"opr 2FM 55-411«ARMY AIRCRAFTQUALITY CONTROLANDMTECHNICAL INSPECTIOifâJANUARY 1981X\\HEADQUARTERS, DEPARTMENT OF THE ARMYRETURN TO/THE ARMY LIBRARYROOM lA5T8"PENTAG0kWASHINGTON, D.C. 20311
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Q* FM 55-411FIELD MANUALNO. 55-411HEADQUARTERSDEPARTMENT OF THE ARMYWashington, DC, 30 January 1981ARMY AIRCRAFT QUALITY CONTROLAND TECHNICAL INSPECTIONPREFACEThis manual describes the duties and responsibilities of aircraft maintenance qualitycontrol personnelspecifically, the technical inspector. It is designed as a general reference for aviation unit maintenance (AVUM) and aviation intermediate maintenance (AVIM)inspectors. Specific instructions are found in technical manuals and Army regulations.Subjects such as nondestructive inspections, the preventive maintenance inspection system,diagnostic equipment, etc., aVe only briefly discussed. Subjects of this nature are covered indepth in other technical publications. In all cases, the applicable publication number isgiven so the inspector can readily gain further information.—»The U.S. Army Transportatioh School is the proponent for FM 55-411. Recommendedchanges and comments for its improvement will be appreciated. Prepare comments andrecommended changes on DA Forrm2028 and forward to:COMMANDANTUS ARMY TRANSPORTATION SCHOOLATTN: ATSP-TD-TLFT EUSTIS, VA 23604»his FM supersedes TM 55-411, 20 February 1967, including all changes.I
FM 55-411i
FM 55-411ARMY AIRCRAFT QUAUTV COWTOOLAND TECH SSCAL Ö SPECTDOMTABLE OF OD TES TSCHAPTER 1PageQUALITY CONTROL DUTIES AND RESPONSIBILITIES .1-1CHAPTER 2PUBLICATIONSCHAPTER 3PREVENTIVE MAINTENANCE INSPECTION SYSTEM .3-1CHAPTER 4TECHNICAL INSPECTION PROCEDURES4-1CHAPTER 5DIAGNOSTIC AND TEST EQUIPMENT5-1APPENDIX AREQUIRED PUBUCATIONS FOR QUALITY CONTROLA-lAPPENDIX BREFERENCE GUIDE FOR THE TECHNICAL INSPECTOR . B-lINDEX2-1Index 1NOTE: The words “he," “him," “his,” and "men," when used in this publication, represent both the masculine and feminine genders unless specifically stated otherwise.iii
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FM 55-411CHAPTER 1QUALITY CONTROL DUTIES AND RESPONSIBILITIESQuality control (QC) activities complementthose of production control to complete the overall control aspect of maintenance management.The quality control supervisor (67W) coordinates the efforts of the QC team, while the narrow-range technical inspectors (67N30, 67Y30,68B30, etc.) do the actual inspecting. Qualitycontrol management is coordinated with allphases of production and workload control to ensure that maximum production effectiveness ismaintained. Properly designed quality controlprocedures can assure an acceptable level ofquality and a decrease in inspection requirements and management effort. However, in noevent are quality standards sacrificed solely toincrease production. Your duty as a technical inspector is to ensure that the aircraft are as mechanically safe as possible. The purpose of thischapter is to introduce you to the functions of aquality control section.Specifically, this chapter covers: Aircraft Maintenance Quality Control Responsibilities of the TechnicalInspector Technical Inspectors Quality ControlDuties.AIRCRAFT MAINTENANCEQUALITY CONTROLWHAT IS QUALITY CONTROL?Quality control is a management function. Itensures that the maintenance is performed correctly and is in accordance with the maintenancemanuals for the specific aircraft. An appropriatebalance must be established, to maintain maximum production effectiveness without loweringquality standards. By demanding high levels ofquality, unscheduled maintenance, which disrupts flight and maintenance schedules, can bedecreased. Thus, more aircraft will be availableto fly.WHY DO WE NEED QUALITY CONTROL?The application of a high level of quality control will minimize waste of time, labor, and material. It will also lessen the possibility ofmaintenance error or inadequate inspection ofaircraft, which can lead to aircraft damage, personal injury, and even death.As a technical inspector, you are the commanders’ system of "checks and balances.” Youensure that the entire maintenance effort is ofthe highest quality. If high standards of qualityare constantly maintained, the need for qualitycontrol will be satisfied.RESPONSIBILITIES OF THETECHNICAL INSPECTORAs a technical inspector, you are