U.S. Navy Aviation Structural Mechanic (AM) - GENERAL AIRCRAFT MAINTENANCE, CONSTRUCTION AND MATERIALS, HARDWARE, NONMETALLIC REPAIR, AND NONDESTRUCTIVE INSPECTIONS, WELDING, AND HEAT TREATMENT

INTRODUCTION TO CHAPTER ONE - GENERAL AIRCRAFT MAINTENANCE:

INTRODUCTION
This chapter discusses the various types of routine
aircraft maintenance performed by the AM ratings.
When performing any type of maintenance, it is your
responsibility to comply with all safety procedures and
tool control requirements. Because no one set of rules
applies to all aircraft, you should refer to the
maintenance instruction manual (MIM) for the tools,
materials, and procedures required for that particular
aircraft or piece of equipment.

TOOL CONTROL PROGRAM
LEARNING OBJECTIVE: Recognize the
importance of the Navy's Tool Control Program (TCP).

Major problems, such as aircraft accidents and
incidents, may result from tools left in an aircraft after
maintenance has been performed. Tools out of place
may result in foreign object damage (FOD). To reduce
the potential for tool FOD-related mishaps, the Tool
Control Program (TCP) provides a means of rapidly
accounting for all tools after completing a maintenance
task on an aircraft or its related equipment.

TOOL CONTAINERS
The means by which tools can be rapidly
inventoried and accounted for is accomplished by using
silhouetted tool containers. All tools have individual
silhouetted locations that highlight a missing tool.

These containers are called "shadow boxes." A shadow
(silhouette) of the tool identifies the place where the
tool belongs. The TCP is based on the instant inventory
concept and is accomplished, in part, through the use of
shadow boxes. See figure 1-1. On containers where
silhouetting is not feasible, a note with the inventory
and a drawing of the container is included. Either
system enables the work center supervisor or inspector
to quickly ensure that all tools have been retrieved after
a maintenance action.

The material control officer is responsible for
coordinating the TCP and for ensuring that tools are
procured and issued in a controlled manner consistent
with the approved tool control plan (TCPL). A TCPL
contains information that includes material requirements,
tool inventories, and detailed instructions for the
implementation and operation of the TCPL for a
specific type/model of aircraft. But the main
responsibility relies with the work center and quality
assurance.

QUALITY ASSURANCE/ANALYSIS (QA/A) RESPONSIBILITIES
The QA/A division is responsible for monitoring
the overall Tool Control Program in the command.
While monitoring the program or performing "spot
checks," the QA/A division will ensure that tool control
procedures are being adhered to. Some of the special
requirements are to ensure the following:

1. That all tools are etched with the organization
code, work center, and tool container number.

2. That special accountability procedures are
being complied with for those tools not suitable for
etching; for example, drill bits (too hard) and jewelers
screwdrivers (too small).

3. That work center inventories are being
conducted and procedures are being adhered to during
work center audits and periodic spot checks.

4. That all equipment, in the work centers or tool
control centers, that require calibration is scheduled
and calibrated at the prescribed interval.

5. That defective tools received from supply are
reported to the Fleet Material Support Office
(FLEMATSUPPO) via CAT II Quality Deficiency
Reports (QDRs).

6. That tools of poor quality are reported to
FLEMATSUPPO via CAT II QDRs.

7. That VIDS/MAFs are annotated with a tool
container number, and appropriate initials are obtained
following task completion/work stoppage.

8. That the department's tool control environment
is maintained when work is to be performed by
contractor maintenance teams or depot field
teams. A QAR will brief field team/contractor
supervisor/leader(s) upon their arrival regarding the
activity's TCP. Depot teams working in O- or I-level
facilities will comply with the host activity's T