Quality Assurance Inspector Course Wk2

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Quality Assurance Inspector Course 2005 Week 2

___ Ensure maintenance organizations comply with Air Force, MAJCOM and unit directives

MAJCOM and wing/unit MSEP

___ may be combined with Logistics Standardization and Evaluation Programs (LSEP) which focus on supply, transportation, and logistics plans functions

Maintenance Standardization and Evaluation Program (MSEP)

___ shall conduct recurring unit evaluations to ensure maintenance technician proficiency

MAJCOM MSEP

Personnel from ___ staff agencies and/or field units may be used to augment the permanent team members

Other MAJCOM

Evaluation standard for evaluations of technician proficiency and equipment condition ?

Applicable technical data

___ administers the wing's Maintenance Standardization and Evaluation Program (MSEP)

Quality Assurance

___ must be designed to provide maintenance managers with a method to evaluate the unit's compliance with Air Force, MAJCOM, and local maintenance directives and policies

Unit MSEP

Units shall be penalized for ___

Technical Data Violations TDV and Detected Safety Violations DSV

___ must cover tasks that are complex and those affecting safety of flight

Key Task List (KTL)

KTL should include those tasks that have been or have the potential to be ___

Problems/high interest areas

All maintenance actions and functions listed on KTLs require ___ each time the maintenance action/function is accomplished

mandatory call-in to QA

KTLs must cover tasks that are complex and those affecting ___

Safety of flight

QA must review and update the KTL at least ___ to ensure it encompasses those maintenance actions/functions that directly affect quality of maintenance

Annually

QA must review and update the KTL to ensure it encompasses those maintenance actions/functions that directly affect

Quality of maintenance

MSEP includes a list of maintenance actions and tasks that require evaluation on a ___ basis

Routine

QA must coordinate with ___ to ensure all required inspections are performed IAW AFI 21-201 and AFI 21-204

Munitions Plans and Scheduling

QA must coordinate with Munitions Plans and Scheduling to ensure all required inspections are performed IAW ___

AFI 21-201 and AFI 21-204

The KTL and RIL provide the "structure" for the ___

Evaluation and Inspection (E&I) plan

The ___ provide the "structure" for the Evaluation and Inspection (E&I) plan

KTL and RIL

QA develops an E&I plan that shows ___ of inspections and evaluations that must be conducted

Areas, Types, and Numbers

QA developing E&I plan shall address ___ areas of concern in determining inspection/evaluation priorities

Wing Weapons Manager and Maintenance Managers'

QA developing E&I plan shall tailor plan for each ___

Squadron, Flight, or Maintenance Section

QA developing E&I plan shall ___ the E&I plan

Review, formalize, and distribute

___ over-the-shoulder evaluation of maintenance action or inspection by an individual or team

Personnel Evaluation (PE)

Use PEs to evaluate :

Job proficiency, degree or training, and compliance with technical data

Individuals performing, supervising, or evaluating maintenance tasks are subject to ___

Subject to PE

QA develops standardized ___ for all tasks

Acceptable Quality Levels (AQL)

___ over-the-shoulder evaluation of a maintenance technician or supervisor while actually performing a job

Individual Evaluation (IE)

___ over-the-shoulder evaluation of a maintenance supervisors and technicians completing a team task

Team Evaluation (TE)

The QA inspector determines if the technician or supervisor performed the job as prescribed by published ___

Technical data and appropriate instructions

Define PE pass

number of discrepancies does not exceed AQL/standards

Define PE fail

Number of discrepancies does not exceed AQL/standards

Technician fails to detect a major discrepancy while complying with inspection or work card requirement

Technician fails to comply with a step of prescribed technical data that could affect performance of the equipment involved, cause injury to personnel

Technician demonstrates a lack of technical proficiency, system knowledge, or training is not documented

Technician commits a safety violation

Technician fails to document maintenance actions in appropriate equipment records

Upon completion of a failed evaluation, evaluator must provide ___

On-the-spot feedback

Define Category I (CAT I)

"Specific" work card item, or TO step, note, caution, or warning for a "specific" condition or action

Define Category II (CATII)

Obvious defect, which could have been readily detected by a technician, or supervisor.