responsible tothe unit commander, the maintenance officer,and the aircrew members.THE UNIT COMMANDERYour primary responsibility is to the commander. You are his representative in areas concerning aircraft safety of flight. He is your onlyboss. If it were any other way, conflicts of interestcould arise and objectivity would be sacrificed.For this reason, it is highly recommended thatthe rating official for Senior Enlisted EvaluationReport (SEER) purposes not be involved in themaintenance production area. If a quality controlofficer is assigned, he should be the rater; otherwise, it should be the unit commander or the executive officer with the commander as endorser.The commander relies on you to ensure that themaintenance performed is of the highest qualityand is conducted with a maximum of safety.THE MAINTENANCE OFFICERThe inspectors are under the operational control, not supervision, of the maintenance officer.Your primary responsibility to the maintenanceofficer is also to ensure that maintenance is ofthe highest quality. Additionally, through quality control, material and man-hour waste can beheld to a minimum.1-1
FM 55-411THE AIRCHEW MEMBERSThe people flying the aircraft depend upon youfor assurance that their aircraft is as safe as humanly possible. Although the mechanics are verycapable, nothing can be left to chance. When your"inspected okay” goes into a logbook, the aircrewis depending upon your knowledge and ability fortheir safety.TECHNDCÂL IMSPECTOR’S QUALITYQOMTIROL DUTIESAs a technical inspector (TI), your primary duties involve more than inspection of aircraft, butyou must remember that aircraft inspection isyour most critical duty. When inspecting an aircraft or component, keep in mind that humanlives depend on how well you do your job. As atechnical inspector, your duties fall in the following areas.PUBLOCÂTOOMSTedhimcaf.Manual (TM) Library. Quality control personnel establish and maintain a completeand up-to-date set of all technical publicationsapplying to the maintenance performed in a shop.These publications include technical manuals(TM), technical bulletins (TB), Army Regulations (AR), modification work orders (MWO), andfield manuals (FM). They provide instructions onthe operation, maintenance, repair, modification, serviceability standards, testing, storage,issue, and inspection of equipment and procedures.TM Familiarization Chart. A technical data familiarization chart as shown on the next pagewill be used and maintained by quality control.Thè chart can be used to ensure that maintenance personnel are familiar with the contentsof each technical manual pertaining to their responsibilities. The chart should list all technicalmanuals pertinent to that equipment for whichthe shop has maintenance responsibilities. Themanuals can be listed in columns at the left of thechart, with the names of the maintenance personnel listed diagonally across the top. Maintenance personnel initial the appropriate block ofthe chart to indicate an understanding of the1-2technical manuals. When an organization contains ten or fewer maintenance personnel, a familiarization chart will not be required. In thiscase, the maintenance personnel should indicatetheir understanding by initialing each manual.It is recommended that the individual shopsmaintain separate charts listing the personneland manuals pertaining only to that shop. You,as an inspector, should check the individualcharts on a monthly basis to ensure that:O All manuals used by that shop are listedO All assigned shop personnel are listedO All personnel have initialed to indicate thatthey are familiar with manual contents.Revision oí Publicaîioinis. Periodically, but noless frequently than every 3 months, the publication files in use throughout the shops will beinspected to ensure that complete, current publications are in use. At this time, pinpoint distribution requirements will be reviewed andupdated. The quality control supervisor will ensure that all applicable incoming publicationsare read by the quality control personnel. Duringeach inspection, inspectors will determinewhether personnel in the maintenance activityare familiar with pertinent directives and are using them in conjunction with repair actions.Quality control will initiate and follow up allcorrespondence necessary for clarification oftechnical publications