title quality requirements for programmed depot ... · documents, the contractual documents, e.g....

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NORTHROP GRUMMAN AEROSPACE SYSTEMS GLOBAL MISSION EXCELLENCE & LOGISTICS

QUALITY ENGINEERING STANDARD

QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

1

Title QUALITY REQUIREMENTS FOR PROGRAMMED

DEPOT MAINTENANCE DATA PACKAGE FOR

THE TOTAL SYSTEM SUPPORT RESPONSIBILITY

PROGRAM

Supersedes MLB-108 Rev 1 05/28/15

Process Owner Manager – Product Quality

Applies To All Programmed Depot Maintenance (PDM) performed under the

Total System Support Responsibility (TSSR) program

Scope Requirements for the Data Package to be generated and delivered to

the Customer.

Aircraft Programmed

Depot Maintenance

(PDM) Data Package

Purpose

The Programmed Depot Maintenance (PDM) data package provides

the Customer with the required information to receive, inspect, update

aircraft records and release the aircraft out of Depot status.

The requirements for the data package are defined in the Total System

Support Responsibility (TSSR) prime contract Technical

Requirements Document (TRD) Tab H, Aircraft Depot Work

Requirements. These requirements have been translated in the PDM

Supplier Statement of Work (SSOW).

The purpose of this QES document is to clarify and expand on data

requirements to ensure consistency in the documentation delivered to

the Customer when the A/C is delivered to Robins AFB after PDM.

When conflict exists between this document and other contractual

documents, the contractual documents, e.g. SSOW, TRD,

SSOW/TRD reference documents, AFIs, etc, shall take precedence.

APPROVED BY ON FILE

Paul J. Morris, Manager, Product Quality




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

2

REVISIONS DATE REVISION REVISED BY

DESCRIPTION

6/12/12

-

D. Brammer Original Issue

5/28/15 1 D. Brammer Adequacy Review – No changes

04/17/18 2 P. Morris Adequacy Review – No changes

Aircraft Programmed Depot

Maintenance (PDM) Data

Package Summary

The PDM data package consists of several elements outlined

below and in the following sections.

Aircraft Forms (Logbook) – AFTO Forms 781s

A/C Blue Book

AFTO 95s

AFTO 95 Summary Document

AFTO 427s

Aircraft Jacket (Accordion) File

Planning Requirements (PRAA) Document

Aircraft Forms (Logbook) –

AFTO Forms 781s

The Aircraft Forms (Logbook) consists of AFTO Forms 781A

thru N. Instructions for maintenance and completion of these

forms are governed by TO 00-20-1. The various AFTO 781

sections are outlined below.

AFTO Form 781A, Maintenance Discrepancy And Work

Document

AFTO Form 781B, Communications Security (COMSEC)

Equipment Record

AFTO Form 781C, Avionics Configuration And Load

Status Document

AFTO Form 781D, Calendar And Hourly Item Inspection

Document

AFTO Form 781E, Accessory Replacement

AFTO Form 781F, Aerospace Vehicle Flight Report And

Maintenance Document

AFTO Form 781G, General Mission Classification




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

3

Aircraft Forms

(Logbook) – AFTO

Forms 781s

(Continued)

The Aircraft Forms (Logbook) consists of AFTO Forms 781A thru N.

Instructions for maintenance and completion of these forms are governed

by TO 00-20-1. The various AFTO 781 sections are outlined below

(Continued):

AFTO Form 781H, Aerospace Vehicle Flight Status And

Maintenance Document

AFTO Form 781J, Aerospace Vehicle Engine Flight Document

AFTO Form 781K, Aerospace Vehicle Inspection, Engine Data,

Calendar Inspection, And Delayed Discrepancy Document

AFTO Form 781L, Record Of Removal/Installation Of

Controlled Cryptographic Items (CCI)

AFTO Form 781M, Status Symbols And Functional System

Codes

AFTO Form 781N, J-79 Engine Runup Record.

Aircraft Bluebook The Aircraft Blue Book is a non-contractual and informal book that

contains (but not limited to) the following items as a record above and

beyond the Aircraft Forms (Logbook) for historical reference

purposes.

