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S5C1 - AERONAUTICAL PRODUCT

Table of Contents

INTRODUCTION

AUTHORITY TO FIT

Authority To Fit Systems

AERONAUTICAL PRODUCT IDENTIFICATION

AERONAUTICAL PRODUCT QUALIFICATION

Approved Documentation

Serviceability Classification

Identifying Details

Physical Characteristics

Damage

HANDLING, STORAGE AND TRACKING OF AERONAUTICAL PRODUCT

Consumable Sub-store

Inspection and Handling Aeronautical Product Containing Elastomers

Identification of Unapproved Aeronautical Product

Reporting Unapproved Aeronautical Product

ACQUISITION OF AERONAUTICAL PRODUCT FROM OTHER THAN APPROVED SOURCES

LOCAL MANUFACTURE OF AERONAUTICAL PRODUCT

SECURITY CLASSIFICATIONS

Classified

Unclassified

REPAIRABLE ITEM PIPELINE

Responsibilities

PREPARATION OF AERONAUTICAL PRODUCT FOR TRANSPORTATION

General Transportation Requirements

Air Transportation Requirements

Personnel Requirements

DISPOSAL OF AERONAUTICAL PRODUCT

Unserviceable Aeronautical Product

Surplus to Requirement

Security Classified Aeronautical Product

RECORDS RETENTION

Annex

A. Aeronautical Product Serviceable and Unserviceable Labels

INTRODUCTION

1. Aeronautical Product is any Systems Program Office (SPO) approved aircraft system, sub-system, component, part or materiel, including computer systems software/firmware and petrol oils and lubricants, whose intended end-use is to form a physical part of an aircraft.

2. The identification of unapproved aeronautical product before its fitment to an aircraft or higher assembly is essential to ensure technical airworthiness is not compromised. Aeronautical product assessing, provisioning and identification within the ADF provides all maintenance personnel with a level of confidence that the aeronautical product provided is approved and meets the required design specification.

3. Maintenance personnel are the final step in the quality assurance process to identify deficiencies/discrepancies in aeronautical product prior to fitment. Therefore, it is essential that maintenance personnel understand their roles and responsibilities in ensuring that only approved aeronautical product is fitted.

4. This chapter prescribes the Approved Maintenance Organisation responsibilities and procedures to be followed when managing aeronautical product.

AUTHORITY TO FIT

5. Only approved aeronautical product may be fitted to aircraft and higher assemblies.

Authority To Fit Systems

6. The responsible SPO is the authority to specify the system to be used by maintenance personnel to demand and fit approved aeronautical product.

7. Maintenance personnel must refer to the authorised Original Equipment Manufacturers (OEM) maintenance data for the description and Manufacturers Reference Number (MRN) (also known as Part Number) of the required aeronautical product and then access the authorised Authority to Fit system to determine the authorised NATO Stock Number (NSN) to demand.

8. Upon receipt of the aeronautical product from the approved supply system, maintenance personnel must ensure the aeronautical product supplied has the correct NSN and MRN or is an approved alternate.

9. If there is any doubt that the supplied aeronautical product is approved for fitment then maintenance personnel must contact the responsible SPO for confirmation.

10. Maintenance Managed Items. For Maintenance Managed Items (MMIs), specific authority to fit details are provided by the Technical Maintenance Plan (TMP) or other SPO approved maintenance plan. For those weapon systems supported by the OmegaPS Weapon System Database, authority to fit can be further defined by batch information, typically Batch Name, ‘Batch From’ and ‘Batch To’ details.

11. Therefore, for MMIs, the SPO authorised system provides the cross reference between the OEM maintenance data or Illustrated Parts Breakdown reference to the authorised NSN to be demanded. In addition the TMP and Maintenance Management System provide verification by reference number, the Manufacturers Commercial and Government Entity (CAGE) code and batch information suitability for the fitment of the MMI to a particular location in a weapon system.

