYCOM before normal operations resume. NAVAIRWARCENACDIV Lakehurst, as the FST, will make an engineering appraisal of the departure when requested by the TYCOM.
11.16.3 PMS Feedback Report. The OPNAV 4790/7B Planned Maintenance System Feedback Report is used to report discrepancies related to the PMS. The report notifies FTSC Atlantic and Pacific, and the TYCOM on PMS issues, procedural problems, or deficiencies in documentation requirements. Instructions on its use are found in NAVSEAINST 4790.8B.
11.16.4 Technical Manual Deficiency and Evaluation Report. Discrepancies in NAVSEASYSCOM technical manuals will be reported via the NAVSEA 4160/1 NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER). 11.17 Address Indicator Group ONE THREE EIGHT EIGHT FIVE 11.17.1 AIG ONE THREE EIGHT EIGHT FIVE contains approximately 30 addressees including each carrier, all ALRE shore activities, all CAFSU field offices, RMCs, and some training commands. To obtain a
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11-51 current list, contact the command communications center AIG clerk. PEO(T) (PMA 251), as the cognizant authority of AIG ONE THREE EIGHT EIGHT FIVE, will update the AIG annually (June) via recapitulation message.
11.17.2 Care shall be taken in preparing naval messages to ensure that the AIG is NOT included in the “INFO” line of the message text. Further, commands shall NOT duplicate addresses, by ensuring that a command listed in the AIG is not also listed in the “TO” or “INFO” text of the message.
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11-52
QA SUPERVISOR CATAPULT QAI
(3 MINIMUM) ARRESTING GEAR QAI
(3 MINIMUM) VLA QAI
(1 MINIMUM) CENTRAL TECHNICAL PUBLICATION LIBRARIAN CATAPULTS
CDQAI 2 MINIMUM PER BRANCH
CDI MINIMUMS PER BRANCH
CENTRAL CHARGING PANEL .......2
ROTARY ......4
WATER BRAKES.4
TOPSIDE P.O..2
HOLDBACK.....4
JBDs ........4
ARRESTING GEAR
CDQAI 2 MINIMUM PER BRANCH
CDI MINIMUMS PER BRANCH
SHEAVE DAMPER .......4
ENGINE ROOM...4
TOPSIDE.......2
ALRE ELECTRICAL
CDQAI 1 MINIMUM
CDI MINIMUMS
CAT EL ......2
FLT DK LTG ..2 VLA
CDQAI 1 MINIMUM
CDI MINIMUMS
IFLOLS ......2
ILARTS ......2
MOVLAS ......2
HUD .........2
RESPONSIBLE TO QA WHEN FUNCTIONING AS CDQAI/CDI Figure 11-1. ALRE Quality Assurance Organization
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11-53 CVN-76 MI 1-00 28 Feb 2011
CVN-76 Maintenance Instruction 1-00 From: ALRE Maintenance Officer
Subj: AIRCRAFT LAUNCH AND RECOVERY EQUIPMENT QUALITY ASSURANCE AUDIT PROGRAM
Ref: (a) (Include references as applicable)
Encl: (1) (Include enclosures as applicable)
1. Purpose
. (The first paragraph of the maintenance instruction shall state the purpose of the directive.) 2. Cancellation
. (The second paragraph must contain a cancellation statement if a prior maintenance instruction was issued.) 3. (Third and subsequent paragraphs contain the text of the maintenance instruction, such as background information, responsibilities, or action requirements.)