when the intent or requirement is not clear or specific. All recommendations for changes to Department of the Army(DA) publications, by use of DA Form 2028, willbe routed through quality control by the personor section recommending the change.Quality control will be responsible for orderingall required publications, using DA Form 4569.In cases where required publications are not onhand, or have not been initially distributed, referto DA Pam 310-10-2 The Standard Army Publications Systems (STARPUBS) Resupply Guide.FORMS AND RECORDSIn general, the technical inspectors are responsible for monitoring all forms and recordsused in aircraft maintenance for accuracy andcompleteness. This duty area includes:
FM 55-411TECHNICAL DATA FAMILIARIZATION CHARTft-&TECHNICAL MANUALW55-1510-201-2377155-1510-202-23 mSi55-1510-205-23m 520-204-2355-1520-205-23 wmB55-1520-208-23B55-1520-210-23 m &H m B Î3 HHm B55-1500-204-25/1WKKH w 7FI Kmn 855-1520-206-2338 750mwmwnmw mmm‘Enter name of section or shop. List manuals usedby that shop.“Enter manuals most commonly used in performing shop’s or section’s duties. .Aircrafthistorical records Weight and balance records Aircraft maintenance records Files management Blank forms Equipment improvement recommendations.Aircraft Historical Records. You are requiredto maintain the historical records for each aircraft assigned to your unit. These records consistof EA Forms 2408-5, 2408-9, 2408-15, 2408-16,2408-17, and 2408-19. For specific information,refer to AR 750-31 and TM 38-750.mK KAs changes are received, the latest changenumber is posted and the initials are erased. Themechanics reinitial the board as they, review thechanges.Weight and Balance Records. As stated inAR 95-16, a weight and balance technician is required to be appointed on unit orders. The assigned technician is responsible for maintainingthe aircraft’s weight and balance records. The inspectors must coordinate with the technician.anytime maintenance that could affect weight andbalance is performed on the aircraft. AR 95-16,TM 55-405-9, the aircraft operator’s manual, andAVUM maintenance manual can be referred tofor more information.Aircraft Maintenance Records. All. recordsused in conducting aircraft maintenance must bemonitored by the inspectors for accuracy and1-3
FM 55-411completeness. These forms include DA Forms2404, 2405, 2407, 2408-13, 2408-4, 2408-12,2408-14, 2408-18, 2410, 2410-1 and materialcondition tags. TB 750-126 and TM 38-750 canbe referred to for complete information.Foies [Wainiagemeiniî. As with any managementfunction, certain files are required to be maintained. As far as quality control is concerned, themost important files are the teletypewriter exchange (TWX) files. These files consist of electrically transmitted messages that may directgrounding of an aircraft, impose operating limitations, or provide general information on aircraft maintenance techniques. Separate TWXfiles will be maintained for each model of aircraftassigned or supported, and one file for generalmessages. These messages apply to all models ofaircraft or are of a general informational nature.Each aircraft TWX file will be separated intotwo sections:O Safety-of-flight (SOF) messagesO Maintenance/technical advisory messages.More guidance on files management and SOFmessages can be found in AR 95-18, AR 340-2,and AR 340-18-1.(Haok Forms. You are required to ensure thatan adequate supply of blank forms is on hand atall times for use by the maintenance section.Specific quantities depend upon many variables.However, enough should be on hand to supportoperations for a 30-day period.(PMIS) is discussed in chapter 3; however, certain actions not covered in PMIS need to bebrought to mind. They are:O Turn-in/pick-up of aircraft at AVIMO Aircraft technical complianceO Investigation of repetitive deficienciesO Army Oil Analysis Program (AOAP).Turn-in/Pick-up of Aircraft at AVIM. The inspector is the most knowledgeable person concerning what must be accomplished while theaircraft is in support maintenance. For this reason, he will accompany the aircraft any time it isturned in for AVIM maintenance. The inspectorshould:i/ O Review records with AVIM personnel andresolve questions on the spotO Perform a joint inventory with AVIMpersonnelO Accompany AVIM inspectors on the initialinspectionO Upon completion of repairs and