Lost Tool Reports applicable to this aircraft

Deferred Nonconformances discovered during this PDM

No Work Nonconformances discovered during this PDM

Noted But Not Corrected (NBNC) Nonconformances discovered

during this PDM

Service Bulletins (S/B) accomplished during this PDM

Time Compliance technical Orders (TCTO) accomplished during

this PDM

The AFTO 103 associated with this PDM

Weight And Balance information of the aircraft after PDM is

accomplished




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

4

AFTO Form 95

– Significant

Historical Data

Record

• The AFTO Form 95 is a record of significant maintenance actions. A

separate AFTO 95 is required for the following items. Copies of the

individual AFTO 95s shall be placed in the proper section of the Aircraft

Jacket (Accordion) File. Refer to T.O. 00-20-1, chapter 9 and T.O. 00-20-1

ANG Sup 1for AFTO 95 guidance.

Airframe (System 11000)

Landing Gear (System 13000)

Flight Controls (14000)

Engine (Power Plant) (System 23000) (separate Form 95 for each

position)

The Auxiliary Power Unit (APU)(System 24000)

Fuel System (46000)

o Verify all required fuel system repair history per -6 for Bladder

#1 - #7.

o Center wing Fuel Cells are listed on separate AFTO Form 95.

o Aircraft Integral Fuel Tank Require a AFTO Form 427 entry

The ”Summary AFTO 95” is a compilation of all the individual AFTO 95s but

also contains other information which does not normally require an AFTO 95

entry. Examples of various pages of the Summary AFTO 95 are included in

Attachment A. This summary AFTO 95 is put together and delivered with the

aircraft to aid the customer and Northrop Grumman personnel during the

Acceptance Inspection process. It also provides a quick reference in one

location of PDM activity if questions arise in the future. The summary AFTO

95 contains the following information as well the date accomplished and the

applicable unique Depot work document number, e.g. Discrepancy tag, TO,

Work Order, etc.




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

5

AFTO Form 95

– Significant

Historical Data

Record

(Continued)

Applicable C Check and card deck revision

Induction date, aircraft cycles and aircraft time

Time Change Items

Time Compliance Technical Orders (TCTO) Accomplished

Service Bulletins Accomplished

Significant Structural Inspection Documents (SSID) Accomplished

Additional Depot Work

AFTO 103 - AFTO 781K Entries

Aircraft Components Changed

o Including Part Number And Serial Number

APU Components Changed

o Including Part Number And Serial Number

Time Change Items Accomplished Not On AFTO 103

o Include Airworthiness Certificate Date, Aircraft Cycles And

Aircraft Time

Engineering Directives Accomplished

o Including Date And Control #

Defects Documented During PDM Not Part Of Planned PDM

Activity, e.g. major Unanticipated Repairs

o Include Document # And Description

Lab Test Results E.G. Oil Samples, Etc.

All Fuel Leak Repairs (From The AFTO 427s)

Compilation Of All Engine Components Changed (Reference

Individual Engine AFTO 95s)

Engine Defects Documented During PDM

o Include Document # And Description




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REV.

2

EFFECTIVE DATE

04/17/18

6

AFTO Form 95 – Significant

Historical Data Record

(Continued)

Aircraft Paint Information (If Applicable). Period

Of Performance

Flight Control Surfaces Information (P/N, S/N,

W&B, Paint, Etc.)

All Information Contained in Required Individual

AFTO 95s Not Listed Above

AFTO Form 427 The AFTO Form 427 is used to document fuel leak

repair activity. Fuel leak repair activity shall be

documented on the AFTO 427 form. The AFTO

427 forms shall be included in the Aircraft Jacket

(Accordion) File as well as on the summary AFTO

95

Aircraft Jacket (Accordion) File The Aircraft Jacket (Accordion) File contains pertinent

aircraft information that accompanies the aircraft

from the PDM facility. It contains the AFTO 95s,

781s, records, etc.

Planning Requirements (PRAA)

Document The PRAA Document is a scheduled maintenance

document generated by the Customer Wing

Planning and Scheduling group which describes

future planned activities for the aircraft. A copy of

the document is included in the Aircraft Jacket

(Accordion) File when the aircraft departs for

PDM. Activities during PDM which affect or are

listed on the PPRAA document should be

annotated with hand written updates and notations

with the applicable information. Approximately 5

days prior to aircraft departure, the PRA document

needs to be sent via FAX to the Planning and

Scheduling organization. The PRAA that is sent to

the Planning and Scheduling group is used to plan

and prepare for the receipt and acceptance of the

aircraft after PDM is complete.