AQL/standards denote the maximum allowable number of ___ findings for the task to be rated "Pass"

Category I minor

___ shall be documented for trends but will not be counted against the AQL

Category II minor

Define QVI fail

Technician failed to etect a CAT I or II "major" discrepancy after completing an inspection, work card, or task requirement

Number of CAT I minor discrepancies exceeds established AQL/standard

Technician is not signed off in training records as task qualified

___ receive their own discrepancy category in the MSEP

DSVs, TDVs, and UCRs

___ personnel are the greatest deterrent to mishaps in the workplace

Well-trained and educated

Define DSV

Unsafe act by an individual

Define TDV

Observation of any person performing maintenance without proper technical data available or in use

Define UCR

Unsafe or Unsatisfactory condition, other than DSV

___ designed to give managers a comprehensive, objective evaluation of mission capabilities and compliance with technical and management directives for each function

Activity Inspection (AI)

When answers are required for minor discrepancies, these items are designated by ___

Asterisk (*)

QA must conduct ___ when a maintenance activity receives a rating of "unsatisfactory" or "marginal" during a MAJCOM LSET/MSET inspection

Follow-up Inspection

Follow-up inspections verify the adequacy of ___

Corrective actions

QA follow-up inspections do not replace activity inspections, but may be performed ___

Concurrently

___ inspections not covered by QVI, PEs, or management inspections (MIs)

Special Inspection (SI)

SI can ___, sample considerably more items or events, and may be condition, procedural, or compliance oriented

Cross many organizational boundaries

Report discrepancies found in historical documents to the appropriate ___

Supervisor

___ follow up on trends, conduct investigations, or conduct research to get to the root of problems

Management Inspection (MI)

___ inspections owning work centers perform to determine equipment condition and adequacy of depot or contractor maintenance as prescribed by TO 00-20-1

Acceptance Inspection

QA PE may be used to satisfy annual recertification requirements if the QA evaluator is a ___

Certifying Official

___ designed to capture assessment and trend data that makes information easily exportable

Quality Assurance Database (QAD)

Every unit must capture and catalog the minimum elements into their database for trending, ___ purposes

Cross tell, and benchmarking

___ as well as Maintenance Operations must have unlimited "read-only" access to the QAD

Production personnel

Highlight trends and ___ in the MSEP monthly summery

Root causes

MSEP summary should include :

Visual information
Graphs
Narratives
Quality trends identified though inspections and evaluations
Discussion of common problem areas
Descriptions of successful programs or initiatives
WS evaluations

To ensure the greatest visibility possible for MSEP summaries, classified parts must be ___

Published separately from the main summary

High-missed carded items are any work card item missed at least ___ times during a one-month period

Three

Units should use ___ to enhance maintenance-training programs, deter trends, and basically improve the quality of maintenance

High-missed carded items

___ is a forum to refine MSEP directions, address maintenance issues and resolve problems, provide cross-feed to all maintenance activities by reviewing QA inspections, evaluations, and trends

MSEP meeting

___ is responsible for ensuring an effective foreign object damage prevention program is established

Vice Wing Commander (CV)

Inspector Do's

Be professional
Maintain a friendly relationship with others
Introduce yourself to supervisors;make your reasons for being in their areas known
Listen
Be explicit when giving instruction and feedback
Be ready to reference all findings

Inspector Dont's

Let a discussion become an argument
Establish policies
Let rank or position overpower you
Be a "know-it-all"
Give unsolicited or supported opinions

Four processes to use to effectively document finding to make them clear and concise:

Organize
Validate
Develop
Audit OVDA

Define Organize

Starts with putting our ideas or findings (facts) on paper in draft form

Define Validate

Process of confirming that the collected data is correct and conclusions drawn from the data is reasonable and defensible

Crosscheck the information to sort out any errors to distortions that can lead to ___

Invalid data

Define Develop

Gather all the data to look for symptoms, causes, problems and mission impact

Define Audit

After the rest of the processes are complete, go over the final report.

Checklist for writing on a specific problem:

What the problem is
What the symptoms are causes are
Mission impact (no impact=no finding)
Recommended fixes

Outline for writing management findings:

An opening statement describing problem or symptoms, causes, and impact

Describe the symptoms
Identify the causes
Describe the mission impact
Review problem and mission impact then state recommended fix

Always consider safety and mission impact during all phases of ___

Problem Solving

Define Problem

Incorrect or inadequate situation resulting from one or more causes

Define Cause

Someone or something whose actions or inactions results in a problem or permits it to exist

First step in the ___ of the problem-solving is to make sure that a problem actually exists