AERONAUTICAL PRODUCT IDENTIFICATION

12. As a minimum all aeronautical product must be labelled with the following information:

  1. item name
  2. manufacturer's part number(s)
  3. stock number (where applicable)
  4. serial number or batch/lot number (where applicable)
  5. status and the date of status change (where applicable)
  6. name(s) and signature(s) of person(s) certifying the equipment as serviceable or unserviceable (where applicable).

13. If an item of aeronautical product is found to have any of the following, the item is to be classified as unapproved for use:

  1. discrepancy in its associated documentation
  2. suspected damage
  3. damage as a result of packaging
  4. material deficiencies
  5. design deficiencies (incorrect part number, MOD/STI status etc).

14. If an item of aeronautical product is not properly identified or is suspected to be unapproved, then it must be placed in quarantine and the SPO notified.

AERONAUTICAL PRODUCT QUALIFICATION

15. Prior to the fitment of aeronautical product to higher assemblies, maintenance personnel must ensure that all steps are taken to qualify the product as follows:

  1. Approved Documentation. The documentation attached to the aeronautical product must be approved and authorised for use.
  2. Classification of Serviceability. All aeronautical product must be classified as serviceable.
  3. Identifying Details. The identifying details on the aeronautical product and the packaging containing the aeronautical product and the documentation must be complete and match.
  4. Physical Characteristics. The physical characteristics must be consistent with the aeronautical product being replaced. The replacement aeronautical product must be physically consistent in form, fit and function with the aeronautical product it is replacing, unless a known approved variation to the physical characteristics, ie Modification (MOD) has occurred.
  5. Damage. The aeronautical product and packaging must not be damaged in any way.

Approved Documentation

16. The following represents the types of acceptable documentation that may be attached to aeronautical product:

  1. SERVICEABLE CAMM2 TRAV TAG - Maintenance Summary Report. This is the label used by CAMM2 Approved Maintenance Organisations (AMO) to classify aeronautical product serviceability.
  2. SERVICEABLE Non-CAMM2 Venue TRAV TAG-Maintenance Control Sheet. This is the label used by Non-CAMM2 AMOs to classify aeronautical product serviceability.
  3. SERVICEABLE CAMM2 BLANK TRAV TAG. This is the label used for CAMM2 Down or by Non-CAMM2 AMO to classify aeronautical product serviceability.
  4. Form EE507-Aeronautical Product Maintenance Record. This is the form used to record maintenance conducted on aeronautical product not identified in a TMP. Form EE507 may be used to classify the aeronautical product as either serviceable/unserviceable or unrepairable.
  5. Form EE209-Serviceable Technical Equipment Label. This is a serviceable label normally used for, but not limited to, aeronautical product not TMP identified.
  6. Form EE435. This is a form that may be used as a serviceable label for aeronautical product.
  7. Certificate of Conformity. A Certificate of Conformity (C of C) is a formal certification that the goods supplied are authentic, their origin is traceable, they meet the specification and conditions contained in the original order, and that it is certified by personnel of the quality control organisation of the supplier. There are two types of C of C:
    1. Manufacturers C of C.
    2. Suppliers C of C.
  8. Foreign Military Sales. For items supplied from the US Department of Defense Foreign Military Sales:
    1. DD Form 1348-Requisition System Document (Manual), DD Form 1348-1A-Issue Release/Receipt Document or DD Form 1149-Requisition and Invoice/Shipping Document.
    2. DD Form 250-Material Inspection and Receiving Report or the electronic equivalent, Wide Area Work Flow (WAWF) form.
  9. Australian Contractors Supplies Acceptance Certificate. Aeronautical product subject to quality assurance at Australian sources are to be accompanied by one of the following ADF forms, as appropriate:
    1. Form SG001-Supplies Acceptance Certificate.
    2. Form SG008-Suppliers Release Note.
    3. Form SG319-Certificate of Conformity.
    4. Contractors Certificate of Conformity.
  10. Military Integrated Logistics Information System (MILIS) Picking Slip/Issue Voucher. When Break Down Spares (BDS) are issued from ADF stock, a MILIS Picking Slip/Issue Voucher or equivalent will accompany the BDS to the ordering AMO, this document provides assurance the aeronautical product was obtained from a known source and was accompanied by the original C of C, MILSTRIP or OEM document.
  11. Form EE059-Unserviceable Equipment. This is an unserviceable label normally used, but not limited to, for aeronautical product not identified in a TMP.
  12. UNSERVICEABLE CAMM2 TRAV TAG-Maintenance Summary Report. This is the label used by CAMM2 AMOs to classify aeronautical product serviceability.
  13. UNSERVICEABLE Non-CAMM2 Venue TRAV TAG-Maintenance Control Sheet. This is the label used by Non-CAMM2 AMOs to classify aeronautical product serviceability.
  14. UNSERVICEABLE CAMM2 BLANK TRAV TAG. This is the label used for CAMM2 Down or by Non-CAMM2 AMO to classify aeronautical product serviceability.
  15. Other Acceptable Documentation. The SPO responsible for management of the aeronautical product must promulgate any other acceptable document as provided by the supplier or repair facility. This includes documentation acceptable to the SPO provided by the OEM.

