COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

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1 BY ORDER OF THE COMMANDER AIR FORCE MATERIEL COMMAND AIR FORCE MATERIAL COMMAND MANUAL JANUARY 2018 Acquisition AIR FORCE MATERIEL COMMAND ENGINEERING TECHNICAL ASSISTANCE REQUEST (ETAR) PROCESS COMPLIANCE WITH THIS PUBLICATION IS MANDATORY ACCESSIBILITY: Publications and forms are available on the e-publishing website at for downloading or ordering. RELEASABILITY: There are no releasability restrictions on this publication. OPR: HQ AFMC/A4FI Supersedes: AFMCMAN21-1, 15 January 2005 Certified by: HQ AFMC/A4F (Mr. Raymond H. Gaier III) Pages: 62 This publication provides policy, responsibilities, and procedures for implementing and managing the Air Force (AF) Engineering Technical Assistance Request (ETAR) process and adheres to the direction of AFI (AFI) /20-101, Integrated Life Cycle Management; and AFMC Instruction (AFMCI) , Implementing Operational Safety Suitability and Effectiveness (OSS&E) and Life Cycle Systems Engineering (LCSE). This publication is the prescribing publication for the AFMC Form 202, Engineering Technical Assistance Request (ETAR). This publication incorporates the six Centers, three Air Logistics Complexes, and applies to all AFMC depot maintenance organizations. This instruction does not apply to the Air National Guard or Air Force Reserve Command units and members. This publication may be supplemented by AFMC Centers, but all supplements must be routed to the OPR listed above for coordination prior to certification and approval. Refer recommended changes and questions about this publication to the OPR using the AF Form 847, Recommendation for Change of Publication; route AF Forms 847 from the field through the appropriate chain of command. Submit requests for waivers through the chain of command to this Publication OPR for nontiered compliance items. Ensure that all records created as a result of processes prescribed in this publication are maintained IAW (IAW) Air Force Manual (AFMAN) , Management of Records, and disposed of IAW AF Records Disposition Schedule located in the Air Force Records Information Management System (AFRIMS). See Attachment 1 for a glossary of references and supporting information. The authorities to waive wing/unit level requirements in this publication are identified with a Tier ( T-0, T-1, T-2, T-3 ) number following the

2 2 AFMCMAN JANUARY 2018 compliance statement. See AFI , Publications and Forms Management, for a description of the authorities associated with the Tier numbers. Submit requests for waivers through the chain of command to the appropriate Tier waiver approval authority, or alternately, to the Publication OPR for non-tiered compliance items. SUMMARY OF CHANGES This document has been substantially revised and needs to be completely reviewed. This publication replaces AFMCMAN 21-1, AFMC Technical Order System, Chapter 5, Engineering Disposition For Nonconforming Technical Problems Beyond Published Authority. Major changes include title changes, updated office symbols, revised organizational responsibilities, and uses of the ETAR to include delegation of engineering technical authority, engineering support processes for Defense Logistics Agency (DLA) managed items requested via DLA Form 339, Request For Engineering Support process; and Special Handling (SH) 252 process. A workscope meeting template has been incorporated to assist with the ETAR process.

3 AFMCMAN JANUARY General Business Practices, Guidance, and Information 1.1. Purpose. This publication standardizes the process for requesting engineering and depot maintenance procedure assistance at organic depots. ETARs from contractor-managed depots are to follow contract-specific direction through the applicable contracting officer. It is intended to provide the engineering and depot maintenance communities with a clear process to develop necessary procedures to mitigate maintenance operation anomalies and work stoppages. This publication addresses business practices to be implemented, and explains the roles and responsibilities of AFMC in providing assistance to depot maintenance organizations. This publication provides information for use by personnel at Air Force Life Cycle Management Center (AFLCMC), Air Force Sustainment Center (AFSC), and Air Force Nuclear Weapons Center (AFNWC). Separate and unique local assistance request processes may exist only as approved waivers to this publication Business Practices and Guidance. The AFMC Form 202, ETAR, is the official method to request and provide engineering technical assistance in support of maintenance operations. AFMC Form 202 Disposition Instructions are used to provide technical assistance for (a) conditions or procedures beyond published technical data and authority under work stoppage and anticipated work stoppage conditions; (b) instances where technical data does not exist and must be developed, approved, and provided to maintenance technicians; (c) procedures and engineering authorization for rework and restoration of damaged or worn parts and components for return to serviceable condition through repair, overhaul, or processes not covered by applicable technical data; (d) engineering authorization for a onetime substitution of parts, components, or materials determined to be suitable replacements for specified items; and (e) engineering authorization for a one-time substitution of support equipment (SE), special tools, test equipment, fixtures or ground handling equipment determined to be suitable replacements for specified items. For the purposes of this manual, the cognizant technical authorities (CTA) in the ETAR process are the Program Manager (PM), Lead Systems Engineer (LSE) and Chief Engineer (CE) as identified in paragraphs and below PM. The PM is responsible for investigating and documenting user-identified changes in operational usage as de-facto requirements baseline changes, and adjusts the engineering support accordingly IAW AFMCI , Implementing Operational Safety, Suitability and Effectiveness (OSS&E) and Life Cycle Systems Engineering (LCSE) Engineering Authority. In accordance with AFMCI , the terms Lead Systems Engineer (LSE) and Chief Engineer (CE) are synonymous, referring to the senior responsible engineer in a Program Office (PO) Information Links. URL links to information in other databases or forms (drawings, electronic technical orders (etos), etc.) pertinent to the recommended solution shall be included on AFMC Forms Limitations. Dispositons listed on AFMC Forms 202 must not degrade reliability, performance, form, fit or function beyond acceptable limits as determined by the CE, or Delegation of Engineering Authority (DEA). The AFMC form will not be used:

4 4 AFMCMAN JANUARY As authorization for part or material substitution unless there is a critical shortage and the item is needed urgently to prevent maintenance or modification work stoppage; As a change to the intent of a Time Compliance Technical Order (TCTO) or to extend TCTO rescission dates or reinstate rescinded TCTOs; To change nuclear certified equipment, systems or technical data unless authorized by the responsible CE (or designee); To change Test, Measurement & Diagnostic Equipment (TMDE) requirements specified in Technical Orders (TOs) and 33K-1-100; As authorization for obtain funding for tools, equipment and other Government expenditures; AFMC Form 202 will not be used for routine TO changes Restriction. The AFMC Form 202 is the only acceptable method for submitting an ETAR AFMC Form 202 Flow and Approval Process. Requests for engineering technical assistance will be initiated via the AFMC Form 202, and will follow the process flow depicted in Figure 1, AFMC 202 Process Flow, which identifies a step-by-step process Completion Timeline. Completion of ETAR Instructions, development/revision of technical data when required, and coordination and approval of submitted AFMC Forms 202 shall be accomplished within 5 business/workdays after Industrial Engineering Technician (IET) has submitted the request to engineering for a work stoppage condition, and within 15 business/workdays for an anticipated work stoppage. If a solution cannot be evaluated and completed within the specified time limits, the requesting facility must be contacted by and provided (a) the intended course of action; (b) and expected resolution date. This must be documented in the Disposition Instructions block of the AFMC From 202. The responsible engineer shall include the required maintenance action, reference sketches, drawings, photographs, and other documents to the AFMC Form 202. The control number shall be annotated in the upper right corner of the AFMC Form Immediate Priority. An Immediate Priority, accomplished within 1 business/workday, may be instituted for an AFMC Form 202 by the cognizant CE in conjunction with the weapon system PM. The immediate need must be substantiated IAW the AFMC Form 202 urgency of mission need entered in the Problem Description and Recommendation block of the AFMC Form 202. When justified, an immediate priority ETAR may only be extended by a memorandum of agreement (MOA) between the submitting and performing engineering organizations and must be approved by the CE ETAR Funding Policies. All AFMC Organizations. Centralized Asset Management (CAM) under the direction of AFMC assumes all programming, budgeting and execution responsibilities for the Department of the AF to including Depot Purchased Equipment Maintenance, Depot Level Reparable (DLRs), Sustainment Engineering, TOs, Contractor Logistics Support, and Support Equipment (Operational and Maintenance only).

5 AFMCMAN JANUARY Unprogrammed Depot Level Maintenance (UDLM) Support. UDLM support for operating weapon/support systems is a priority task for AFLCMC, AFSC, and AFNWC. In addition, when justified on the basis of mission urgency, ULDM support shall be given precedence over programmed workloads.

6 6 AFMCMAN JANUARY 2018 Figure 1. AFMC Form 202 Process Flow

7 AFMCMAN JANUARY Engineering Order (EO). When the solution to the problem reported on an AFMC Form 202 is an engineering drawing (ENG DWG) change, an EO will be completed and processed. If a solution requires a change to an ENG DWG, an AF Form 3925, Engineering Order, must be completed, a project number obtained, and a copy of the EO must be attached to the AFMC Form 202 providing the solution Automated Systems Enhanced Technical Information Management System (ETIMS). ETIMS is the AF System of Record, a secure web, GCSS-AF application accessible via the AF portal with the TO catalog, ordering and the TO Distribution Office (TODO) account management functions. ETIMS system functions to acquire, improve, publish, catalog, manage, store, distribute and display official TOs needed for the safe and effective operation of AF weapon systems and equipment. An organizational TODO must establish an account and register electronic Tools (etools) devices for non-repudiated electronic distribution Item Unique Identification (IUID). If the IUID marking is not legible on an asset identified for serialized tracking, an ETAR shall be submitted to include all available information about the part as well as instructions as to how to mark the part (including a replacement data label or data plate as required). ETARs initiated for this reason shall be forwarded to the Item Manager (IM) for the asset Delegation of Authority DEA. DEA will be documented in writing via a delegation letter IAW with AFMCI Typical tasks include those that have the following characteristics: negligible consequences IAW Military-Standard (MIL-STD) 882, DoD Standard Practice System Safety; known approved repair using standard process; qualified proven process; repair expected to last through Programmed Depot Maintenance (PDM) cycle. Depot maintenance tasks that typically have these characteristics include, but are not limited to AFMC Form 202 rejection, condemnations, reclamations, oversize holes/fasteners, rework assessment, primary and secondary structure repairs, clarification of TO, troubleshooting, catalog analysis, remove and replace a qualified part, temporary Systems Engineering (SE) substitutes, repairing beyond TO limits due to limited supply, repeat authority, sequencing of subsystem/component removal/installation, and parts substitution where previously approved or not yet in TO and Consumables (Common, Recurring, Bench Stock). (T-2) Delegable and Non-Delegable Tasks. IAW AFI , the CE may delegate down to a qualified person. Delegations will be documented in a delegation letter IAW AFMCI Tasks must be specific in nature, documented by official memo and regularly reviewed/updated over time. IAW applicable policy and local instructions, individuals with delegated authority may temporarily sub-delegate one level down to a qualified person; however, responsibility for sub-delegated actions remain with the delegated authority. Sub-delegations will be documented IAW AFMCI (T-2) AFMC Form 202, Engineering Technical Assistance Request (ETAR). All AFMC activities shall submit requests for engineering technical assistance to the applicable LSE/CE/Engineering Approval Authority (EAA) using the AFMC Form 202.