SAMPLE
S.V.L. COUPLING (Signature and typed name of the ALRE maintenance officer)
Distribution: (Include a listing of applicable work centers)
Figure 11-2. Sample Maintenance Instruction
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11-54
Figure 11-3. ALRE PQDR Process Flow CLOSE OUT REPLY TO SCREENING
REPLY TO ORIGINATION POINT NOTIFY DESIGN GROUP ORIGINATION POINT INVESTIGATION AND CLOSE OUT SUPPORT POINT FST ACTION POINT EXHIBIT REQUIRED DESIGN OR PROCUREMENT PROBLEM NEW OR REWORKED ? ACTION POINT ACCEPTS REPLY? EXHIBIT REQUIRED OVERRIDE FINAL REPLY TO ORIGINATOR PREVIOUS INVESTIGATION SUPPORT POINT INVESTIGATION REPLY TO ORIGINATION POINT
REWORKED NEW NO YES INFO NO YES NO YES YES NO YES NO REPLY FROM OTHER SERVICES ACTION
PROCESSED BY SUPPORT POINT ACTION POINT FORWARDS PQDR TO OTHER
FST SCREENING POINT FST SCREENING POINT ORIGINATION POINT NOTIFIED; FORWARDS EXHIBIT ALRE ORIGINATED PQDR ON NAVAIR PROCURED & REWORKED ITEMS ALRE ORIGINATED PQDR ON OTHER SERVICE FURNISHED
ORIGINATION POINT PQDR
FST SCREENING POINT REPLY TO ACTION POINT CLOSE OUT PQDR FORWARD PQDR & RESULTS TO DESIGNATED PROCUREMENT ACTIVITY
A
A
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11-55 FROM: USS SHIP// TO: NAVAIRWARCENACDIV LAKEHURST NJ// AIG ONE THREE EIGHT EIGHT FIVE// UNCLAS //13800// MSGID/GENADMIN/V-2// SUBJ/ALRE HAZARDOUS MATERIAL REPORT// REF/A/DOC/OPNAV/26JUN02// NARR/REF A IS OPNAVINST 4790.15E. THIS MSG ACTION FOR NAVAIRWARCENACDIV LKE. INFO ALL OTHERS. // RMKS/1. USS SHIP (CVN 00)/03300 2. NAVAIRWARCENACDIV LAKEHURST NJ 3. R03300-95-8032 4. 02300/DEPLOYED 5. 5R, 1710-00-102-7796, EY 6. PURCHASE CABLE ASSEMBLY 7A. 91796, RIDON AMERICAN CORP, SPRINGFIELD, NH 7B. N/A 7C. A-1 SHIPPERS INC., NORFOLK, VA 8. 515659-2, 515659-2 9. UNK, UNK 10A. N00383-91-C-5158 10B. N/A 10C. N0330050329003 10D. N/A 11. N/A 12. UNK 13. 50 ARRESTMENTS 14. N/A 15A. 1 15B. 1 15C. 1 15D. 0 16A. MK7 MOD3 ARRESTING GEAR P/N 624216-15, N/A 16B. N/A, PENDANT ENGINE, 624216-15, N/A 17. 10777.00 DOLLARS, 25 MHRS, UNK 18. N/A 19. UNK 20. 7C1A140 21A. USS SHIP SUPPLY 21B. EXHIBIT HELD BY CV-00 V-2 (ALRE) MATERIAL CONTROL FOR 60 DAYS PENDING DISPOSITION INSTRUCTIONS. 22A. DURING FIRST 50 HIT PMS, INSPECTED CONTRACTOR POURED TERMINAL. FOUND SIX CAVITIES ON FACE OF TERMINAL. FIVE OF THESE HOLES WERE GREATER THAN ACCEPTABLE CRITERIA IAW NAVAIR 51-5BCA1.1 CHAPTER 17. 22B. COULD CAUSE WIRE TO FAIL AT TERMINAL RESULTING IN REDUCED OPERATIONAL CAPABILITY, LOSS OF AIRCRAFT OR LIFE. 22C. NONE 22D. VISUAL INSPECTION 22E. N/A 22F. N/A 22G. N/A 22H. N/A 22I. L.H. CROSSHEAD, CWO4, ALRE MAINTENANCE OFFICER, DEPLOYED 22J. VB07 22K. N/A 22L. N/A //
Figure 11-4. Sample ALRE Hazardous Material Report Message