17. Guidelines on the use of the ADF sponsored serviceable and unserviceable labels are detailed in Annex A.

Serviceability Classification

18. All aeronautical product must be classified as either serviceable or unserviceable. Documentation attached to the aeronautical product must be certified with a signature or authorised stamp.

19. Maintenance personnel must inspect the label attached to an aeronautical product for correctness and completeness. Where there is a discrepancy with the documentation or classification of serviceability, the discrepancy must be reported to the Maintenance Manager (MM). While investigating the discrepancy, the aeronautical product must be placed in quarantine.

20. Aeronautical product that does not have a serviceable label attached because of its size, method of packaging or maintenance management policy, eg BDS such as nuts, washers, split pins, must have as a minimum, a single C of C, MILSTRIP or OEM document on receipt. This documentation is retained after receipt of the aeronautical product into the ADF and forwarded to the responsible SPO Purchasing Authority.

21. When BDS are issued from ADF stock, a MILIS Picking Slip/Issue Voucher or equivalent will accompany the BDS to the ordering AMO. This document provides traceability and assurance the aeronautical product was obtained from a known source and was accompanied by the original C of C, MILSTRIP or OEM document.

Identifying Details

22. A physical check of the identifying details marked on the aeronautical product and annotated on the attached document must be carried out to ensure correctness and consistency. In some instances the aeronautical product may be marked with less detail than the attached document. Where there appears to be a discrepancy with the identifying details, the discrepancy must be reported to the MM. If the MM concurs, the aeronautical product must be placed in quarantine.

23. For serviceable aeronautical product removed for access or maintenance, the following identification requirements apply:

  1. For TMP identified aeronautical product, raise a serviceable label and enter identification details. This label should be certified as required and attached securely to the aeronautical product.
  2. For non-TMP identified aeronautical product, other than BDS, raise a serviceable label and enter identification details. This label should be certified as required and attached securely to the aeronautical product.
  3. For BDS, place in a secure container, eg Foreign Object Damage (FOD) bag and attach securely to the parent aeronautical product.

24. For aeronautical product removed for access or maintenance that is unserviceable or unrepairable, the following identification requirements apply:

  1. For TMP identified aeronautical product, that is classified as repairable, raise an unserviceable label and enter identification details. This label should be certified as required and attached securely to the aeronautical product.
  2. For TMP identified aeronautical product, that is classified as unrepairable, raise a Form EE059 and enter identification details. This label should be certified as required and attached securely to the aeronautical product.
  3. For non-TMP identified aeronautical product, other than BDS, that is classified as repairable, raise maintenance documentation, eg Form EE507, and enter identification details and the details of any unserviceability. This label should be attached securely to the aeronautical product.
  4. For non-TMP identified aeronautical product, other than BDS, that is classified as unrepairable, raise a Form EE059 or Form EE507 and enter identification details. This label should be certified as required and attached securely to the aeronautical product.
  5. For BDS, dispose of in accordance with paragraph 52.