8 8 AFMCMAN JANUARY Requests for Assistance by Non-AFMC Activities. Non-AFMC requests for engineering technical assistance should submit requests to the applicable PM using automated systems, if available, or by completing the AFMC Form 202 and send via encrypted to the responsible LSE/CE Attachments to Approved ETARs. The DEA for ETAR Instructions may attach an EO or SH 252, TO PCR, that will be an integral part of the ETAR Instructions approved for use by the depot maintenance activity. Supplemental information may also be included as part of an approved ETAR. All attachments/supplemental information will be marked with corresponding ETAR Control Number IAW paragraph and appropriate distribution statement IAW AFI , Management of Scientific and Technical Information (STINFO). (T-2) The evaluation of an ETAR by the assigned DEA may result in the development of an EO, when the solution requires an ENG DWG change. The DEA will complete and expedite processing of an EO IAW AF Pamphlet , Integrated Life Cycle Management. A copy of the EO may be attached to the ETAR as illustration AFMC Form 252, TO Publication Change Request. When evaluation of an ETAR by the DEA results in the need to change information in a published TO, the DEA will submit the results to the Equipment Specialist (ES) and/or Technical Content Manager (TCM) who will prepare an AFTO Form 252 to document the specific changes required to the affected TO. The Publication Change Request (PCR) requires immediate implementation to support the approved ETAR Instructions and will be processed as a SH 252 IAW TO , AF Technical Order Life Cycle Management. If the change prescribed on the approved SH 252 cannot be published within 120 days, an Interim Operational Supplement (IOS) cover sheet will be attached to the SH 252 IAW TO The SH 252 shall be removed from the ETAR once the PCR has been formally published in the affected TO Weapon System POs and maintenance units may develop supplemental information and attach to an ETAR as supporting information and reference the applicable block of the ETAR. Examples of supplemental information include an assembly or component schematic specifically formatted for use in reporting a recurring Non-Destructive Inspection (NDI) task, drawings, a list for data which must be fully reported to properly address a specific hazard, and tailored bad actor information forms. All supplemental information shall include an ETAR control number ETAR SH 252 Procedure Verification. When a SH 252 is attached as part of ETAR instructions, verification of revised TO procedures shall be conducted IAW TO Nuclear and Non-AFMC ETARs.

9 AFMCMAN JANUARY Nuclear ETARs. Assistance for all items listed as Nuclear Accountability Reporting System in D086 Mission Workload Assignment System shall be provided to the organizations (POs) listed in the system when furnishing assistance on AF owned and procured components associated with nuclear weapons. This does not include organizational and intermediate level support to an operational unit s non-nuclear munitions Nuclear System CE. The Nuclear CE or designee for each nuclear system shall determine the conditions for which a Nuclear Surety review is required. (T-2) The Center Nuclear Surety Office (NSO), or designee, shall review forwarded ETARs for nuclear surety compliance and coordinate on these ETARs by electronic or digital signature. (T-2) If the weapon system has no resident NSO or designee, then the weapon system PO shall establish procedures with the AFNWC for Nuclear Surety reviews The NSO (if required) shall be included as an additional reviewer parallel with the Base Environmental Engineer and/or Base Safety reviews ETARs for Nuclear Systems. ETARs for nuclear systems shall include the following information in the request: Nuclear Weapons Personnel Reliability Program Department of Defense Directive (DoDD) , Nuclear Weapons Personnel Reliability Program, applicability Other information as required by AFI V1, Missile Maintenance Management, applicability Intercontinental Ballistic Missile systems and AFI V2, Cruise Missile Maintenance Management, applicability Air Launched Cruise Missile systems. (T-2) Nuclear Weapons Related Materiel (NWRM). PO/Supply Chain (e.g., engineers and ESs) personnel providing technical assistance which drives updates to any identifying information on NWRM (i.e., data plate changes or updates to National Stock Number (NSN), Part Number, Serial Number, etc.) must contact the applicable IM before taking any action IAW AFI , Nuclear Weapons-Related Materiel Management. This must be done to ensure measures are in place to update the applicable NWRM Accountable Property System of Record (APSR) and prevent NWRM discrepancies. PO/Supply Chain personnel must receive written approval ( or written correspondence) from the applicable IM before directing any change in identifying information on NWRM. Any direction provided to a customer to update identifying information on NWRM must contain instructions for the customer to notify the applicable NWRM Accountable Officer or NWRM Property Custodian prior to making directed change to ensure the local Supply Chain Management organization updates the applicable APSR to maintain positive inventory control. (T-2) Aerospace Maintenance and Regeneration Group. For desert storage operations at Aerospace Maintenance and Regeneration Group, refer to TO , Aerospace Equipment Maintenance Inspection, Documentation, Policies and Procedures and TO , Maintenance Data Documentation.

10 10 AFMCMAN JANUARY ETARs from Outside the AF Security Assistance Program (SAP) recipient country requests for engineering assistance shall be submitted through the designated country representative using the AFMC Form 202. ETARs shall be submitted via secure e- Mail by the designated country representative to the Weapon System PO via the Foreign Military Sales Foreign Disclosure Office ETAR for SAP aircraft under the control of Air Combat Command Air Defense Group during flight delivery shall be submitted directly to the LSE/CE Records. Copies of completed AFMC Form 202s shall be physically and/or electronically stored until such time that the approved AFMC Form 202 procedure has either been merged into the affected TO, and published in the ETIMS, or the CE deems that they are no longer required. (T-2). 2. Completion of the AFMC Form 202, ETAR 2.1. ETAR. Requests for engineering technical assistance to complete depot maintenance tasks beyond the scope of published technical data are documented and submitted using an AFMC Form 202, ETAR. An ETAR is initiated by a depot maintenance technician and validated by an IET/Maintenance Planner when technical problems are encountered during depot maintenance that are beyond the scope of technical data (Process Order, TO, ENG DWGs) prescribed within the depot maintenance Work Control Document (WCD). The following general procedures apply to the preparation, submission, processing, and execution of all AFMC Form 202 s, as shown in Figure 2. There are three Parts to the AFMC Form 202 as displayed in Figure 2. Part A, Maintenance, represents the initial submittal of the AFMC Form 202 and defines the urgency of need (i.e., work stoppage or anticipated work stoppage). Part B, Engineering Direction, represents disposition direction provided by the LSE/CE, including whether to repair, rework, use as current, or condemnation of the item/part and coordination and approval of the proposed disposition within the applicable engineering offices. Part C, Maintenance Coordination/Approval, documents coordination and approval of the AFMC Form 202 submittal.

11 AFMCMAN JANUARY Figure 2. AFMC Form 202. Engineering Technical Assistance Request

12 12 AFMCMAN JANUARY Any entries on paper/handwritten forms must be typed or neatly printed in blue or black ink. The PO shall be responsible to ensure all form information is maintained in the official repository system. The AFMC Form 202 is available from AF epublishing at the following link Part A Maintenance. A complete and validated Part A is submitted to the responsible LSE/CE for the problematic system/end item. An ETAR may be initiated to request one-time authority to use a specific defective part/commodity item or deviate beyond technical data limits, and/or receive authorization for limited use of non-listed substitutes (supplies, components, support equipment, etc.) to prevent depot maintenance work stoppages. Part A is completed by the Initiator and reviewed/validated by the responsible IET/Maintenance Planner before being submitted to the LSE/CE for assistance. The Problem Description and Recommendation section must completely describe the problem (nonconforming situation), and provide information to support the data included in the End Item Serial/Tail/Work Rqst No. section of AFMC Form 202. Once Part A information is complete, priority is established and validated by the IET/Maintenance Planner, will assign the control number at the initiation state, and the AFMC Form 202 is delivered to the responsible Disposition Engineer (DE)/EAA To Block. Enter the office symbol, address, and/or name of the cognizant technical authority (PM, LSE/CE) from whom engineering assistance is being requested From Block. Enter the name, office symbol, phone number and of the depot maintenance organization requesting assistance. Enter the name of the requestor as it appears in the Microsoft Outlook Global Address List. If the paper version of the Form is used, the entry must be made in permanent ink Date Submitted. Enter the date that the IET/Maintenance Planner approves the Work Stoppage condition, Need Date, and the completeness and clarity of Problem Description and Recommendation section Control Number Assigned. If an automated 202 system is not available, a manually generated AFMC Form 202 will be entered into the automated 202 system as soon as the system becomes accessible. (T-2) If manually prepared, enter the next available control number from a log maintained by the IET/Planner for the depot maintenance activity. The local depot maintenance activity establishes requirements for the construction of the AFMC Form 202 Control Number The control number must be included in the upper right hand corner of all attachments regardless of the method created. This is required to maintain configuration control and ensure safety of the technicians performing maintenance. (T-2). NOTE: There are no exceptions. The LSE/CE is responsible for ensuring control numbers are included on all attachments Nomenclature. Enter the nomenclature of the part(s)/item(s) affecting the problem. Use the associated Illustrated Parts Breakdown (IPB) TO nomenclature reference whenever possible. If applicable, include the affected Mission Design Series (MDS) of the system/end item.

13 AFMCMAN JANUARY Part Number. Enter the number of the affected part(s)/item(s) in the Part Number block. Enter the corresponding Commercial and Government Entity (CAGE) Codes in the Problem Description and recommendation block of the AFMC Form 202. Parts may be manufactured by multiple companies, therefore, the CAGE Code will be used to be certain that the correct part is addressed NSN. Enter the NSN for the item(s) and/or part(s) affected to be used in the Instructions section for the AFMC Form 202. The NSN in conjunction with the part number(s) ensure that the identical part number(s) used by different manufacturers for completely different parts are not confused with each other End Item Serial/Tail/Work Request No. Enter the affected end item serial number, tail number, and/or work request number. When an ETAR applies to the repair or substitution of more than a specific end item serial, tail number, or work request number, enter Not Applicable (N/A). A period of time, not to exceed 120 days to which the ETAR instructions, will be entered in the instructions block of the AFMC From 202. Select from the following boxes: Serial Number; Tail Number; Work Request Number or N/A Location(s). Enter the physical location(s) (Resource Control Center [RCC], post/building number, shop, etc.) where the item causing the problem is located TO/ENG DWG Number. If the ETAR is associated with a specific TO process, operation, or ENG DWG, enter the affected TO Number or the ENG DWG Number Work Stoppage. If depot maintenance cannot be completed, check the YES box and enter the date the work stoppage has or will occur. If the NO box is checked, describe the impact in the Problem Description and Recommendation section. The initiating depot maintenance organization shall first determine the urgency of the request. NOTE: Work stoppage refers to the inability to proceed with production on a repair or modification of an end item or commodity, or where a given process stops due to nonconforming material, inadequate technical data, or lack of proper parts, materials, components, tooling or facilities. Halted production of a component or part that negatively impacts the critical path of an end item or scheduled flow of a commodity prodcuton line (from an operational/systemic view) constitutes a work stoppage Organically Caused. Check the appropriate response to indicate if the problem was or was not caused by an organic maintenance action. If the YES box is checked, enter the date that Quality Assurance (QA) was notified in Block QA Notified. If the ETAR was organically caused during the performance of depot maintenance, enter the office symbol, date and time that the responsible QA office was notified Problem Description and Recommendation. List the MDS and include aircraft serial number or Type, Model, Series (TMS), as well as applicable software version numbers of corresponding Line Replaceable Units for involved equipment (include the serial number for serialized items). In addition, for non-end items of equipment, list the nomenclature and the part number.