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11-56 FROM: USS SHIP// TO: NAVAIRWARCENACDIV LAKEHURST NJ// AIG ONE THREE EIGHT EIGHT FIVE// UNCLAS //13820// MSGID/GENADMIN/V-2// SUBJ/ALRE ENGINEERING INVESTIGATION REQUEST// REF/A/DOC/OPNAV/26JUN02// NARR/REF A IS OPNAVINST 4790.15E. THIS MSG ACTION FOR NAVAIRWARCENACDIV LKE. INFO ALL OTHERS.// RMKS/1. USS SHIP (CVN-00)/03300 2. NAVAIRWARCENACDIV LAKEHURST NJ 3. R03300-95-8032 4. 02355/DEPLOYED 5. 5R, 1720-00-476-0009, EY 6. CHOKE RING 7A. 32145, TEXAS ELECTRONICS INC., DALLAS, TX7B. N/A 7C. UNK 8. TXEL50684, 14-50684-3 9. UNK, UNK 10A. V00383-87-C-9621 10B. N/A 10C. N0330050329003 10D. UNK 11. NEW 12. UNK 13. UNK 14. N/A 15A. 1 15B. 1 15C. 1 15D. 0 16A. C13 MOD2 CATAPULT P/N 622295-1, N/A 16B. N/A, WATER BRAKE INSTALLATION, 622123-1, N/A 17. 482 DOLLARS, 55 MHRS, UNK 18. N/A 19. UNK 20. 7A1AK00 21A. USS SHIP SUPPLY 21B. EXHIBIT HELD FOR 60 DAYS CVN-00 V-2 (ALRE) MATERIAL CONTROL AWAITING DISPOSITION INSTRUCTIONS. 22A. LEFT HAND CHOKE RING FROM CATAPULT 3 HAS A CRACK IN SIX O'CLOCK POSITION. CRACK IS 1/32 IN. WIDE ON SURFACE AND 2 IN LONG. 22B. CAN CAUSE DEGRADED WATERBRAKE PERFORMANCE. 22C. NONE 22D. VISUAL INSPECTION 22E. N/A 22F. PHOTOS AVAILABLE UPON REQUEST. 22G. N/A 22H. N/A 22I. J.W. BOWCAT, LT, ALRE MAINTENANCE OFFICER, DEPLOYED 22J. VB03 22K. N/A 22L. N/A //
Figure 11-5. Sample ALRE Engineering Investigation Request Message
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11-57 FROM: USS SHIP// TO: NAVAIRWARCENACDIV LAKEHURST NJ// AIG ONE THREE EIGHT EIGHT FIVE// UNCLAS //13800// MSGID/GENADMIN/V-2// SUBJ/ALRE ENGINEERING INVESTIGATION REQUEST// REF/A/DOC/OPNAV/26JUN02// NARR/REF A IS OPNAVINST 4790.15E. THIS MSG ACTION FOR NAVAIRWARCENACDIV LKE. INFO ALL OTHERS. // RMKS/1. USS SHIP(CVN-00)/03300 2. NAVAIRWARCENACDIV LAKEHURST NJ 3. R03300-95-8032 4. 03114/DEPLOYED 5. 9C, 9150-00-272-7652, EY 6. GREASE, GRAPHITE 7A. UNK, NONFLUID OIL CORP, BOSTON, MA 7B. N/A 7C. N/A 8. N/A, N/A 9. N/A, N/A 10A. DLA 40089 MA028 10B. N/A 10C. N/A 10D. N/A 11. N/A 12. N/A 13. NONE 14. NO 15A. 1 15B. 0 15C. 1 15D. 0 16A. MK 7 ARRESTING GEAR ENGINE ASSY P/N 624216-15, N/A 16B. N/A, A/G ENGINE, 624216-15, N/A 17. 54.00 DOLLARS, N/A, N/A 18. MILSPEC VV-G-671 19. UNK 20. SPMIG NR 568 21A. USS SHIP SUPPLY 21B. EXHIBIT HELD FOR 60 DAYS CVN-00 V-2 (ALRE) MATERIAL CONTROL AWAITING DISPOSITION INSTRUCTIONS. 22A. VV-G-671 IS USED THROUGHOUT THE A/G SYSTEM. VV-G-671 IS NOT ABLE TO BE ACQUIRED THROUGH THE LOCAL SUPPLY SYSTEM. SUPPLY IS UNABLE TO BRING THIS ITEM ABOARD SHIP DUE TO LOCAL AND STATE EPA REGULATIONS. DISPOSITION HAS BEEN DIFFICULT DUE TO HIGH COSTS. 22B. UNK 22C. ORIGINAL 22D. SUPPLY ORDER REJECTED 22E. N/A 22F. N/A 22G. N/A 22H. N/A 22I. ABEC L. RUNOUT, QA, LCPO 22J. VB20 22K. N/A 22L. N/A //