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

7

References

Other T.O. 00-20-1 Aerospace Equipment Maintenance

Inspection, Documentation, Policies, And

Procedures

T.O. 00-20-1 ANG Sup 1

Aerospace Equipment Maintenance

Inspection,

Documentation, Policies, And Procedures –

Air National Guard Supplement

Forms AFTO Forms 781 Aircrew/Mission Flight Data Document

AFTO Form 95 Significant Historical Data Record

AFTO Form 427 Aerospace Vehicle Integral Fuel Tank Repair

Historical Data




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

8

ATTACHMENT A (Summary AFTO 95 Example)

SIGNIFICANT HISTORICAL DATAPAGE 1 OF 7 PAGES

1. MISSION DESIGN SERIES/TYPE, MODEL AND SERIES 2. MANUFACTURER 3. SERIAL NUMBER 4. ACCEPTANCE DATE

DATE

A

REMARKS

B

PREVIOUS EDITIONS WILL BE USED.AFTOFORM

FEB 65 95

ORGANIZATION

C

E8C BOEING

Northrop Grumman Corp.

LCMMC

4400 Sen. J. Bennett Johnston Ave.

Lake Charles, LA 70615- 5157

00-2000

20110929 ACFT ARRIVED AT LAKE CHARLES FOR C1 REV 14 PDM INSPECTION

ACFT TIME: 55,792.4 CYCLES: 24,692

PDM/ISO CLOCK STARTS ON 20120215

20120128 ACFT WEIGHT AND BALANCE C/W 90-1E-8C-5-PDM

20120209 ACFT PDM INSPECTION C/W 2060838

20120209 ACFT MINOR INSPECTION C/W 2060838

20120209 ACFT HOME STATION CHECK C/W 2060838

20111003 ACFT WASH C/W 10-6WC-4-3001-M

TIME CHANGE ITEMS

20111205 REMOVE AND REPLACE L/H SIDE STRUT ASSY 2060744

20111205 REMOVE AND REPLACE R/H SIDE STRUT ASSY 2060745

20120116 REMOVE AND REPLACE L/H & R/H MLG TRUNNIONS 2060746

TCTO’s

20111107 501 INSP OF HORIZ STAB TRAILING EDGE ELEVATOR HINGE SUPPORT FTG 2060747

20111026 771 DEACTIVATION OF POTABLE WATER SYSTEM WOSN 74068

(DEFERED FULL M185 RIBBON CABLE REMOVAL UNTIL NEXT C4 PDM)

20120201 762 AN/ARC-210 (8.33) RADIO MOD ACCOMPLISHED BY MELBOURNE

SERVICE BULLETIN’S

20111031 142 INSP L/H MLG TRUCK BEAM 2060749

20111031 142 INSP R/H MLG TRUCK BEAM 2060749

20111115 A3518 C1-H-STAB ELEVATOR HINGE SUPPORT FITTING-INSP PER FSER 07-0335 2060750

(ATTACHED APPENDIX A)

20111025 A3526 WINDOWS-CONTROL CABIN-FLIGHT DECK #2, #4 AND #5 WINDOWS – INSPECTION 2060752

20120131 A3527 ENGINE FUEL SUCTION FEED SYSTEMS OPS TEST, PERFORM DURING OUTSIDE OPS 2060753

20120116 3523 REV 1 MOD-ELEVATOR CONTROL GUST SNUBBER SUPPORT STRUCTURE 2062319




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

9

ATTACHMENT A (Summary AFTO 95 Example) cont.


1. MISSION DESIGN SERIES/TYPE, MODEL AND SERIES 2. MANUFACTURER 3. SERIAL NUMBER 4. ACCEPTANCE DATE

DATE

A

REMARKS

B


FEB 65 95

ORGANIZATION

C

BOEING


LCMMC



00-2000E8C

COMPONENTS CHANGED

YYYYMMDD P/N S/N DOC #

20120205 SCDL ANTENNA A0S-1543B 0136 2067841

20120207 02 REGULATOR O&C 14 29270-10A-B1 706180 2069312

20120207 02 REGULATOR O&C 18 29270-10A-B1 000001930 2069312

20120207 RH ACM AIR TEMP SENSOR H65-1/10-3063-5 5015 2069325

20120209 #2 YAW DAMPER 18749-1A 7071000 2069493

20120209 NAV MFD DISPLAY C99A9407-1 5730 2069520

20120210 PILOTS ADI 622-3374-002 1023 2069519

20120213 DUAL PILOT VALVE 204-15069-11 0808 2068636




QES NUMBER

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REV.