14 14 AFMCMAN JANUARY Enter a complete, concise description of the problem and include any recommended corrective actions. Indicate if the problem is related to a faulty TO or Process Order operation. If so, identify the TO number, Process Order, and operations reference. Include a detailed description of visible damage; malfunctioning items; and operating anomalies. As applicable, include left/right, forward/aft, upper/lower, inboard/outboard dimensions (length/width/depth); fuselage station; wing station; water line; photographs; plus applicable ENG DWG, TO IPB figure, and index; part number; stock number; Next Higher Assembly (NHA) part number; serial number; and aircraft tail number If a SH 252 is attached as part of the ETAR Instructions, it will apply to the Effectivity Record block End Date specified. The TO Manager (TOMA) will attach a SH 252 IOS cover sheet to update the corresponding TO. A formal TO update will be published and distributed to incorporate the SH 252 PCR. See TO for additional information. (T-2) Any attachments provided with the ETAR must be annotated with the Control Number of the ETAR as well as the appropriate Distribution statement IAW AFI (T-2) Initiator Name. Enter the signature and/or printed name, office symbol and phone number of the maintainer reporting the problem IET/Planner. Enter the signature and/or printed name, office symbol, phone number of the IET/Maintenance Planner or other designated person validating that information entered into the ETAR, Part A. Ensure information is complete and accurate before the ETAR is assigned a Control Number Part B Engineering Direction. Part B of the Form is completed by the DE to evaluate the non-conforming deficiency description, and develop and document disposition instructions. The designated DE will enter their name and the date the ETAR was received Disposition. The DE will determine and document the type of disposition (Repair, Rework, Use As-Is, Condemn or Other) and document the procedure to resolve the problem in the Disposition Instructions block. The DE must also indicate the event or date when the Disposition Instructions are to be rescinded, identify authoritative technical data that must be updated; e.g., Process Order, TO, or ENG DWG; and, whether Safety, or Biological Environmental (BIO ENV) reviews are required Instructions. As defined by AFI and Department of Defense Instruction (DoDI) , Distribution Statements on Technical Documents, technical documents/information attached to or documented as ETAR Instructions are considered to be STINFO, and shall be marked with the appropriate Distribution Statement. The LSE/CE, or delegated engineering authority, will determine and mark the ETAR Instruction, as well as any attachments, with appropriate Distribution Statements (DoDI ). Additional information to be included in the Instructions include the organization/office symbol of the DEA responsible for providing Direction to resolve the reported problem if applicable; if the Other box is checked in the Disposition block, explain in the ETAR Instruction block.

15 AFMCMAN JANUARY If the solution requires a change, attach the SH 252 prepared by the responsible ES/TCM containing the corrected maintenance operation. The SH 252 must be referenced in this block and attached to the ETAR If the solution requires a change to an ENG DWG, reference section 1.5. Any draft EO must be referenced in the Instructions block and attached to the ETAR If the solution requires a change to a Process Order, reference the process order and the specific changes required. Attach corrected Process Order to the ETAR If the solution does not immediately require a TO, ENG DWG or Process Order change, enter the complete, concise, step-by-step instructions for resolving the problem Any attachments provided with the ETAR must be annotated with the Control Number of the ETAR as well as the appropriate Distribution statement IAW AFI NOTE: A corresponding entry in the End Item Historical Form/Record Notes Block will be required to specify the notation that will be made in the appropriate Form/Record Authorized Until Date or Completion Of. Enter the date at which the instruction will be valid, or select the applicable box if it is to be based upon the serial number, tail number or a work request Requirements. Check the applicable box or boxes from TO Change, ENG DWG Change, Safety Review, or Biological Environmental Engineering (BEE). The following paragraphs provide the instructions for each of the options Check TO Change Box if a SH 252 will be completed, and attached to the ETAR Instructions. ETAR Instructions are incomplete without SH 252 if this Box is checked Check the ENG DWG Change Box if an AFMC Form 3925, Engineering Order (EO), will be completed and attached to the ETAR Instructions. ETAR Instructions are incomplete without SH 252 if this Box is checked Check the Safety Review Box if Safety Office review of the ETAR Instructions are required. If required, the designated Safety Office will sign in the Coordination/Approval Block Check Biological-Environmental Engineering (BEE) Review Box if Biological-Environmental (BIO-ENV) Review of the ETAR Instructions is required. If required, the designated BIO-ENV Office will sign in Coordination/Approval Block Enter Not Applicable or document the exact wording of statements to be placed on the applicable End Item Historical Form/Record form (AFTO 95, Significant Historical Data, or AFTO 781 series, DoD Form 1574, Service Tag, etc.). (T-2).

16 16 AFMCMAN JANUARY Provide instructions as required to document weapon system s historical records concerning significant maintenance actions resulting in conditions that could have a bearing on future maintenance actions, deferment until future maintenance, and nonstandard repairs, which will be readily apparent to field/owning organizations If future actions are required on aircraft, such as inspections or component replacement, an AFTO Form 781 entry shall be made Include a complete description and location of nonstandard repairs (e.g., fuselage station) as well as the AFMC Form 202 control number, and the name, office symbol and phone number of the engineer authorizing the repair IAW TO , Aerospace Equipment Maintenance Inspection, Documentation, Policies and Procedures Equipment Historical Entry. Enter the historical historyof the equipment Engineering Coordination/Approval. In the Coordination/Approval section, the name, signatures, and signature dates of the following will be required as stated in the following paragraphs DE. Enter the Name, Signature, Office Symbol, Phone, address, and Date of the of the DE preparer of the disposition or repair instructions Safety Office. When Safety Review is checked in the Requirements Block, the individual designated by the applicable Safety Office will enter their Name, Signature, Office Symbol, Phone, address, and Date of their signature Bio-Environmental Review. When BIO-ENV Review is checked in the Requirements Block, the BEE office representative will enter the Name, Signature, Office Symbol, Phone, address, and the date signed ES/TCM. When a TO Change is checked in the Requirements Block, the DE will enter the respective ES/TCM s Name, Signature, Office Symbol, Phone, address, and indicate the date if ES/TCM coordination IM. If Condemn Box is checked in the Disposition Block, the IM will enter their name, signature, office symbol, phone address, and indicate the date signed LSE/CE/EAA. Enter the Name, Signature, Office Symbol, Phone, address, and Date of the LSE/CE/EAA approving the disposition, or repair instructions Part C Maintenance Coordination/Approval. Under the Coordination/Approval block, the names, signatures, signature dates, addresses, and phone numbers of the IET Planner and the Maintenance Supervisor (MS) will be required as stated in the following paragraphs IET/Planner. Enter the Name, Signature, Office Symbol, Phone, address, and Date of the IET/Planner MS. Enter the Name, Signature, Office Symbol, Phone, address, and Date of the MS.

17 AFMCMAN JANUARY ETARs Responsibilities The following subparagraphs identify the responsibilities associated with the ETAR Process Headquarters (HQ) AFMC/A4 Responsibilities. HQ AFMC/A4 shall be responsible for the following: ETAR Policy. Issuing and sustaining AFMC ETAR process and policy including supporting changes to AFMC Form ETAR Process Policy Waivers. Requests for waivers to processes or policy within this publication must be prepared on an AF Form 679, Air Force Publication Compliance Item Waiver Request/Approval. HQ AFMC/A4F will evaluate waiver requests IAW AFI (T-2) Recommending Changes to ETAR Process and Policy. All recommendations for change to ETAR process, policy and/or corresponding AFMC Form 202 will be submitted by any AF user using AF Form 847, Recommendation for Change of Publication. HQ AFMC/A4F will evaluate all recommendations for change to this publication and the AFMC Form 202. All changes to this publication will be vetted with the using community before publication. (T-2) ETAR Functional Responsibilities. The following paragraphs identify the responsibilities of engineers and depot maintenance process Supervisor, Planner, Functional within the AF ETAR process Director of Engineering Responsibilities Ensures all AFMC engineering entities (i.e., AFNWC, AFSC, AFLCMC, AFRL, AFTC) implement AFMC Form 202 process controls to ensure an accurate and efficient process Develops, implements, and maintains SE policies, processes, metrics, tools and training to enable the life cycle management of technologically-superior weapon systems that are operationally safe, suitable, and effective Ensures implementation of standard LSE and OSS&E related procedures with tailoring/waivers as authorized and appropriate PO/Complex Engineering Office Responsibilities Ensures internal reviews of completed ETARs to identify duplicate/similar failures and repair trends IAW internal processes Ensures compliance with AFI /20-1 and AFMCI Ensures AFMC Forms 202 are processed Ensures standard LSE and OSS&E related procedures are implemented across PO/Complex programs and projects, with delegation, tailoring and waivers as authorized and appropriate Ensures best practices appropriate to the nature of Center programs are implemented.

18 18 AFMCMAN JANUARY Develops and implements LSE and OSS&E policy consistent with DoD, AF, and AFMC policies DE. Serves as the DE authority as delegated by the LSE/CE to evaluate the submitted ETAR and to develop ETAR corrective action, step-by-step instructions, and complete the ETAR Part B. A DE signature in the ETAR Part B attests that engineering analysis was completed IAW AFMCI DE authority may not be delegated to an ES/TCM Ensures authorities are executed within the scope of the DEA letter from the CE. The DE will collaborate with other engineers/es in the PO as needed to develop complete ETAR Part B Instructions Develop agreements with maintenance office supported counterparts in defining how they will interact with the development of AFMC Form 202 issues Review ETAR Part A Problem Description and attachments to ensure problem is clearly described and that pertinent technical data references, pictures, etc., are provided When necessary, to review the problem, if you have access to the weapon system asset, first action is to view the actual item and if necessary converse with the maintenance personnel to ensure visibility of the solution Utilize all available technical data, information, and resources to analyze reported problems, establish solution, and assess related risks to establish appropriate ETAR Instructions When there is a need to correct or update formal technical data (TOs, Process Orders, ENG DWGs, etc.) document the specific problem, recommended resolution as required for the type of technical data, and notify the responsible activity When the DE determines that a permanent update is required to a TO in order to correct a reported ETAR Problem, the DE shall notify the responsible ES/TCM of the need for the change. Ensure TO change(s) directed by an ETAR are processed as separate action parallel to the AFMC Form 202 process Coordinate and document the word-for-word change(s) required to be documented on the AFTO Form 252. Mark the AFTO Form 252 as a SH 252 and attach to the ETAR Instruction. Specify the verification method to be used IAW TO in the ETAR Instructions The ES/TCM will provide a copy of the SH 252 to the responsible TOMA who will prepare an IOS cover sheet necessary to update the affected TO IAW TO Ensure the ETAR control number is annotated on the SH Document in the ETAR Instructions the manner or method that will be used to verify new and/or revised maintenance operation or TO procedures. The new or revised TO Procedures are verified as required IAW TO

19 AFMCMAN JANUARY If the Safety Office and/or BEE office must review ETAR Instructions, the ETAR will be forwarded to the appropriate Safety Office and/or BEE. A qualified -018 or -803 series safety office representative will review ETAR Part B Instruction for safety impacts and date and sign the ETAR. NOTE: The Safety Office shall notify engineering of the Estimated Completion Date for reviewing AFMC Form 202 submittals when a response cannot be provided within the allowable timeframe. (T-2) Certain categories of ETAR Instructions will require PO Subject Matter Expert (SME) coordination. As specified below, the DE will coordinate developed ETAR Instructions with appropriate PO SMEs prior to submitting the ETAR to the EAA The DE will contact the Aircraft Structural Integrity PM when replacement of fatigue critical structure must be addressed with PO NDI required in the ETAR instructions shall be conducted IAW published AF NDI TO guidance. All revised, new, or prototyped NDI related procedures that are not included in existing published TO guidance, shall be reviewed and approved by certified Level 3 NDI personnel prior to approval by delegated EAA as required by AFI , Aircraft and Equipment Maintenance Management. (T-2) Work-arounds, complicated structural repairs, efforts to save structure, or repair/replacement that requires analysis to ensure the integrity of the disposition approach will require coordination with PO LSE/CE. If required, the LSE/CE will arrange for Original Equipment Manufacturer support in the DE s development of the ETAR Instruction The DE will coordinate with the PM to assess life cycle impacts when the ETAR Instruction defers repairs, establishes interim repairs, or specifies substitution of alternate parts The DE shall coordinate with the responsible ES/TCM if new or alternate parts are specified to be used in the ETAR Instructions. The ES/TCM will initiate action to stock list the part(s), update the D043 system, Master Item Identification Control System, and update the affected IPB TO as required to preclude future AFMC Form 202 reissue. The ES/TCM will collaborate and coordinate with the respective IM for parts forecasting to ensure availability for maintenance activities. (T-2) LSE/CE. The LSE/CE is the overall Engineering/Technical Authority for programs and systems Delegate engineering authority for completion of AFMC/Forms 202. Such delegations shall be documented in writing in a DEA letter with a written or electronic signature. Delegations may include EAA and DE authority for the review, analysis, disposition and approval of ETARs Ensure DEA letters are reviewed annually.