Physical Characteristics

25. Replacement aeronautical product should be received in a new or as new condition. Where there appears to be a discrepancy with the physical consistency, the discrepancy must be reported to the MM. If the MM concurs, the aeronautical product must be placed in quarantine.

Damage

26. Aeronautical product received in a damaged state must not be used. Where there appears to be damage to the aeronautical product, it must be reported to the MM. If the MM concurs, the aeronautical product must be placed in quarantine. Where the damage was caused by faulty preservation or packaging, the aeronautical product must be placed in quarantine and the damage reported in accordance with DEF(AUST)1000C—Part 8—Defective Packaging Reporting System. Additional requirements are specified in the Electronic Supply Chain Manual (ESCM).

HANDLING, STORAGE AND TRACKING OF AERONAUTICAL PRODUCT

27. All aeronautical product must be handled, stored and tracked in accordance with the ESCM and promulgated procedures, including:

  1. designating storage locations for, and methods of handling of aeronautical product to prevent damage or deterioration
  2. segregating serviceable, unserviceable and quarantined aeronautical product
  3. ensuring all aeronautical product is clearly labelled and fully identified
  4. recording and tracking all aeronautical product that is received, stored, issued and used within the AMO
  5. disposing of aeronautical product in accordance with responsible SPO requirements.

Consumable Sub-store

28. Consumable Sub-Stores (CST) are established to handle, store and track frequently used aeronautical product associated with the maintenance activities undertaken within an AMO. Stock holders and management of these stores are to consider:

  1. annual usage
  2. cost
  3. time to supply in normal process
  4. critical path items
  5. special to type management requirements, eg shelf life.

Inspection and Handling Aeronautical Product Containing Elastomers

29. Aeronautical product containing elastomers are susceptible to deterioration due to permanent set or constriction of the elastomeric components, eg ‘O’ rings, seals, hoses, following protracted periods in storage.

30. Aeronautical product containing elastomers which are received in sealed export type tropic proof packs or hermetically sealed evacuated polythene bags, only require visual inspection and/or functional testing immediately before installation into an aircraft or aeronautical product.

31. SPOs must define the preservation and storage of aeronautical product containing elastomers. Inspection and storage life of elastomeric components, eg ‘O’ rings, seals, hoses, must be carried out in accordance with DEF(AUST)9000—Storage Life Management of Elastomeric Items and Materials For Use In Aircraft, Aircraft Engines and Aeronautical Equipment.

Identification of Unapproved Aeronautical Product

32. Regardless of the rigour applied to the aeronautical product provisioning system, the potential always exists for an unapproved aeronautical product to be supplied and fitted without the knowledge of those involved. Maintenance personnel are the last line of defence in preventing the fitment of an unapproved aeronautical product. Therefore, it is vital that maintenance personnel are provided with a criterion by which they are able to assess the suitability of an aeronautical product.

Reporting Unapproved Aeronautical Product

33. If it is suspected that an aeronautical product is unapproved for fitment, the following actions must be carried out:

  1. The MM must inform the Senior Maintenance Manager (SMM) or delegate.
  2. The occurrence is to be reported in accordance with Section 6 Chapter 2-Report on Aircraft and Aeronautical Product.
  3. Place all stock holdings of the affected aeronautical product in quarantine.

34. Placement of the unapproved aeronautical product in quarantine needs to occur without delay, particularly for high use aeronautical product, to prevent the issue of potentially unapproved aeronautical product to other users. As a result, the quarantine of an aeronautical product may need to be initiated on verbal advice from the responsible SPO. Notwithstanding, a defect notification must be compiled and distributed within 24 hours.