Figure 11-6. Sample ALRE Engineering Investigation Request Message (Environmental Impact)
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11-58 FROM: USS SHIP// TO: NAVAIRWARCENACDIV LAKEHURST NJ// AIG ONE THREE EIGHT EIGHT FIVE// UNCLAS //13820// MSGID/GENADMIN/V-2// SUBJ/ALRE HAZARDOUS MATERIAL REPORT/ENGINEERING INVESTIGATION REQUEST// REF/A/DOC/OPNAV/26JUN02// NARR/REF A IS OPNAVINST 4790.15E. THIS MSG ACTION FOR NAVAIRWARCENACDIV LKE. INFO ALL OTHERS.// RMKS/1. USS SHIP(CVN-00)/03300 2. NAVAIRWARCENACDIV LAKEHURST NJ 3. R03300-95-8032 4. 02351 5. 5RM, 1720-00-716-1269, EY 6. EMERGENCY CUTOUT VALVE 7A. 80012, TELEDYNE REPUBLIC MFG., COLUMBUS, OH7B. N/A 7C. N/A 8. 3124WLH127RH, 407530-2 9. UNK, UNK 10A. N68335-86-C-1221 10B. N/A 10C. UNK 10D. N/A 11. N/A 12. UNK 13. 12 MONTHS 14. N/A 15A. 1 15B. 1 15C. 1 15D. 816A. C13 MOD1 CATAPULT P/N 622295-1, N/A 16B. 9876-32-321-4321, CENTRAL CHARGING PANEL, 624123-13, N/A 17. 400 DOLLARS, 15 MHRS, UNK 18. N/A 19. UNK 20. 7A6A100 21A. USS SHIP SUPPLY 21B. EXHIBIT HELD CVN-00 V-2 (ALRE) MATERIAL CONTROL FOR SIXTY DAYS AWAITING DISPOSITION INSTRUCTIONS. 22A. VALVE STEM SNAPPED AT HANDLE DURING MONTHLY PMS FUNCTIONAL TEST. HANDLE CANNOT BE REMOUNTED ON VALVE STEM. VALVE STEM APPEARS TO BE INADEQUATELY DESIGNED AT THREADED HOLE FOR THE HANDLE FASTENING SCREW. STEM SNAPPED AFTER LIGHT IMPACT OF HANDLE AGAINST VALVE STOP. 22B. POSSIBLE CATASTROPHIC POTENTIAL IF THIS OCCURRED DURING AN AIRCRAFT HANGFIRE; LOSS OF AIRCRAFT OR LIFE. NO EMERGENCY PROCEDURES EXIST IF CUTOUT VALVE STEM FAILS IN MID STROKE. 22C. NONE 22D. FUNCTIONAL TEST 22E. N/A 22F. N/A 22G. N/A 22H. N/A 22I. R.T. LAUNCHVALVE, LT, ALRE MAINTENANCE OFFICER, DEPLOYED 22J. VB03 22K. N/A 22L. N/A //
Figure 11-7. Sample ALRE Hazardous Material Report and Engineering Investigation Request Message
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11-59 FROM: USS SHIP// TO: NAVAIRWARCENACDIV LAKEHURST NJ// AIG ONE THREE EIGHT EIGHT FIVE// UNCLAS //13810// MSGID/GENADMIN/V-2// SUBJ/ALRE CAT I PRODUCT QUALITY DEFICIENCY REPORT// REF/A/DOC/OPNAV/26JUN02// NARR/REF A IS OPNAVINST 4790.15E. THIS MSG ACTION FOR NAVAIRWARCENACDIV LKE. INFO ALL OTHERS.// RMKS/1. USS SHIP(CV-00)/03300 2. NAVAIRWARCENACDIV LAKEHURST NJ 3. V03300-95-8032 4. 02330/DEPLOYED 5. 5RM, 1710-00-102-7796, EY 6. CABLE AND REEL ASSEMBLY 7A. 98247, CANADIAN COMMERCIAL CORP., ONTARIO, CANADA 7B. N/A8. 515659-2, 515659-2 9. UNK, UNK 10A. N00383-85-C-3512 10B. N/A10C. N033005032900310D. UNK 11. NEW 12. UNK 13. 0 ARRESTMENTS 14. NO 15A. 3 15B. 1 15C. 1 15D. 2 16A. MK7 MOD2 ARRESTING GEAR ENGINE P/N 624216-15, N/A 16B. N/A, PENDANT ENGINE, 624216-15, N/A 17. 10820 DOLLARS, 40 MHRS, N/A 18. N/A 19. UNK 20. 