acceptingaircraft: Perform a joint inventory with AVIMpersonnel Review aircraft records for accuracy andcompleteness Inspect the aircraft to ensure that: Requested work was performedEegu«pmeriiî ¡mprovsmeiniî [Recommèndatioirîis(EUR). You must check all EIR’s submitted for accuracy and completeness. The EIR file should bereviewed to see if any trends are developing. If so,this fact should be mentioned in the EIR being,submitted, and reference should be given to theprevious EIR numbers. QC should also determine the EIR priority and the nèed for an EIR exhibit, and dispose of the exhibit as directed byTSARCOM.OMSPECTIQNAircratfU. Your most critical duty is inspectionof aircraft. The safety of the aircraft and crew depends upon how well you do your inspections. APreventive Maintenance Inspection System1-4 Required parts were ordered for workrequested but not performed.Aircraft Technical Compliance (MWO’s andTB’s). The inspector ensures that all requirements of applicable aircraft TB’s and MWO’s aremet and required DA Form entries made. The inspectors are responsible for:O Grounding the aircraft if required by the TBor MWO (AR 95-18)O Ensuring that needed MWO kits are orderedand DA Form 2408-17 entry made upon theirreceipt (TM 38-750)O Forwarding DA Form 2407 as stated in TM38-750
FM 55-411O Maintaining a card file showing the status ofMWO/TB compliance for all assigned aircraft (see Chapter 4)O Submitting reports required by AR 95-18 toreport TB compliance.Investigation of Repetitive Deficiencies. Any deficiency that repeats itself on a continuing basisusually indicates a defect in either material orworkmanship. The inspector’s duty is to investigate the problem and get corrective action started.If a material defect is involved, an EIR must besubmitted to inform TSARCOM of the problem.If the defect is due to workmanship, all maintenance personnel must be made aware of the fact,and must be fully informed of:O The problem .O Its possible effectsO How to correct it.It is only through effective communication thatthe problem can be solved.Army Oil Analysis Program. The inspectors areresponsible for ensuring that all aircraft are entered in the program and the required records aremaintained. Refer to Chapter 3 and TB 43-0106for specific instructions.Components. Two areas fall under.the head-ing of component inspection:O Time change components — time, bet weenoverhaul (TBO)O TBO component chart.Time Change Components (TBO). Quality control will monitor the time in service of all aircraftcomponents required to be replaced on an hourlyor calendar basis. For a list of these components,,refer to the AVUM/AVIM maintenance manualfor the aircraft concerned. Additionally, the inspections ensure that component lives are not overflown unless specifically authorized in TM 551500-328-25.TBO Component Chart. There are two chartvariations for use by quality control personnel:the Time Change Component Schedule Chart,and the Time Change Bar Graph ComponentSchedule. Samples of these two charts are shownon the next two pages. Use of either chart willprovide confidence that the aircraft componentwill be subjected to inspection at the appointedtime, since both give ready reference to hours remaining until replacement on all installed aircraft time change components.Quality Control personnel must coordinatewith maintenance officers and NCO when:O One hundred hours remain to change onhourly componentsO Two months remain to change on calendarcomponents.This notification is to allow replacement parts tobe ordered in advance of their replacement time.Shop Inspection. This duty is divided into twoareas:O Facility/equipment inspection (shop safety)O Accuracy of test equipment.Faciüty/Equipment Inspection. Inspection of thisarea consists of checking the shop and shopequipment for:O Proper layoutO Clear fire lanesO Fire extinguisher serviceabilityO Equipment safety devices installed and used.The inspection procedures and what to look forare more fully covered in Chapter 4. Other details are provided in TM 55-1500-204-25/1.Accuracy of Test Equipment. Quality control isresponsible for ensuring that all calibration requirements are met. The technical inspectormust:O Ensure that items requiring calibration arecalibrated at proper intervals. Refer to TB43-180 and TB 43-180-1 for items requiringcalibration and intervals.O Check individual items to ensure that calibration intervals are not being exceeded.O Ensure that DA Form 2416 is maintained foreach item requiring calibration. Refer to TM38-750.1-5