ACQUISITION OF AERONAUTICAL PRODUCT FROM OTHER THAN APPROVED SOURCES

35. The acquisition of aeronautical product from other than SPO approved sources may be necessary to meet operational commitments or due to the limited access to the ADF supply system.

NOTE

For Embarked Operations acquisition procedures are detailed in ABR4.

36. When aeronautical product is unavailable through the ADF supply system, a request to approve the acquisition and fitment must be sent to the responsible SPO and, if applicable, an information copy forwarded to the parent AMO.

37. Commercial Approved Maintenance Organisations. Commercial AMOs requesting procurement of aeronautical product which is unavailable through the ADF supply system must raise a request in accordance with procedures in the ESCM.

38. All documentation attached to the aeronautical product must be retained and inserted into the aircrafts documentation pack and a copy of the documentation forwarded to the responsible SPO, as soon as possible.

LOCAL MANUFACTURE OF AERONAUTICAL PRODUCT

39. Occasionally, AMOs may need to locally manufacture aeronautical product in the course of maintenance of aircraft and aeronautical product. AMOs may only locally manufacture aeronautical product when:

  1. the manufacturing procedure is covered in authorised maintenance data
  2. the AMO has the capability and authorised personnel to carry out the manufacture.

40. However, prior to locally manufacturing aeronautical product, the SMM or delegate must consider the following:

  1. delivery time of replacement aeronautical product through the supply chain system against the time for the manufacture of the aeronautical product, versus the operational requirement
  2. availability of a higher assembly.

41. Where the manufacturing procedure is not covered by authorised maintenance data, approval to manufacture aeronautical product must be obtained from the responsible SPO.

42. All locally manufactured aeronautical product must be identified in accordance with SPO instructions.

SECURITY CLASSIFICATIONS

Classified

43. Classified aeronautical product are those items that have been allocated a security classification of TOP SECRET, SECRET, CONFIDENTIAL, or RESTRICTED. Although the aeronautical product itself may not be classified, the information related to it, ie number of assets, distribution and location may be. Depending on its classification, aeronautical product must be handled, stored and transported in accordance with procedures outlined in the ACSI 103(A) - Handling and Accounting Policy and Procedures for Controlled Cryptographic Items (CCI), ADFP 6.0.3.1 - Communications Security Instructions and ESCM Vol 4 Section 8 Chapter 3 - Management and Accounting for Classified and Sensitive Equipment.

Unclassified

44. Unclassified aeronautical product does not have any of the security classifications detailed in paragraph 43.

REPAIRABLE ITEM PIPELINE

45. The ability of the ADF to carry out assigned missions depends on ADF aircraft operational availability. In turn, the operational availability of aircraft depends on the availability of replacement aeronautical product. A typical repairable item pipeline provides for maintenance or repair as appropriate, transport and transfer of the aeronautical product to a holding store, and eventual return to the end user for fitment. With a limited number of aeronautical product above aircraft fit available, the time spent by an aeronautical product in the repairable item pipeline is one of the major determinants of aeronautical product availability.

46. To ensure that assets are used efficiently and to minimise delays in the repairable item pipeline, AMOs are to evacuate all aeronautical product into the Repairable Item pipeline with minimum delay. Unserviceable aeronautical product must not be stored at an operational AMO with the intent of forwarding a number of items into the Repairable Item pipeline.

Responsibilities

47. AMOs are responsible for ensuring:

  1. Local instructions are developed detailing responsibilities with respect to the evacuation of all aeronautical product.
  2. Periodic checks are carried out to ensure that all aeronautical product is being evacuated from the AMO in a timely manner and in accordance with the local instructions.