7C1A140 21A. USS SHIP SUPPLY 21B. EXHIBIT HELD BY CV-00 V-2 (ALRE) MATERIAL CONTROL FOR 60 DAYS AWAITING DISPOSITION INSTRUCTIONS. 22A. DURING INSTALLATION OF NEW PURCHASE CABLE DISCOVERED BOTH MANUFACTURER POURED TERMINALS DID NOT MEET REQUIRED SPEC'S IAW NA 51-5BBA-1.1. BOTH TERMINALS HAD EXCESSIVE NUMBER OF PULLED WIRES AND CAVITIES. ZINC RECESSION ON THE STARBOARD SIDE WAS 0.098 IN. INSTEAD OF MAXIMUM 0.060 IN. DISCREPANT TERMINALS WHERE CUT AND REPOURED ONBOARD. 22B. POSSIBLE WIRE FAILURE AT TERMINAL RESULTING IN REDUCED OPERATIONAL CAPABILITY; POSSIBLE LOSS OF AIRCRAFT OR LIFE. 22C. NONE 22D. DETECTED DURING VISUAL INSPECTION PRIOR TO INSTALLATION. 22E. N/A 22F. PHOTOS ARE AVAILABLE UPON REQUEST. 22G. N/A22H. N0330050329003 22I. L.H. CROSSHEAD, LT, ALRE MAINTENANCE OFFICER, DEPLOYED. 22J. VB08 22K. N/A 22L. N/A //
Figure 11-8. Sample ALRE CAT I Product Quality Deficiency Report Message
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11-60 FROM: USS SHIP TO: NAVAIRWARCENACDIV LAKEHURST NJ// AIG ONE THREE EIGHT EIGHT FIVE// UNCLAS//13800// MSGID/GENADMIN/V-2// SUBJ/ALRE CAT II PRODUCT QUALITY DEFICIENCY REPORT// REF/A/DOC/OPNAV/26JUN02// NARR/REF A IS OPNAVINST 4790.15E. THIS MSG ACTION FOR NAVAIRWARCENACDIV LKE. INFO ALL OTHERS.// RMKS/1. USS SHIP(CV00)/03300 2. NAVAIRWARCENACDIV LAKEHURST NJ 3. R03300-96-8001 4. 03034/DEPLOYED 5. S9C, 1720-00-476-0009, EH 6. CHOKE RING 7A. 62577, PIONEER SALES COMPANY, CLEVELAND, OH 7B. N/A 7C. UNK 8. PSC55432-012, 14-50684-3 9. SN312, N/A 10A. N00383-97-C-9621 10B. N/A 10C. N033050329003 10D. N/A 11. NEW 12. 12 DEC 98 13. 0 CAT SHOTS 14. NO 15A. 10 15B. 10 15C. 10 15D. 0 16A. C13 CATAPULT 10-61316-1, N/A 16B. 3214-12-123-1234, WATER BRAKE ASSY, 610614-1, N/A 17. 829.20 DOLLARS, 3 MHRS, UNK18. N/A 19. UNK 20. 7A1AK3421A. USS SHIP SUPPLY 21B. EXHIBIT HELD BY CV-00 V-2 (ALRE) MATERIAL CONTROL FOR 60 DAYS AWAITING DISPOSITION INSTRUCTIONS. 22A. LOW URGENCY. ADEQUATE SPARES FROM ANOTHER CONTRACT ONBOARD. 22B. SAFETY NOT A FACTOR/MISSION NOT AFFECTED. 22C. NONE 22D. DURING PMS DISCOVERED LEFT CHOKE RING, CATAPULT THREE OUT OF TOLERANCE. ATTEMPTED TO INSTALL NEW CHOKE RING. RING WOULD NOT THREAD INTO WTR BK CYL. USING BOTH OLD RING FOR COMPARISON AND APERTURE CARD, QA DISCOVERED THREAD PITCH OF NEW CHOKE RING INCORRECTLY MANUFACTURED. 22E. PACKING SEEMS SUFFICIENT 22F. PHOTOS TAKEN AND AVAILABLE ON REQUEST. 22G. N/A 22H. ORIGINAL REQ NR: N03305032900322I. A.B. CRUISER, CWO4, ALRE MAINTENANCE OFFICER, DEPLOYED. 22J. VB03 22K. N/A 22L. N/A //
Figure 11-9. Sample ALRE CAT II Product Quality Deficiency Report Message