20 20 AFMCMAN JANUARY Periodically review completed ETAR(s) to ensure appropriate changes are identified, and take appropriate action to update technical data (Process Orders, TOs, and ENG DWGs). Ensure OSS&E is maintained through robust and thorough engineering analysis and solutions Ensure adequate engineering analysis training, tools, and facilities are available to maintain OSS&E Assist the PM to develop and track metrics necessary to gauge key Technical Performance Measures and state of OSS&E baseline characteristics. Collect ETAR usage and response data, and track the number of repeat AFMC Forms 202 that drive permanent change to TOs IAW Paragraph 5, Metrics Ensure organizational processes are in place to address contractual agreements for depot assistance requests to/from contractor based maintenance or engineering functions to include incorporation of this supplement where appropriate An automated ETAR system may support implementation of some or all of administrative tasks, which consist of the following: Receive and record AFMC Form 202 sent from maintenance activities Immediately notify the designated DE who will be responsible for evaluating ETARs Verify that required/referenced attachments (ETAR Problem Description and Instruction) are included and correctly marked and that required coordination (e.g., Safety, Bio-Environmental, and TOMA etc.) has been obtained Provide the IET/Planner a copy of the approved ETAR and attachments Maintain a file copy of approved ETARs and attachments IAW AFI , Publications and Forms Management. Copies of completed ETARs shall be stored for historical purposes with a preference for electronic media The EA designated by the LSE/CE reviews and approves ETAR Part B Instructions and approves the ETAR (signs as EAA). The engineer delegated as EAA shall not be the same engineer delegated as the DE who developed the ETAR Instructions Ensure ETAR documented instructions are accurate, represent engineering analysis, and are within the scope of the written DEA for the DE Ensures that the documented instruction considered cost, schedule, and weapon system life cycle Ensures that required coordination is complete and annotated on the ETAR Ensures Part B Instructions and information provided is adequate.

21 AFMCMAN JANUARY EAA. The LSE/CE EAA reviews and approves ETAR Part B Instructions and approves the ETAR (signs as EAA). The engineer delegated as EAA shall not be the same engineer delegated as the DE who developed the ETAR Instructions Ensures ETAR documented Instructions are accurate, represent engineering analysis and are within the scope of the written DEA for the DE Ensures that the documented Instruction considered cost, schedule, available resources and materials, and weapon system life cycle Ensures that required coordination is complete and annotated on the ETAR Ensures Part B instructions and information provided is adequate In conjunction with the DE, ensure that ETAR Instruction steps provide available published AFTO numbers and paragraphs to govern maintenance action. Ensure all revised, or modified NDI procedures developed to support ETAR Instructions have been reviewed and approved by certified for level 3 NDI personnel Air Logistics Complex Maintenance Office Responsibilities. The Air Logistics Complex Maintenance Directorates shall be responsible for the following: Setting local policy and establishing a focal point for the collection of monthly ETAR usage data from maintenance sections to ensure TO health metrics are generated and forwarded to the Center Engineering Offices IAW AFMCI The depot Maintenance Process Engineer (MPE) will coordinate with the IET/Planner office to validate PDM process requirements as part of the LSE/CE engineering requirements review process IAW AFMAN , AF CAM Process. Review all pertinent technical data currently governing the maintenance process; accomplish a business case analysis to determine the viability of a maintenance process change, evaluate process capability control, and support the LSE/CE Engineering Requirements Review Manager to identify engineering maintenance requirements impact of governing depot maintenance technical data and maintenance process operations ETAR Initiator/Submitter Responsibilities. The ETAR Initiator/Submitter shall be responsible for the preparation and completeness of the AFMC Form 202 ETAR Part A information Ensure initiated ETAR complies with established local quality control criteria at all locations Notify first level supervisor of the affected maintenance operation problem - unworkable item, damage, or other discrepancy that require engineering assistance and complete an AFMC Form 202. Review the Problem Description with the Supervisor/IET/Planner and if valid, direct that the ETAR be submitted. NOTE: If the problem was organically caused, the supervisor will coordinate with Maintenance QA Office who will sign and date the ETAR Part A.

22 22 AFMCMAN JANUARY Include a detailed description of the problem, the maintenance operation requirement and attach photographs and/or sketches necessary to clarify the location and extent of the problem. Any attachments to the ETAR referenced in Part A must be annotated with the ETAR Control Number and be marked with the appropriate Distribution Statement IAW AFI Submit the complete and validated Part A to the ETAR administrator designated by the LSE/CE within two hours of signature for work stoppage requests and within five business/work days for non-work stoppage ETAR. Submit using automated system if available Include details concerning recommendations for a solution to the problem, or limitations which would impact the ability to perform a particular repair ES/TCM Responsibilities. The ES/TCM responsibilities consist of executing the TO change process per TO , ensuring procedure verification, obtaining required coordination, ensuring that use of warnings and cautions are representative of MIL-STD 38784, Standard Practice for Manuals, Technical: General Style and Format Requirements and working closely with the applicable IM to ensure the required parts are forecasted and available for maintenance activities The ES/TCM should follow-up with the IET/Planner to ensure verification of new TO procedures was accomplished per ETAR Instructions (desktop analysis, simulation, or performance verification IAW TO , AF Time Compliance Technical Order (TCTO) System) Maintenance QA Activity Responsibilities. The QA Activity shall be responsible for the following: A QA representative shall be present at maintenance operation problem review meetings between maintenance personnel and the DE developing ETAR Instructions for a validated problem A QA representative shall participate in required ETAR procedure/sh 252 verification of new or revised procedures As established within local policy, periodically inspects nonstandard repairs and maintenance procedures Each local maintenance quality organization shall jointly review the ETAR process with its Process Engineering PO on a quarterly basis and make recommendations to improve the process as required IET/Planner. The IET/Planner shall verify if current technical data (ENG DWGs, TOs, Process Orders, etc.) already exists to address the maintenance operation problem. If technical data does not exist, they will ensure that the problem description is accurate and clearly documented in Part A of the ETAR. The IET/Planner shall be responsible for the following. (T-2).

23 AFMCMAN JANUARY Reviews Forms 202 to ensure Part A is complete and correct, and the conditions cited are valid. Assigns control numbers to track valid requests, if not assigned by an automated system. Returns invalid requests (e.g., those for which existing technical data is adequate) to the initiating activity and assist them with problem resolution Ensures the MPE is involved in the initial problem resolution. Coordinates with the MPE to ensure production functions have the necessary tools, and machines to meet TO requirements. The IET/Planner will coordinate directly with the DE to resolve any questions or problems with implementation of ETAR Instructions Once the ETAR Instruction is approved by an EAA and provided to maintenance, the IET/Maintenance Planner shall ensure that new or changed maintenance operation procedures are verified as specified in the ETAR Instructions by the DE or ES/TCM for SH 252. Plan the verification of SH 252 TO procedures and notify the responsible ES/TCM of completion of the SH 252 procedure verification including needed changes, if any. Verificaton on the procedure(s) will be documented on the AFTO Form 27, Preliminary Technical Order (PTO) Publication Change Request (PCR)/TO Verification Record/Approval. NOTE: An SH 252 requires an IOS coversheet that will be posted to the TO by the responsible organization Technical Order Management Agency Sign the ETAR Part C within two days of completion of Part B Instructions. Ensure the MS has also signed in Part C within two days of AFMC Form 202 Part B completion. Copies of the completed and signed ETAR shall be provided to the MS, and (if required) to QA activities Review all ETAR Instruction for the need to recommend permanent technical data updates. Initiate an AFTO Form 22 IAW TO when governing TOs specified in Depot Maintenance Work Specification must be corrected or improved. When applicable, note the TO recommended change Local Control Numbers on the AFMC Form Forward all copies of AFMC Form 202 procedures to affected TOMAs for TO posting Maintain a file of the completed AFMC Forms 202 with the master WCD file or in a planning file Forward AFMC Form 202 monthly usage data to designated Center Engineering Office focal points IAW local policy. This data shall include, as a minimum, the number of AFMC Forms 202 pending, the number approved and the number associated with work stoppages MS Responsibilities The MS shall be responsible for the following: Review AFMC Form 202s initiated by assigned personnel and forward to the IET/Planner for a technical review.

24 24 AFMCMAN JANUARY When the AFMC Form 202 is intended to alleviate parts or material shortages, attach a completed logistics parts supportability checklist to the AFMC Form 202 by either electronic or paper media. This checklist should provide detail on all logistics/material supportability efforts conducted to engineering partners. Organizations may choose to use a tailored version of the example provided or develop their own based on unique requirements Notifying maintenance QA when a nonstandard deficient condition is organically caused by maintenance procedures or malpractice Review disposition instructions and/or procedures provided on AFMC Forms 202 and SH 252s for any compliance problems, support equipment shortfalls, or personnel training issues. Sign to indicate concurrence with implementing the proposed procedures Ensure technicians annotate applicable DoD Forms 1574, Serviceable Tag Materiel, with comments required by AFMC Form 202 and forward the data to the records section for annotation on equipment historical documents (Air Force TO (AFTO) Form 95, Significant Historical Data, or AFTO Form 781-series aircraft forms). (T-2) Notify the IET/planner five days before the rescission event/date of any AFMC Forms 202 for which a requirement still exists Inform the IET/Planner or QA of any issues encountered during accomplishment of the instructions TOMA Responsibilities The TOMA shall be responsible for the following: Ensure each SH 252 is worked as a priority and incorporated into the affected TO, not to exceed 120 days from the date the SH AFTO Form 252 is received by the TOMA. An IOS shall be issued if the TO cannot be incorporated into the affected TO within the 120 day timeframe. If an AFMC Form 202 is attached to the SH 252, the TOMA shall ensure that the Requirements block is marked TO change and sign The TOMA that receives copies of extended use AFMC Forms 202s shall annotate the project/control numbers in the ETIMS records for affected TOs. If the TO is maintained in a paper library, reproduce enough copies of the forms to file with each affected TO copy. The AFMC Form 202 project/control number shall be written on the title page and the AFMC Form 202 shall be filed in the back of the TO. If the TO is digital, the AFMC Form 202 project/control number shall be made a public annotation on the title page of the TO and shall be linked to the AFMC Form 202 filed in a supplement folder on the master. The TOMA will remove AFMC Forms 202 once they are either rescinded or completed In conjunction with CE, ensure proper use of Warnings and Cautions IAW MIL-STD when failure to comply with instructions could result in injury to personnel or damage to equipment.