48. The handling and packaging requirements of specific aeronautical product is to be carried out in accordance with authorised instructions, including DEF(AUST)1000C-Australian Defence Force Packaging Standard, WHS manual Vol 2 Part 3A Chap 1 - Hazardous Chemicals Management and eDEOP 101-Department of Defence Explosives Regulations however, where instructions are unavailable the following may be used as a guide:

  1. Aerofoils. Aerofoils must not be placed directly onto the ground. They must be placed in their appropriate cradles/trestles. When returning unserviceable aerofoils they must be placed in their applicable transportation container.
  2. Propellers. Propellers must to be securely installed on an approved transportation stand, when being returned to store. Each blade tip is to have additional protection applied to ensure that no damage can be caused to the propeller or personnel.
  3. Radiators and Oil Coolers. Radiators and oil coolers must be drained and returned to store empty, except those made of light alloy which must be returned full of the appropriate fluid. All radiators and oil coolers must be returned to store in an approved shipping container.
  4. Fuel Tanks. Fuel tanks can only be returned to store when they are classified ‘gas free’. This can be achieved by draining and then ventilating with forced air. A gas vapour meter is to be used to ensure that the tank is ‘gas free’.
  5. Components Fitted with Cartridges. Components normally fitted with cartridges must NOT be returned to stores with cartridges installed, unless otherwise directed by the responsible SPO.
  6. Gaseous Tritium Light Sources. Gaseous tritium light sources, eg Beta lights, require handling with extreme care, as they may be a radioactive source if the outer case is broken.

PREPARATION OF AERONAUTICAL PRODUCT FOR TRANSPORTATION

General Transportation Requirements

49. All aeronautical product, support equipment and flyaway kits (FAKs) (including equipment classified as dangerous goods) are to be packaged, labelled and dispatched with all applicable documentation in accordance with the responsible SPO requirements, DEF(AUST)1000C and other relevant publications.

Air Transportation Requirements

50. Where aeronautical product, support equipment and FAKs (including equipment classified as dangerous goods) are to be transported by air, additional packaging requirements are laid down in AAP 3631.001(AM1)-RAAF Manual of Air Movements and AAP 3631.002 -Dangerous Goods - Transport by Service Air.

Personnel Requirements

51. Personnel involved in packaging of aeronautical product, support equipment and FAKs (including equipment classified as dangerous goods) are to meet the requirements in DEF(AUST)1000C and where applicable, the requirements in AAP 3631.001(AM1) and AAP 3631.002.

DISPOSAL OF AERONAUTICAL PRODUCT

Unserviceable Aeronautical Product

52. To prevent the re-sale and re-introduction into the inventory of disposed unserviceable aeronautical product, AMOs must ensure that the unserviceable aeronautical product is rendered unusable and irreparable following approval, as determined by the responsible SPO, by one or more of the following ESCM endorsed methods:

  1. removal and destruction of identifying labels or data plates and mutilation of part number and other identifying markings
  2. bashing or breaking up to ensure that product has no further value, other than as scrap
  3. cutting, crushing or incineration
  4. mutilation and depositing the scrap in a refuse container for disposal
  5. if applicable, transfer of stores to a hazardous/toxic waste management facility.

Surplus to Requirement

53. Surplus aeronautical products are those items that are:

  1. no longer needed to support the ADF
  2. excess to requirements
  3. unsuited for use due to obsolescence or expired shelf life
  4. provided by alternative means in a more economic manner; or
  5. beyond economic repair.

54. The ADF policy for the disposal of surplus aeronautical product is DEFLOGMAN Pt 2 Vol 5 Chap 10 - Defence Disposal Policy. Any disposal of surplus aeronautical product must have the endorsement of the responsible SPO.

Security Classified Aeronautical Product

55. Security classified aeronautical product must be disposed of in accordance with ESCM Vol 4 Section 08 Chapter 03.

RECORDS RETENTION

56. Aeronautical product records must be retained in accordance with Section 4 Chapter 2 Annex C—Retention and Archiving of Aircraft and Aeronautical Product Maintenance Records.

Annex:

  1. Aeronautical Product Serviceable and Unserviceable Labels
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