2

EFFECTIVE DATE

04/17/18

10



1. MISSION DESIGN SERIES/TYPE, MODEL AND SERIES2. MANUFACTURER 3. SERIAL NUMBER 4. ACCEPTANCE DATE

DATE

A

REMARKS

B


FEB 65 95

ORGANIZATION

C

BOEING


LCMMC



00-2000E8C

ENGINEERING DIRECTIVE

DATED: 20091223 CONTROL #: 116MXG09069

#4 ENGINE S/N E5617, SOLID RIVET ON FORWARD OUTBD TURNING VANE HAS ONE EACH RIVET

HEAD MISSING. RIVET IS THE MOST FORWARD/LOWER SECTION OF THE TURNING VANE.

#4 ENG SUBJECT TURNING VANE REPLACED DURING PDM . THIS TERMINATES THIS E.D. SEE 781A,

PG 27, BLK 3, DATED 20111206.




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

11




DATE

A

REMARKS

B


FEB 65 95

ORGANIZATION

C

BOEING


LCMMC



The following defects were documented during the PDM work card inspection of Aircraft 00-2000.

00-2000E8C

MES DOC # 2062387

20110707 LAB RESULTS FOR THE BMS 3-11 HYDRAULIC FLUID SHOW PARTICULATE CONTAMINATION AS

FOLLOWS:

FED-STD-791D -3012 PARTICULATE CONTAMINATION, NAS 1638, TABLE 1, CLASS 8

MAX RESULT

5-15 MICRONS (PARTICLES/100 ML) 64000 125480




>100 MICRONS (PARTICLES/100 ML) 64 488

20120124 LAB RESULTS PASSED MAX RESULTS





>100 MICRONS (PARTICLES/100 ML) 64 0




QES NUMBER

MLB-108

REV.

2

EFFECTIVE DATE

04/17/18

12




DATE

A

REMARKS

B


FEB 65 95

ORGANIZATION

C

BOEING


LCMMC



00-2000E8C

FUEL LEAKS/REPAIRS - #4 MAIN

MES DOC # 2068636

20120210 # 4 MAIN, RWS 384, FASTENER LEAKING LOWER WING C/T S1, CLASS A SLOW SEEP.

20120211 PERFORMED BLOWBACK AND COULD NOT LOCATE LEAK, SO WE SEALED VOIDS AROUND FLAPPER IN

BAY 1 OF 4 MAIN BETWEEN REAR SPAR AND STR 1. STILL LEAKING.

20120210 RWS LOWER 733, AFT DOUBLER LEAKING AT SEAM, CLASS B SEEP.

20120210 PERFORMED BLOWBACK AND FOUND LEAK IN # 4 MAIN TANK, BAY 13 AFT OTBD. CORNER. CLEANED,

PROMOTED, AND SEALED IAW TO 1-1-3. LEAK CHECK FAILED.

TEMP REPAIR

20120212 #4 MAIN, RWS 384, FASTENER LEAKING LOWER WING C/T S1. CLASS A LEAK.

20120213 REPAIR FUEL LEAK IAW T.O. 1-1-3 FIELD REPAIR AS PER ATTACHED EMAIL WITH P/N PTY201

BATCH/LOT 1203. NO LEAKS NOTED AFTER TEMP REPAIR.




QES NUMBER

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REV.

2

EFFECTIVE DATE

04/17/18

13




DATE

A

REMARKS

B


FEB 65 95

ORGANIZATION

C

BOEING 00-2000E8C

AIRCRAFT 00-2000 – PAINT FLT CONTROLS

ACFT TT: 55,792.4


LCMMC



20120206 R&L AILERONS, R&L ELEVATORS, AND RUDDER WERE STRIPPED, PRIMED, PAINTED, WEIGHED AND

BALANCED IAW T.O. 1-1-8 AND T.O. 1E-8C-3-51-1 51110-8 AND WERE INSTALLED ON 00-2000.

SEE P/N & S/N MATIRX.

Component P/N Installed S/N Installed Inst Job Number Inst WOSN

L/H ELEVATOR 65-48584-1 RR115 65-82084-501LC 074602

L/H I/B AILERON 5-86072-3099 RR265 65-01016-501LC 074572

L/H O/B AILERON 5-88190-3163 NA-117L 65-1034-501LC 074582

R/H ELEVATOR 65-48584-2 RR193 65-82084-502LC 074600

R/H I/B AILERON 5-86072-3076 RR 91 65-01016-502LC 074586

R/H O/B AILERON 5-88190-3164 NA-64R 65-1034-502LC 074580

RUDDER 50-9788-31 TIC372 IN-50-9788-501LC 074597




QES NUMBER

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REV.

2

EFFECTIVE DATE

04/17/18

14

ATTACHMENT B (Example of PRAA Document)