25 AFMCMAN JANUARY Workscope Meetings. Workscope meetings are encouraged to discuss and plan resources for accomplishment of ETARs. These meetings shall be attended by Engineering, and Process Engineering; ES/TCM; Records personnel; QA; and representatives of both Planning and Scheduling. Other functionals may also be required to attend dependent upon the particular workscope. Workscope meetings shall be documented using the Workscope Meeting Minutes Sheet depicted in Figure 3. The Workscope Meeting Minutes Sheet serves as an enterprise record for meeting documentation, and shall not be used in lieu of critical official forms such as the AFMC Form 202.

26 26 AFMCMAN JANUARY 2018 Figure 3. Workscope Meeting Minutes Sheet.

27 AFMCMAN JANUARY Special Handling 252 (SH 252) for Requesting Engineering Assistance for Nonconforming Maintenance Technical Problems Beyond Published Authority 4.1. ETAR. Requests for engineering technical assistance may be executed in one of two ways, either by the submittal of an AFMC Form 202, ETAR as discussed in Chapter 1, or by the submittal of an AFTO Form Special Handling 252 (SH 252). An AFTO Form 252, fully-coordinated and approved IAW TO , may be issued to provide the corrected or newly developed data necessary to resolve an actual or anticipated work stoppage when the applicable TO is in error or inadequate. The SH 252 may be issued to expedite a permanent change. The following statement shall be either Stamped or typed on the top of each AFTO Form 252 authorized for implementation, Special Handling and if applicable, all attachments. An alternative method is to enter AUTHORIZED FOR SPECIAL HANDLING in the Instructions block of the form Formal TO Change. TO changes need to be documented after the AFMC Form 202 is complete and initiated by the IET/Planner. An IOS Cover Sheet with an SH 252 attached may be used to incorporate a change into the affected TO. An example of the IOS cover sheet may be found in TO Engineer or ES. The responsible Engineer or ES shall ensure the SH 252 is routed to the applicable TOMA for processing. 5. Metrics 5.1. Performance Metrics AFMC Form 202, ETAR Metrics. Emphasis is placed on the AFMC Form 202, receipt and completion process. This metric is based upon a Work Stoppage request which must be resolved within 5 business/work days, and anticipated Work Stoppage which must be resolved within 15 business/work days. Requests for engineering assistance categorized as immediate priority must be resolved within 1 day after prioritization. Immediate priority ETARs may be extended by a MOA between the submitting and performing engineering organizations with the approval of the CE. The following AFMC Forms 202 metrics will be provided once per quarter to AFLCMC, AFSC, and AFNWC, and aggregately, to AFMC/A4 leadership: Total number of open AFMC Form 202s, percent on-time and average flow times by work stoppage vs. non-work stoppage by MDS and PO.

28 28 AFMCMAN JANUARY Number or percent of instances that AFMC Form 202s exceed predefined threshold limits (one day for Immediate, five days for work stoppage, and 15 days for non-work stoppage) Average total time and percent on time by MDS and PO Trailing 12 month history of each of the above Annual Disposition Metrics. The LSE/CE or their staff should meet (either inperson or by telecon) annually with the delegated Engineering Authority engineers (DEs and EAAs) to assess the AFMC Form 202 disposition response time and the rationale for resources (if any) that were required from the PO MOA. Depending on the needs of the PO and the maintenance organization, it may be necessary to document organizational level agreements to facilitate delegated engineering authority. A tailorable MOA template is provided in AFMCI DLA Metrics. Metrics pertaining to DLA Form 339, Request for Engineering Support will be performed and documented IAW the Performance Based Agreement (PBA) between the AF and DLA. 6. AFMC Engineering Support Provided to the DLA 339 Process 6.1. Purpose. The purpose of this chapter is to establish policy, assign responsibility, and define the process for engineering support provided by AFMC Engineering to the DLA IAW DoDD Instruction , Engineering Support Instructions for Items Supplied by Defense Logistics Agency, and the AF/DLA PBA, Annex 5, Engineering Support, Version 3. DoDI provides guidance for the process whereby DLA requests engineering support for NSNs which are items managed by DLA, and for which AFMC is the Engineering Support Activity (ESA) AFMC Engineering Support to DLA. AFMC Engineering, as an extension of the AF, provides engineering support to the DLA. Engineering Technical Assistance shall be provided to DLA using the DLA Form 339, Request for Engineering Support. Engineering support provided shall encompass First Article Test (FAT), Critical Safety Items (CSIs) assistance, developing, validating and approving Technical Data Packages (TDPs), developing and engineering criteria, representing the military service engineering interests, and providing technical guidance and decisions required in the management and procurement of an item for its entire life cycle. As an agent of AFMC/A4, AFLCMC is responsible for assigning focal points that act as the entry and exit points for requests for engineering support within the AF Examples of CSIs include safety of flight, parts/repairs with catastrophic failure consequences, major structural repairs, nuclear certified items, deferred repairs, interface changes, deviation to work specifications, new manufacturing processes, low observable critical processes, disposition of Product Quality Deficiency Report material substitution, new repairs and/or repair processes, changes with the potential to degrade reliability or performance, changing of test limits/requirements, changing of calibration requirements on weapons system support equipment, Hardness Critical Items/Hardness Critical Processes, corrosion prevention

29 AFMCMAN JANUARY and control requirements, changes that affect PO contract or warranty, and dispositions that require contracted expertise Examples of TDP include applicable technical data such as models, drawings, associated lists, specifications, standards, patterns, performance requirements, QA provisions, software documentation and packaging details AFMC ESA Responsibilities Receive and perform quality checks of DLA Form 339 submittals for completeness, accuracy, and adequacy of the requested engineering support Assign DLA Form 339 submittals to an engineer Identify/Verify CSIs IAW established procedures Provide timely engineering support to DLA requests IAW response times defined in established engineering PBA Respond to DLA Form 339 requests for engineering support requests pertaining to Extended Engineering Effort (EEE), as necessary Negotiate an EEE request with DLA IAW established engineering PBA All such notifications shall be coordinated through Focal Point offices at the applicable Complex All EEE information provided to DLA shall include all of the following that apply: Technical Scope, Temporary Duty Requirement, and Itemized estimated cost Provide comments for topics of discussion prepare for and attend AF/DLA crosstalk meetings, as required Coordinate with appropriate personnel in POs that have an interest in the item. The service ESAs are to ensure a single coordinated ESA response provided to DLA Review and determine the validity of Engineering Data List (EDL), Engineering Notes and Screening Analysis Worksheet (SAW) provided and populate, as applicable. This is accomplished using the AF Purchase Request Process System The screening technician shall review the SAW for completeness, review all available ENG DWGs, engineering notes and specifications and prepares an EDL and recommends Acquisition Method Code/Acquisition Method Suffix Code (AMC/AMSC) based on what the data supports The engineer must validate the AMC/AMSC code recommendation and ensure that all required documentation for the TDP IAW the PBA is provided to DLA, when required Request cataloging actions, as necessary, to include, but not limited to updating of Material Management Aggregation Code, ES Code, AF IM code, and Major Organizational Entity Rule.

30 30 AFMCMAN JANUARY Request/initiate with appropriate personnel to ensure updates occur to all TOs, technical and engineering data, as applicable Provide engineering technical assistance in the analysis and process/procedures of FAT. The engineer provides a complete test requirements at the time the FAT is imposed. NOTE: These requirements will be included in the solicitation as required by Federal Acquisition Regulation Part Serve as the focal point for OSS&E for technical descriptions created via the DLA Form 339 process when selected as the service supporting an item Ensure compliance with the DoDI and associated PBA for items managed by DLA Provide spares and screening support. When reviewing/supporting a Consumable Item Transfer, update the TDP as applicable Ensure that all applicable sections of Part III of the Form 339 (blocks 18 through 24) are complete and executable Verify criticality of the item, correct configuration, need for the NSN and part number and, validity of the support request Ensure all supporting man-hours for the engineering support request are captured on the DLA Form Depot Control of Nonconforming Engine Parts 7.1. Nonconforming Parts. Nonconforming engine hardware review is conducted in large numbers that necessitate streamlined procedures. This unique need necessitates a high-flow, low-complexity Nonconforming Material Review (NCMR) in a dedicated pool area of the maintenance shops. Engine maintenance issues of a batch nature, such as permission for use of alternate materials in out-of-stock situations or engine performance waivers, will be conducted IAW this AFMCMAN. An AFTO Form 840, Nonconforming Material Review Request and Reply, (Figure 4) will be initiated for each multiple, or numerous components of the same nonconformities for tracking purposes in the NCMR database. AFTO Form 840 depicts the flow process for the movement of the AFTO Form 840 from initiation through completion. Automated system electronic reproductions of the AFTO Form 840 are authorized Informal Requests. The AFTO Form 840 is the official method for submitting requests for instructions pertaining to nonconforming engine hardware. Informal requests for technical assistance are NOT authorized. Automated system electronic reproductions of the AFTO Form.

31 AFMCMAN JANUARY Figure 4. AFTO Form 840 Nonconforming Material Review Request and Reply Page 1

32 32 AFMCMAN JANUARY 2018 Figure 5. AFTO Form 840 Nonconforming Material Review Request and Reply Page 2

33 AFMCMAN JANUARY Engineering Instructions. Engineering instructions provided on or associated with the AFTO Form 840 must be strictly adhered to and must be verifiable upon completion of assigned work. It cannot be altered and can only be amended by the applicable engineers when second or subsequent actions and/or instructions are required. The applicable engineers shall evaluate the deficiencies noted in Shop Discrepancy block of the AFTO Form 840 and provide disposition instructions (use as is, repair, re-inspect, hold awaiting repair development, condemn, etc.) within 5 business/work days of either the initiation date for on-site reviews, or arrival of the item(s) at the NCMR pool. The responsible engineer can attach or reference sketches, drawings, and other documents when determined appropriate. The responsible engineer will also reference applicable TOs or WCD steps to identify specific repair or inspection procedures on the AFTO Form 840. The NCMR control number from the AFTO Form 840 will be entered in the upper right corners of all attachments Technical Data. Use the AFTO Form 840 to furnish technical data for conditions or procedures beyond published authority for nonconforming engine and engine parts under work stoppage and non-work stoppage conditions. It is also used when technical data does not exist and must be developed, approved, and provided to maintenance technicians. The AFTO Form 840 will be issued to provide procedures and engineering authorization for restoration of damaged or worn parts and components. These procedures will bring the parts into serviceable condition through repair or overhaul covered by applicable TOs, drawings, or other technical data. Engineering determinations of a "use-as-is" or "satisfactory-as-is" condition will be provided. Items determined to be beyond safe, and cost effective repair, shall be condemned Limitations. NCMR decisions must not degrade reliability, performance, form, fit or function beyond the acceptable limits or tolerances as determined by the CE (or their designee). The AFTO Form 840 will NOT be used: As interim TOs pending receipt of formal TOs As changes to the intent of TCTOs or to extend rescission dates or reinstate rescinded TCTOs To change nuclear certified equipment, systems or technical data To change TMDE requirements specified in TOs , AF Metrology and Calibration, and 33K-1-100, Calibration Procedure for Maintenance Data Collection Key Definitions Pertaining to Nonconforming Product Repair. An action taken on a nonconforming product so that it will fulfill the intended usage requirements although it may not conform to the originally specified requirements Rework. Action taken on a nonconforming product so that it will fulfill the specified requirements.