FM 55-411Aircraft HoursAircraft12001300140016001500M/R Blades 1590 hr73-571 (UH-1 )T/R Blades 1550M/R Blades1690 hr74-878 (UH-1)T/R Hub 1310 hr75-495 (UH-1)Components must be placed in flying hour order.Eng Ex 1350 hrsT/R Blades 1520 hr75-555 (OH-58)JRed lines for each aircraft areextended with flying hours.M/R Blades 1550 hr75-617 (OH-58)120013001400' 15001600?SAMPLE BAR GRAPH COMPONENT CHARTQ Ensure that DA Label 80 is attached to itemsrequiring calibration. If the calibration duedate on the label is within seven days, thatitem must be separated from the others toensure that its calibration date will not beexceeded. It must then be turned in forcalibration. Refer to TB 43-180 and TB 43180-1 to determine where particular itemsare calibrated (i.e., support unit or areacalibration team).As a quick review, this chapter points out that:1-6O Quality control is the basis for ensuring thatall aircraft maintenance is performed athighest standards possible.O Your duties as a technical inspector involvemore than the inspection of aircraft; inspection of facilities, records, and equipment arealso part of your job.O As a technical inspector, you have loyaltiesand responsibilities toward the unit commander, maintenance officer, and aircrewmembers.
FM 55-411TIME CHANGE COMPONENT SCHEDULEReplacement Due(Black) Replacement time(Red) Item on requisition(Green) Posted 1 JULY 1971&Item on hand&AcftTypeAcftSerial No.TotalhrsPeriodicdueU8D65-123455010020002000JULY 76 DEC 72TIME CHANGE COMPONENT CHART1-7.
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FM 55-411CHAPTER 2PUBLICATIONSArmy publications describe the policies andprocedures used in maintaining aircraft and accomplishing maintenance management. Manydifferent types of publications are required to beon hand in the maintenance area. Quality control personnel must ensure that these publication libraries are constantly updated with thelatest changes. Additionally, the master reference library is set up and maintained by thetechnical inspectors. The purpose of this chapteris to familiarize you with Army publications andtechnical libraries. It covers:DA Pam’s are numbered in the same manneras Army Regulations; that is, a basic numberidentifies the subject matter. A subnumber, preceded by a dash, is a serial number distinguishing between DA Pam’s with the same basicnumber. For example:DA Pam 310-1 Index of Ad
This manual describes the duties and responsibilities of aircraft maintenance quality control personnel — specifically, the technical inspector. It is designed as a general refer- encefor aviation unit maintenance (AVUM) and aviation intermediate maintenance (AVIM) inspectors. Specific instructions are found in technical manuals and Army .
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Army Materiel Command (AMC) http://www.amc.army.mil/ AMCOM -Redstone Arsenal http://www.redstone.army.mil/ Association of the US Army (AUSA) http://www.ausa.org/ Army Center for Military History http://www.army.mil/cmh-pg/ Army Training Support Ctr http://www.atsc.army.mil/ CECOM http://www.monmouth.army.mil
- B734 aircraft model added - B735 aircraft model added - E145 aircraft model added - B737 aircraft model added - AT45 aircraft model added - B762 aircraft model added - B743 aircraft model added - Removal of several existing OPF and APF files due to the change of ICAO aircraft designators according to RD3: A330, A340, BA46, DC9, MD80
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F/A-18E/F Super Hornet Fighter 1,253.1 million (14 aircraft) 1,996.4 million (24 aircraft) V-22 Osprey Tiltrotor Aircraft 961.8 million (6 aircraft) 1,280.1 million (7 aircraft) C-130J Hercules Military Transport Aircraft 886.1 million (9 aircraft) 1,571.9 millio
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Quality control (QC) activities complement those of production control to complete the over- all control aspect of maintenance management. The quality control supervisor (67W) coordi- nates the efforts of the QC team, while the nar- row-range technical inspectors (67N30, 67Y30, 68B30, etc.) do the actual inspecting. Quality
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