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11-61 FROM USS SHIP TO AIG ONE THREE EIGHT EIGHT FIVE// NATEC SAN DIEGO CA//685.3// UNCLAS //13820// MSGID/GENADMIN/V-2// SUBJ/ALRE CAT I TECHNICAL PUBLICATION DEFICIENCY REPORT// REF/A/DOC/OPNAV/01OCT00// AMPN/OPNAVINST 4790.15E// RMKS/THIS MSG DUAL ACTION FOR NATEC AND NAVAIRWARCENACDIV LKE. INFO FOR ALL OTHERS. 1. ORIG: USS SHIP (CVN-00) 03300 2. CFA: NAVAIRWARCENACDIV LAKEHURST NJ 3. RCN: N03300008032 4. DATE DISC: 0249 5. NSN: 0851-LP-005-7041 6. THROUGH 21. N/A 22. A. TECH MAN: NA 51-15ABD-2 B. EQUIP MODEL: N/A C. BASIC PUB DATE: 1 AUGUST 1990 D. CHG DATE/NO: N/A E. WK PACK NO: N/A F. PG NO: 3-23 G. PARA NO: 3-39.8 H. FIG NO: N/A I. APTR CARD NO: N/A J. APTR CARD DATE: N/A K. APTR CARD REV: N/A L. DEF: PARAGRAPH 3-39.8 STATES LAUNCH VALVE STROKE TIMER TIMES WILL BE DETERMINED USING CSV SETTINGS OF 050, 150, AND 120. CSV SETTINGS ARE INCORRECT AND SHOULD BE 050, 150, AND 250. ALL OTHER PARAGRAPHS RELATING TO CSV SETTINGS FOR LAUNCH VALVE STROKE TIMER TIMES CONFIRM THIS ERROR. M. REC: CHANGE THE 120 SETTING TO READ 250. N. POC: R.T. LAUNCHVALVE, LT, ALRE MAINTENANCE OFFICER, DEPLOYED.//
Figure 11-10. Sample ALRE CAT I Technical Publications Deficiency Report Message
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11-62
Report Criteria Precedence When to send 1. Part malfunctions or fails; may cause injury or death, or damage to or loss of aircraft, equipment or facilities. ALRE HMR 2. Configuration deficiency is a safety hazard. 3. Urgent assistance required; corrective action needed because of operational requirement. 4. Condition detected allows incorrect installation; system malfunction or failure may occur. PRIORTY Within 24 hours after discovery. 1. Safety is involved. ALRE EI 2. Additional technical or engineering info for an aircraft mishap investigation. 3. Launch and recovery systems readiness impaired by material reliability. 4. When directed by higher authority ROUTINE Within 3 calendar days after discovery. 1. Combination of ALRE HMR and ALRE EI criteria. ALRE HMR/EI 2. Safety concerns should be emphasized when submitting this combined report. PRIORITY Within 24 hours after discovery. CAT I 1. New or newly reworked component. ALRE PQDR 2. Affects safety including injury or death; can cause equipment damage. PRIORITY Within 24 hours after discovery. 1. Component may cause widespread material or human resource impact. CAT II ALRE PQDR 2. Does not meet criteria for a CAT I ALRE PQDR. ROUTINE Within 3 calendar days after discovery. 1. Publication deficiency which may cause injury or death or damage equipment. CAT I ALRE TPDR
PRIORITY Within 24 hours after discovery. 1. Does not meet criteria for CAT II ALRE TPDR a CAT I ALRE TPDR. ROUTINE (OPNAV 4790/66) Within 10 working days after discovery.
Figure 11-11. ALRE Discrepancy Reports Matrix