34 34 AFMCMAN JANUARY Records. When an AFTO Form 840 and the authorization memorandum are initiated, they become records. All pen and ink changes must be initialed and dated immediately adjacent to the change. Any supporting documentation can be attached as reference material to a repair or inspection action of an engine part Nonconforming Parts. Nonconforming parts are engine components worn, cracked or damaged beyond TO authority and requiring special engineering disposition. Parts that qualify for NCMR are those valued at $10,000 or more. Parts valued less than $10,000 may have the engineers review on-site or at the NCMR pool. All other products will be processed IAW applicable TO instructions without NCMR initiated action Condemned Parts. Parts determined not repairable are considered to be condemned, supply condition code H. Condemned parts will be identified and segregated at all times. When a determination has been made that a part is no longer repairable, the part is identified by plainly marking in red with a water-proof marker, paint, dye, ink or similar material (known as painting red ). A DoD Form 1577, Unserviceable (Condemned) Tag Materiel, will be completed and attached (known as red tagging ). Ensure the tag is filled out precisely as to why the part was condemned. Give specific details as to what was wrong with the part to cause the condemnation. The part will be annotated with a condemned code in the G337 system, Inventory Tracking System (ITS), if applicable, and subsequently segregated and sent back to the shop for condemnation credit and finally, shipped to the appropriate Defense Distribution processing area Parts identified in the Mutilation Listing, are considered to be a high-risk type of condemned parts. Mutilation is required upon condemnation for this (these) item(s). Parts requiring mutilation will be painted red, red tagged, condemned in ITS, if applicable, mutilated and subsequently shipped to the appropriate Defense Distribution processing area for processing. (T-2) Parts costing over $10,000 will not be condemned by shop personnel and must have an AFTO Form 840 filled out for engineering evaluation. This may include parts valued less than $10,000 when determined necessary for review by engineering Parts costing over $10,000 may be condemned by shop and not require NCMR action if the part has an insufficient number of cycles remaining to meet the minimum build requirement as specified in the Tech data. All condemned Comprehensive Engine Management System (CEMS) traced components should be reported to the Engine Records office prior to turn in. (T-2) Organizational Responsibilities The Complex shall provide an NCMR pool manager, and an alternate pool manager in his/her absence and shall provide sufficient propulsion engineers to conduct review of their engine parts within the time constraints The Complex shall provide: dedicated floor space; material handling equipment (conveyors, hoists etc.); sufficient Local Area Network-connected computers to permit access to ITS, Interactive Electronic Technical Manuals System, Joint Engineering Data Management Information and Control System, HAYSTACK, etc., for no fewer than three people at once (an experienced planner, an expeditor and an administrative clerk).

35 AFMCMAN JANUARY The Complex will ensure the ES, IM, Engineers, NCMR Pool Manager, NCMR planner, administrative clerk and expeditor perform their responsibilities. Any deviations or issues to these responsibilities will be brought to the attention of the NCMR Pool Manager for their initial research, coordination and resolution Process Responsibilities The NCMR Pool Manager will: Review the AFTO Form 840 packages for completeness. Inputs changes in ITS to read M-Code Assign control numbers and sign or initial appropriate blocks, as necessary, for release of parts back to maintenance Provide To/From sheets on parts to be shipped out of pool back to shops Write and update the local instruction that controls and regulates the operations of the NCMR pool. Document all activities pertinent to the AFTO Form Oversee the management of the NCMR database for the AFTO Form 840. Ensure record-keeping maintenance is IAW AFRIMS User s Guide Responsible for the entire process of all engine parts with a disposition code X. This will include access to D043, Item Management Control System, G337, ITS systems, and the NCMR database for research, updates and inputs as required. In addition, responsible for the coordination and follow-up actions with the ES, IM, leads/supervisors and/or the appropriate engineers Responsible for the Open NCMR Listing of the outstanding AFTO Form 840. These listings consist of initial engineering action/disposition (i.e.re-inspect return to NCMR, repair deficiency, Continued Processing, etc.) of an engine part and an AFTO Form 840 that has been returned for subsequent review or final disposition by the engineer within the last 60 calendar days. The administrative clerk will provide the NCMR pool manager this listing for his review or follow-up actions on a 30-day basis and forward it to maintenance production for a resolution The NCMR Planner will: Review the AFTO Form 840 packages for completeness Assign NCMR control numbers. Sign or initial appropriate blocks, as necessary, for release of parts back to maintenance Prepare supplemental WCDs or designate responsibility to appropriate Resource Create an AFMC Form 959, Work Control Document, for the work authorized by the cognizant engineer on the AFTO Form 840. Initiate request for AFMC Form 206, Temporary Work Request, when necessary for over and above costs If necessary, paint the parts red to allow visibility of the NCMR before return to the shop.

36 36 AFMCMAN JANUARY Maintenance Administrative Clerk. The Maintenance Administrative Clerk (assigned to NCMR Area) will: Provide clerical and administrative support to NCMR Section Process the AFTO Form Upon receipt, screen each submitted AFTO Form 840, and input data to G337 and NCMR Enterprise Information Management (EIM) Database Notify responsible RCCs of pending X account action Provide technical assistance on the NCMR database. Extract AFTO Form 840 or statistical data from the database for various shops and/or engineering departments upon request File copies of AFTO Form 840 and supporting documents IAW AFRIMS Monitor AFTO Form 840 requests for engine parts pending special attention or actions (e.g., NCMR asset, special projects) Provide assistance, answer questions and/or information pertinent to the AFTO Form 840 or office administration to engineers, shop personnel and other Complex organizations. Refer technical questions and issues to the NCMR unit Serves as office custodian for office records and administration, including other duties associated with NCMR operations Ensure stock of AFTO Form 840 and NCMR tags are available for use by shop personnel Maintenance Expeditor. The Maintenance Expeditor (Assigned to Work the NCMR Pool) will: Contact responsible RCC if AFTO Form 840, WCDs or NCMR tags are missing or engine parts are misrouted. Ships parts back to responsible RCC as necessary Contact the NCMR pool manager when engine lines are full Place date stamp on upper right hand corner of the AFTO Form 840 for all incoming engine parts into the NCMR pool. Move all engine parts to their respective engine lines for review/disposition Move engine parts to out-going lines after TO/FROM routing sheets have been completed. Notifies the NCMR pool manager when parts have been dispositioned and are pending shipment from the pool Make input into ITS for destination of in-coming and out-going engine parts PM Engineer. The PM Engineer will: Take action within 5 business/working days from date stamped on the top of the AFTO Form 840 at the NCMR pool Review/research problems with maintenance if required.

37 AFMCMAN JANUARY Develop repair and/or corrective actions and provide step-by-step instructions, as required. Completes part B of the AFTO Form 840, along with any other required documents, and provides the completed package to the NCMR pool manager for their required actions and return to maintenance PM EAA. The PM EAA will: If necessary, delegate PM EAA in writing for specific areas of responsibility to one or more individuals. The PM EAA cannot be delegated to the same engineer that develops procedures or makes a disposition on any AFTO Form 840. (T-2) If necessary, delegate in writing authority to engineers to develop Part B instructions at locations not co-located with the responsible engineering activity Verify and approve instructions developed in Part B and sign engineering section/branch office block Coordinate (no delegation) on all NCMR Request and Reply forms that could affect the OSS&E of the system or equipment covered by the AFTO Form ES. The responsible ES will: Assist the engineer as required Prepare and process an AFTO Form 252, TO PCR, when indicated by a mark in Description of Discrepancy section of the AFTO Form Have AFSC ES coordinate on X-Condition memoranda or provides appropriate disposition instructions. Pool Manager provides X-Condition memoranda to the AFSC ES for concur/non-concur and disposition of asset. Disposition will be accomplished within ten working days Assist in initiation of AFMC Form 206 for over and above work including price estimate and automation system entries. Use pre-agreed to menu pricing estimates for standard type repairs to hasten AFMC Form 206 initiation rather than seek formal price estimates one at a time. This is usually good enough as actual pricing will occur at the time of rework and this is only an estimate Responsible IM. The responsible IM will: Coordinate on X-Condition memoranda and provide appropriate disposition instructions forwarded for concur/non-concur from ES When the IM non-concur with the ES automated approval of an X-Condition item, the IM needs to consult with the ES/Engineer for a resolution. Should the ES/IM decide to place the item in other than X-Condition, the IM/ES must coordinate with pool manager to make the appropriate change in the NCMR database Procedures Initiation of an NCMR Action. Any mechanic, welder, machinist, inspector, etc., who recognizes or identifies a nonconforming part requiring NCMR activity will fill out Part A, Blocks 1-13 of the AFTO Form 840, and provide a clear explanation of the deficiency, problem or condition including TO reference. Ensure the tag is filled out

38 38 AFMCMAN JANUARY 2018 precisely as to why the part was condemned. Give specific details as to what was wrong with the part to cause the condemnation Parts Requiring Engineering Disposition Parts requiring engineering disposition will immediately be segregated by placing in a clearly designated area marked "Parts Awaiting NCMR." The top of the first page of the WCD, or AFTO Form 840 if no WCD is available, will be stamped with a transparent red ink containing the letters NCMR. The AFTO Form 840 will be completed and the part readied for shipment to the NCMR pool. For parts too large to fit on the conveyor or at the responsible engineers discretion, on-site disposition will be allowed Parts requiring engineering disposition are considered as nonconforming and will be clearly identified by attaching a NCMR tag to the part in a manner that will allow easy visibility. The tag will remain attached to the part until released from the NCMR area. The tag may be removed for processes that cannot be accomplished with a tag attached but must be reattached at the first opportunity AFTO Forms 840 will be initiated by the responsible RCC and either hand carried or scanned to the NCMR pool for control number assignment and returned to the RCC point. After disposition by engineering, the AFTO Form 840 and WCD will be returned to the NCMR pool for release regardless of disposition, e.g., condemnations Receipt of Part in NCMR Pool The NCMR part expeditor receives the nonconforming part, at the NCMR pool, date stamps in the upper right portion of the AFTO Form 840 and moves the parts to its segregated engine line for easy access and identification by engineers On-site NCMR transactions are permitted for whole up assemblies or engines without accompanying WCD. The AFTO Form 840 and WCD or an AFTO Form 840 with a red NCMR stamp, if no WCD is available, will be hand-carried to the NCMR pool for a control number and stamp Parts repaired in lots or batches will have the Inventory Tracking Number (ITN) split if applicable, when a portion of the lot or batch is determined to be nonconforming. In instances where parts are repaired in designated containers (usually in lots or batches), the nonconforming parts will immediately be moved to another container with a tag attached, as above. The tag will remain attached to the container until the parts within are no longer nonconforming at which time it is removed. Parts repaired in lots or batches will never have nonconformity types mixed in the same container unless a positive identification method is used. An example would be to number each part with a marker and referencing the nonconformity by the NCMR Control Number on the AFTO Form 840.