Problem-analysis phase

By careful analysis, the ___ will usually reveal the ___

Symptoms/Causes

The problem analysis phase usually leads to suggestions about what it will to take to ___

Cure the problem

In the ___ the task is to recommend or make decisions intended to clear up symptoms or "fix" the problem

Decision-making phase

Two types of fixes which may be implemented in the decision-making process of problem solving:

Short term fix or long term fix

Define Short term fix

Intended to remove symptoms

Long term fix Goal

To completely overcome the problem so that it no longer exists

___ prescribes and explains how to create and manage AF publications and to whom they apply

AFI 33-360 Vol 1, Air Force Content Management Program-Publications

___ publications are the two systems of Air Force publications

Standard and specialized

___ is a "standalone" system

Special publication

___ working documents, not for implementation or compliance until certified and approved.

Draft publication

Two categories of AF publications:

Directive an Non-directive

___ are informational and suggest guidance that you can modify to fit the circumstances

Non-directive publication

TO changes, revisions, and supplements are known as ___

Increment

___ used to indicate material on a TO page has been changed

Change bars
Miniature pointing hand
Shading and screening

___ must be available and used at the job site

Operational and Maintenance (O&M) TOs

TO 00-5-1, ___ describes various types of TOs used in the Air Force

AF Technical Order System

Terms ___ and manual are used interchangeably

Technical manual

O&M TOs cover ___, operation, maintenance and handling of AF military systems and end items

Installation

O&M TOs provide detailed procedures in ___form for operational checkout, test, repair, adjustment, and R2 of accessories

Step-by-step

___ apply to a system installed on more than one type of aircraft, missile, engine

System general TO

___ general in content and are not issued against specific military systems or end items

Method and Procedure Technical Order (MPTO)

___ referred to as "work simplification" devices

Abbreviated TO

___ are developed in sets by type of inspection, and (normally) work area or zone being inspected

Inspection work cards

___ provide a means of identifying needed TOs. group TOs pertaining to specific items of equipment, and show the status of all TOs

Index TO

___ authorized method of directing and providing instructions for modifying military systems and end items, and performing or initially establishing one-time inspections

Time Compliance Technical Order (TCTO)

Write-in Changes to the technical content in TOs are generally not authorized, except for ___

Specified updates to flight manual publications

Write-in changes are authorized for corrections to the title page and ___ and references though out TOs

List of Effective Pages (LEP)

LEP checks are ___ when changes and revisions to paper TOs are posted

Mandatory

___ digital TO change files distributed electronically, used in place of interim supplements

Rapid Actions Changes (RAC)

TOPS are printed on ___ to distinguish them from other supplements

Green paper

TOPS title page will be filed in front of, and facing the same directions as, the existing TO ___

Title page

File ___ in reverse numerical sequence

Safety and Operational Supplements

___ should be printed on colored paper (other than green) to distinguish them from other TO increments

Local Page Supplements

___ are established and located to support operations and maintenance missions

Operational Libraries

___ may be stablished and maintained to control tower, base operations, or the command post as a local option

Emergency Operating Instructions Libraries

MAJCOMs may direct retention of operations and maintenance TOs on board aircraft :

Aircraft Libraries

___ may be stablished on bases where it is common to service or perform organizational or intermediate level maintenance on transient aircraft not normally assigned to the base

Transient Aircraft Libraries

___ authorized for use by activities whose duties do not include operation or maintaing equipment

Reference Libraries

AF activites may maintain a library of rescinded TOs when needed for special programs and projects

Rescinded Copies Library

Every TODA POC and/or library custodian must review the internet TO Catalog ___

Monthly

Uncorrected existence of safety conditions which could result in fatality or serious injury to personnel, result in extensive damage to or destruction of valuable property

Immediate Action TCTO

Immediate Action TCTO must be through ___

Interm TCTO message (ITCTO)

Time line for commanders to ensure distribution to all affected personnel of Immediate Action TCTOs within ___ after receipt

Four hours

Potentially hazardous conditions which could result in injury to personnel, damage to property or unacceptable reductions in combat efficiency

Urgent Action TCTO

If uncorrected, could create a hazard though prolong usage, have a negative effect on operational efficiency, reduce tactical or support utility, reduce operational life or general service utilization of systems or end items

Routine Action TCTO

___ are non-configuation change TCTOs that direct a one-time inspection (OTI) to determine equipment condition or configuration

Inspection TCTO

___ do not contain step-by-step instructions in the "how work is accomplished" paragraph

Record TCTO

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