39 AFMCMAN JANUARY Analytical Condition Inspection Nonconforming Parts. Analytical Condition Inspection parts will not be sent to the NCMR pool. Engineers will make an on-site disposition to these types of parts. The AFTO Form 840 and WCD will then be immediately hand-carried to the NCMR pool manager/ncmr planner for a NCMR Control number, Release Stamp and input in the NCMR database for tracking purposes. (T-2) AFLCMC/LP Review The appropriate engineer will take initial action on parts in the NCMR pool and sign AFTO Form 840 Part C, Coordination/Approval section as evidence of review. A maximum of 20 calendar days is allowed for parts to remain in the NCMR pool with the engineer reviewing and dating the AFTO Form 840 every 7 business/workdays after their initial review of an engine part (i.e. Hold for Engineer review). Should the engineer need additional time beyond the 20 calendar days for further evaluation of disposition instructions or to initiate paperwork to establish a repair currently not available, the nonconforming part will be held at the NCMR cage area for a maximum of 90 days and will be re-identified as an NCMR asset. Approval to hold these assets will require an initial memorandum signed by the applicable engineering branch. A sequential memorandum will be required each time the NCMR asset needs to be held beyond each 90 day period. Prior coordination must be made with the NCMR pool manager/planner if any NCMR asset parts will be stored other than at the NCMR pool. (T-2) The PM engineer will complete Part B of the AFTO Form 840 packages with orderly, clear, concise and complete technical instructions, including references to TOs or WCD line references if required If no special instructions are needed, the engineer may write "see Block 13" in Block 12 and then select the proper action codes on the maintenance and supply action lists For a procedure that is repeatedly required, the engineer should consider requesting an AFTO Form 252 or an AFTO Form 22, Technical Manual (TM) Change Recommendation and Reply, through the appropriate ES If acceptable discrepancies beyond TO limits will be readily apparent to field organizations, instructions must be included for documenting the repairs on the AFTO Form 95, Significant Historical Data If a completed AFTO Form 840 does not require additional review of the nonconforming part at the NCMR pool or on-site review, the engineer will sign and date Block 15A and, as applicable, obtain signature in Block 15B when Block 14 directs use of AFTO Form 252. If the AFTO Form 840 requires return of the part to the NCMR pool or on-site review for additional inspection and/or instructions, the engineer will sign in Block 12, leaving Block 15 open for final approval signature When the nonconforming product is generated and damage is evidently attributed to the current repair cycle, shop damage will be marked in Shop Discrepancy block of the AFTO Form 840 and a circled S will be entered in Block 12.

40 40 AFMCMAN JANUARY The PM engineer contacts the ES to initiate an AFMC Form 206 action for over and above repair work Placement of Parts in X-Condition When the AFTO Form 840 indicates the nonconforming part is dispositioned to condition code X (X-Condition), the NCMR pool manager/planner initiates an to the appropriate AFSC ES for approval/disapproval. Coordination is required from the ES, IM and IM lead/supervisor or the ES and IM must agree to provide different appropriate disposition instructions for non-concurrence. Coordination for an authorized memorandum will be returned to the NCMR pool manager/planner within 10 working days. XCondition items will be monitored daily by the NCMR pool manager/planner, and affected parties will be notified after the 10 business/working days in order to find lost, delayed or misrouted coordination. After AFSC ES, IM and IM lead/supervisor have coordinated and approved the authorized memorandum or the X disposition code has been changed by the ES, an automated notification will be sent to the NCMR pool manager/planner. The NCMR pool manager/planner will print each authorized memorandum or the notification to the change of disposition code by the ES. Each authorized memorandum will be date stamped & signed by the NCMR pool manager/planner. The authorized memorandum or notification will be used to update the NCMR database. Two copies of the AFTO Form 840 and either the authorized memorandum or notification will be provided to the appropriate organization for turn-in processing. NOTE: The M code, verifying the part is in NCMR, will need to be changed in G337 to the correct status and condition codes by the NCMR pool manager/planner when the ES or engineer changes the X disposition code to a different code in the ITN block of the AFTO Form When the engine part in X-Condition is being re-dispositioned due to a repair or for excess storage parts, the ES or the engineer will coordinate with the NCMR pool manager/planner for the correct disposition process and documentation for the office files. For condemned parts, G337 will be updated with the correct condemned status and condition codes and the NCMR database will be updated by the NCMR pool manager/planner Release of Parts to Maintenance Shops When parts are received at the NCMR Pool, the NCMR pool manager/planner will enter status code M (NCMR) in the ITS QN2097 status screen and then assign a NCMR Control Number. This will place the item on HOLD status until the engineers make their final disposition on the AFTO Form 840. When the part is released, the administrative clerk will then change the M code in the ITS to the new status and/or condition codes, as applicable. NOTE: The M code in G337 can be temporarily removed for a supplemental or recycle WCD to be pulled at the shop location and will immediately be re-coded M when completed with prior coordination with the NCMR pool manager/planner.

41 AFMCMAN JANUARY Parts having a transparent green Released Stamp placed across the NCMR stamp on the front page of the WCD or the AFTO Form 840, as applicable, will no longer be considered as nonconforming. The next RCC to handle the released NCMR item will remove the NCMR tag. Access to the green Released Stamp is for use by only authorized NCMR pool manager/planner. Repaired parts will not be made serviceable until a green Released Stamp has been placed over the red NCMR stamp on the top of the WCD or the AFTO Form 840. Parts with the front page of the WCD that have been stamped with the red NCMR stamp by mistake, will have the WCD hand-carried to the NCMR office to have the green Stamped by Mistake placed over the red NCMR stamp on the first page of the WCD. The ITS screen QN2097 will be reviewed to ensure that an "M" status (NCMR code) does not remain prior to scanning the part as serviceable. Parts not having a green released stamp across the NCMR stamp and/or having an "M" code status remaining on the QN2097 screen will be returned to the NCMR area for investigation and will not be put in a serviceable status in ITS Follow-on Shop Actions The appropriate maintenance shop(s) will accomplish the repairs, reinspections, condemnations, etc., as indicated on the AFTO Form 840. Repaired or reworked nonconforming products will be re-inspected per the applicable TO and signed off by certified Complex personnel. In these cases, the mechanics inspection stamp applied to the applicable step of the WCD is the evidence of TO compliance Nonconforming parts that require work/rework as result of engineering disposition will be returned to the NCMR pool or shop location as instructed by the engineer on the AFTO Form Distribution and Posting Information from each AFTO Form 840 will be input into the NCMR database. The administrative clerk will maintain an NCMR control data file of AFTO Form 840 for use by both production and management. This file will be arranged in NCMR control number sequence. The AFTO Form 840 is a four-part form. For parts making one trip through the NCMR pool, the first copy (1-NCMR File) is retained in the NCMR file. The second (2-Work Package Copy), third (3-Suspense) and fourth copies (4-Other) are retained in the work package with the part and returned to the shop. When additional inspections or repairs are required and the part is returned to the NCMR pool or shop location for another review, the copy will be retained for the NCMR file, remaining copies will go with the work package and the part until all work is completed. After the work is completed and the engineer makes a final disposition, then the first copy is retained for the NCMR file. For condemned parts, the fourth copy is for CEMS processing. When X letters are required, both the first and second copies are retained for the NCMR file and the first copy will be used to initialize the authorization memorandum. When the X Condition Memorandum or the correct change of disposition codes is finalized, the original copy is retained for the office files attached with either the authorized memorandum or notification and the third copy is disposed of. The second and fourth copies will stay with the part.

42 42 AFMCMAN JANUARY 2018 NOTE: When the first copy is inadvertently removed or lost, any of the other AFTO Form 840 copies or a machine made copy may be retained in the NCMR file Rescission and Removal. This applies only to actions taken on AFMC Forms 202. AFTO Form 840 is for single-instance use only on each part Standardizing Procedures. When responses to a particular problem with an engine part are repeated, the cognizant engineer or ES should determine whether TO changes are preferable to additional NCMR activity AFTO Form 840 Completion Instructions All entries must be typed or neatly printed in blue or black ink. The NCMR control number shall be placed in the upper left corner of all attachments, continuation sheets, sketches, etc All boxes on the AFTO Form 840 must be completed or annotated with "NA" (not applicable) if information is not available by the initiator. The initiator will ensure a WCD and NCMR tag is attached to the nonconforming part going to the NCMR pool or on-site review Part A, Production Completion Instructions. The initiator will provide information for Blocks 1-13 of the AFTO Form NCMR Control block. The NCMR Control Number will be assigned by NCMR pool manager or planner before the engineer makes a disposition to an engine part Date Submittal block. Enter the date the AFTO Form 840 was initiated by shop discovering the problem Engine Type, Model, Series block. Enter the TMS (example: F ) of the engine to be addressed Requestor block. Enter the requestor s full name Requestor Phone Number block. Enter the requesters phone number including area code. Do not enter the Defense Switched Network (DSN) as the sole number provided Office Symbol block. Enter the office symbol of the requester RCC block. Enter the appropriate RCC. The RCC must be included by discovering shop Part Number. Enter the lowest indenture level item part number of the nonconformity (i.e., the actual part to be reviewed rather than the next highest assembly Serial Number. If the item is serialized. If not serialized enter Not Applicable NSN. Enter the NSN for the part number as indicated in If a NSN does not exist, enter Not Applicable.

43 AFMCMAN JANUARY Nomenclature. Enter the nomenclature of the part as it appears in the applicable IPB TO Reference. Enter the applicable TO reference for the discrepancy described Inventory Tracking Number. Enter the ITN number Description of Discrepancy. Enter the a detailed description of the of the nonconformity and its deviation from TO limits Part B, Management Instructions. Enter specific instructions pertaining to special re-inspection, rework instructions, or other dispositions. When known, enter enter the applicable supply point where part is to be routed. If no special instructions are required and disposition. If part is to be returned to NCMR pool or to the on-site location for further action after the initial instruction is met, the assigned engineer will sign the form in Part C coordination block Disposition. Eter the dispositions for the nonconformity Part C, Maintenance/Supply/Requirements Maintenance. Check the boxes that are applicable to the nonconformity Supply Action. Check applicable box if part will be routed for a supply action Requirements. Mark the applicable requirements to be accomplished Part C, Coordination/Approval Engineer Signature. Enter the assigned engineers name, office symbol, and phone number. The assigned engineer shall enter their electronic signature and date to signify completion of the discrepancy and recommended instructions for remedy Part D, Engineering Branch/Section Coordination/Approval Interim Engineering Branch/Section. If applicable, enter the name of the interim engineer, office symbol, and phone number of the assigned engineering branch/section. The engineering supervisor and/or designee will initial the block if further repair or inspection will be required. If so, the part will be returned to the NCMR pool shop location for an on-site review Final Engineering Branch/Section. Upon completion of required engineering activity, the nonconforming item instructions will be signed by the Final Engineering Branch/Section to signify completion of instructions for the part. The engineering signatory for this final block will include the individuals office symbol and phone number.

44 44 AFMCMAN JANUARY Records Management Official Records. The AFTO Forms 840 are official records IAW the AFRIMS User Guide. The active copies will be maintained in numerical order and retained at the NCMR office until last entry, after which they will be put in inactive file for a period of 1 year then destroyed (AFRIMS T21-05R1200) The NCMR files are input using an EIM database system to summarize each AFTO Form 840, and provide data from the form this data via a computer spreadsheet. The database is available through the engineering EIM and can be accessed by engineers, ESs, pool managers, NCMR planners and pool admin clerks The AFTO Forms 870 are evidence of actions taken and, as such, will be maintained in the NCMR area file plan Use of Forms High Flow Engine NCMR Environment. The AFTO Form 840 is the preferred form for the high flow engine NCMR environment. It has been tailored to provide more space for description of problems, deficiencies, instructions, responses or resolutions. This is important because of the cyclic nature of the NCMR repair activity, wherein parts might return to the dedicated NCMR pool or shop location (on site) for engineer examination following a second or subsequent inspections or repairs. The AFTO Form 840 also contains information not reflected on AFMC Form 202 that is peculiar to the NCMR database that maintains engine component information. The database itself is important to engineers for hardware trend recognition and to TCMs for quarterly spares computations. It is also used to gather statistical data for various Complex organizations. This version of the AFTO Form 840 requires the same signatures as the AFMC Form 202. The AFTO Form 840 signature requirements have been simplified for the following reasons: (a) ground safety is not an issue in engine NCMR because only maintenance procedures already planned and in use may be invoked by the engineers and product engineers (nuclear hardness engineers) are not involved as the parts subject to this instruction are not nuclear hardened; (b) the shop supervisor approval signature is not required. Thus, only three (3) signatures remain: engineer, TOMA (as applicable) and engineering branch, unit or designee Repetitive NCMR Assessments. An AFTO Form 252 may be initiated by the TCM if NCMR assessments become repetitive and warrant inclusion in TOs to alleviate unnecessary traffic of parts into the NCMR pool or on site reviews at various shop locations An AFMC Form 206 for funding will be requested for any disposition given by engineering on AFTO Form 840 that is determined to be over and above work.

45 AFMCMAN JANUARY Figure 6. AFTO Form 840 Process Flow ALLAN E. DAY, Brig Gen, USAF Director of Logistics, Civil Engineering and Force Protection

46 46 AFMCMAN JANUARY 2018 References Attachment 1 GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION DoDD , Distribution Statements on Technical Documents DoDI , Engineering Support Instructions for Items Supplied By Defense Logistics Agency (DLA) AFI , Aircraft and Equipment Maintenance Management AFI V2, Cruise Missile Maintenance Management AFI , Publications and Forms Management AFI /20-101, Integrated Life Cycle Management AFMAN , Management of Records AFMCI , AFMC TO System Implementing Policies AFMCI , Implementing Operational Safety, Suitability and Effectiveness (OSS&E) and Life Cycle Systems Engineering (LCSE) AF Pamphlet , Integrated Life Cycle Management MIL-STD 882, DoD Standard Practice: System Safety TOs cited in this AFMC Manual may be accessed via ETIMS at An ETIMS account is required. If you have an essential requirement for an ETIMS account, contact the AFTO Field Support Team at DSN , Commercial or af.etimstofst@us.af.mil. TO , AFTO System TO , AFTO Life Cycle Management TO , AF TCTO Process TO , Aerospace Equipment Maintenance Inspection, Documentation, Policies and Procedures TO , Maintenance Data Documentation TO , Maintenance Assistance TO , AF Metrology and Calibration Program TO 33K-1-100, Calibration Procedure for Maintenance Data Collection Adopted Forms AF Form 3925, Engineering Order AF Form 847, Recommendation for Change of Publication AFMC Form 959, WCD AFMC Form 202, Nonconforming Technical Assistance Request and Reply

47 AFMCMAN JANUARY AFMC Form 206, Temporary Work Request AFTO Form 22, Recommended Change Request AFTO Form 95, Significant Historical Data AFTO Form 840, NCMR (NCMR) AFTO Forms 781(A-P), Maintenance Data Documentation Series DLA Form 339, Request for Engineering Support DLA Form 1912, Defense Logistics Agency Local Purchase Technical Support Request DoD Form 1574, Serviceable Tag Materiel Terms AF Materiel Management Aggregation Code A two-position alphabetic code authorized to identify specific items (NSNs) to be managed by a specific manager. Materiel Management Aggregation Codes apply to systems, programs, aggregation to related equipment, and selected Federal Supply Class. AFMC Form 202 ETAR. The document and process used within a depot-level maintenance activity to request the responsible engineer and ES develop technical data or determine serviceability when published data is in error or not adequate to complete the task at hand (work stoppage or anticipated work stoppage) and provide the response to the maintenance technicians. The AFMC Form 202 process is also used to alleviate critical parts or material shortages by authorizing substitutes determined suitable by the responsible engineer Purpose is to provide EAA engineering determination and authorization to resolve: (1) Procedures for restoration of damaged or worn parts and components to serviceable condition through repair or overhaul procedures or processes not covered by applicable TOs, drawings or other technical data.(2) A serviceability condition of "Use-as-is" or "Satisfactory-as-is" (3) A one-time substitution of parts, components or materials determined to be suitable replacements for specified items.(4) A one-time substitution of support equipment, special tools, test equipment, fixtures or ground handling equipment determined to be suitable replacements for specified items. Alternate Source An offeror (Government or Contractor) other than the Prime Contractor or Original Equipment Manufacturer to provide the identical part numbered item. Approved Source Any supplier who has been approved by the cognizant engineering organization(s) to supply parts manufactured to the original specifications of the item. Authority The legitimate right or power of an individual to make determinations or direct actions within the scope of the position to achieve specific objectives. Assigned persons are responsible to exercise their authority to accomplish the assigned task(s). Chief Engineer (or Designee) The CE for any system is the individual designated as the CE per AFMCI and has ultimate cognizant technical authority responsibility for that system. The CE may designate an individual(s) to assist with the approval of ETAR requests. This (these) designee(s) shall be designated by name in writing annually.

48 48 AFMCMAN JANUARY 2018 Critical Application Item An item that is essential to weapon system performance or operation, or the preservation of life or safety of operating personnel, as determined by the engineering activity(s). Critical Safety Item CSIs are categorized as either Aviation CSIs or Ship CSIs. For the purpose of this instruction, any reference to CSI includes both Aviation CSIs. A part, assembly, installation equipment, launch equipment, recovery equipment, or support equipment for an aircraft or aviation weapons system that contains a characteristic for which any failure, malfunction, or absence could cause a catastrophic or critical failure resulting in the loss or serious damage to the aircraft or weapons system; an unacceptable risk of personal injury or loss of life; or an uncommanded engine shutdown that jeopardizes safety. Disposition Engineer Maintenance engineer with delegated authority to develop the AFMC Form 202 engineering disposition. Distribution Statement A statement used in marking a technical document, regardless of publication media or form, to denote the extent of its availability for distribution, release, and disclosure without additional approvals and authorizations from the controlling DoDD office. DLA Form 339 Form used to obtain engineering support for standardization for DLA managed items supplied to the services/agencies. Categories of engineering support supplied and Decision Support Center/service/agency responsibilities are defined in General Services Administration Revision Control System DoD-DLA (A) 259(s)) and DLA Regulation , Engineering Support Instructions for Items Supplied by DLA. Engineering Change A change to the current approved configuration documentation of a configuration item. Any alteration to a product or its released configuration documentation. Effecting an engineering change may involve modification of the product, product information, and associated interfacing products. Emergency Maintenance Support Maintenance assistance required by AF activities to satisfy urgent unprogrammed requirements for depot level maintenance or Organizational and intermediate O&I level maintenance which is beyond the capability of the maintaining command. Engineering Support Engineering and technical assistance, including, but not limited to: developing, validating and approving TDPs; developing and reviewing engineering criteria; representing the military service engineering interests; and providing technical guidance and decisions required in the management and procurement of an item for its entire life cycle. Engineering Support Activity The organization/individual designated to provide engineering or technical assistance, including the development of technical data and engineering criteria, engineering representation, guidance, and decisions. Engineering Support Activity Focal Point Entry and exit point(s) for requests for engineering support within each service. Extended Engineering Effort A request for engineering support that requires the use of dedicated resources to work a defined requirement, has a clearly specified end product, and incurs a one-time negotiated charge. Item Unique Identification DoD program that that enables easy access to information about DoDD possessions that make acquisition, repair, and deployment of items faster and more

49 AFMCMAN JANUARY efficient to track. It is a permanent marking method used to give equipment a unique identification. Marking is essential for all equipment with an acquisition cost of over $5,000, equipment which is mission essential, controlled inventory, serially-controlled, or consumable. Item Unique Identification-marking is a set of data for assets that is globally unique and unambiguous. Tangible items are distinguished from one another by the assignment of a unique identifier in the form of a unique data string and encoded in a bar code placed on the item. An item unique identifier is only assigned to a single item and is never reused. Once assigned to an item, the Item Unique Identification is never changed even if the item is modified or reengineered. Life Support Item All equipment and components designed to protect, sustain, or save human lives as designated by the engineering activity. Maintenance Engineering For the purposes of this AFMC Manual maintenance engineering is referred to as logistics support for depot maintenance repair facilities and provides plant facilities, equipment engineering, calibration, and installation support as required. Operational Safety The level of safety risk to the system, the environment, and the occupational health caused by a system or end item when employed in an operational environment. The PM shall utilize the established system safety process to assure operational safety. Planner Persons (typically GS0895, IETs) responsible for development, preparation, revision, coordination and accuracy of technical content of WCDs. Reviews/updates/maintains files of WCD change requests, and maintain documentation for AFMC. Program Manager The PM is the senior individual responsible and accountable for management of a weapon system or sub-systems. PM refers to Product Group Manager which has engineering and programmatic responsibility for the discrepant item. Reverse Engineering The process of examining an item to determine its function, material composition, construction, and its electrical, physical, and environmental requirements for the development of a TDP adequate for procurement. The output of the reverse engineering project will be a TDP for an item that has the same form, fit, and function of the original item. Scientific and Technical Information Information relating to research, development, engineering, testing, evaluation, production, operation, use, and maintenance for military products, services, and equipment for military systems. This includes production, engineering, and logistics information. Systems Engineering Comprises the scientific, technical, and managerial efforts needed to define/refine requirements, develop, test, verify, deploy, support, sustain and dispose of a product, platform, system, or integrated System-of-Systems/Family-of-Systems capability to meet user needs. SE may be referred to as a discipline, a methodology, an approach, a practice, a process, a set of processes and sub-processes, or various other terms; however, its fundamental elements systematic technical and managerial processes and measurements remain the same regardless of the collective nomenclature. Technical Content Manager The individual, usually an ES or Engineer, responsible for maintaining the accuracy, adequacy, modification, classification, review, and currency of the technical content of TOs and TCTOs supporting assigned systems, commodities or processes.

50 50 AFMCMAN JANUARY 2018 Technical Data Recorded information, regardless of form or method of recording, of a scientific or technical nature. Information that can be used, or adapted for use, to design, develop, assemble, engineer, produce, manufacture, modify, operate, repair, test, overhaul, maintain, or reproduce equipment and related technology. Technical Data Package A technical description of an item adequate for supporting an acquisition strategy, production, engineering, and logistics support. The description defines the required design configuration or performance requirements, and procedures required to ensure adequacy of item performance. It consists of all applicable technical data such as models, drawings, associated lists, specifications, standards, patterns, performance requirements, QA provisions, software documentation and packaging details. Test, Measurement, and Diagnostic Equipment Devices used to maintain, evaluate, measure, calibrate, test, inspect, diagnose, or otherwise examine materials, supplies, equipment, and systems to identify or isolate any actual or potential malfunction, or decide if they meet operational specifications established in technical documents. Work Control Document The official record for (depot) work including control, identification, certification, and routing of items. It is an instruction document summarizing sequenced steps and the TO references for processing the item. WCDs are developed by authorized planner/iet IAW approved technical data. The WCD is the record documenting that the task was performed by certified technicians IAW authorized technical data.

51 AFMCMAN JANUARY Attachment 2 SAMPLE DLA FORM 339 Figure A2.1. DLA Form 339, Request For Engineering Support.

52 52 AFMCMAN JANUARY 2018 Figure A2.2. DLA Form 339, Request For Engineering Support.

53 AFMCMAN JANUARY Figure A2.3. DLA Form 339, Request For Engineering Support.

54 54 AFMCMAN JANUARY 2018 Figure A2.4. DLA Form 339, Request For Engineering Support.

55 AFMCMAN JANUARY Figure A2.5. DLA Form 339, Request For Engineering Support.

56 56 AFMCMAN JANUARY 2018 Figure A2.6. DLA Form 339, Request For Engineering Support.