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CHAPTER 7

MAINTENANCE PLANNING AND ADMINISTRATION

As the workcenter or branch supervisor, you aredirectly responsible for the maintenance effort of yourworkcenter. The planning, scheduling, control andparts ordering are essential to its accomplishment.

The factors that you must consider in maintenanceplanning are equipment status, operationalrequirements, the workload, and the personnel assetsavailable to perform the job.

PLANNED MAINTENANCE SYSTEM

LEARNING OBJECTIVES: State who hasthe responsibility for managing PMS programsfor equipment aboard ship. Identify threeconsiderations used to determine PMSprocedures.

The Planned Maintenance System (PMS) is asimplified, yet thorough means of accomplishingpreventive maintenance aboard ship. It identifiesmaintenance requirements, and schedules maintenanceactions to make the best use of your resources. Itincreases economy and simplifies records. It improvesmanagement, workload planning, equipmentreliability, and on-the-job training of shipboardpersonnel. As a system, however, it is neitherself-starting nor self-sustained, and careful supervisionat all levels is required.

PMS procedures and how frequently the actionsshould be done are developed for each piece ofequipment based on good engineering practices,practical experience, and technical standards. Thesestep-by-step procedures are published on maintenancerequirement cards (MRCs). The cards contain detailedinformation on each maintenance requirement, such aswho (specific rate) should perform the maintenance,and when, how, and with what resources. Some MRCshave equipment guide lists (EGLs) to identify thelocations of various pieces of the same type ofequipment, such as motors, controllers, valves, liferafts, deck fittings, and hatches that are serviced at thesame time.

Keep in mind that PMS actions, as preventivemaintenance actions, are the minimum maintenanceactions required to maintain the equipment in a fullyoperable condition. If PMS actions are performed

according to schedule, they will allow equipmentoperators and maintenance personnel to identifypossible problems before equipment failure. Properlyperformed PMS actions will help prevent failures thatcould result in repeated corrective maintenance actions.

PMS procedures are developed by the activities andoffices of the systems commands responsible for thedevelopment and procurement of the systems andequipment they control. PMS maintenance index pages(MIPs) and MRCs are developed as part of theIntegrated Logistics Support effort for all newprocurements, alterations, and modifications ofsystems and equipment.

Management tools provided by PMS for each ship,department, and supervisor include the following:

• Comprehensive procedures for planned main-tenance of systems and equipment

• Minimum requirements for planned main-tenance

• Scheduling and control of maintenance

• Description of the methods, materials, tools, andpersonnel needed to perform maintenance

• Prevention or detection of hidden failures ormalfunctions

• Test procedures to determine material readiness

PMS, though standard in concept and procedures,is flexible enough to be adjusted by the ship to becompatible with operational and other types ofschedules.

DEPARTMENTAL MASTER PMS MANUAL

A Departmental Master PMS Manual is maintainedin each departmental office for use in planning,scheduling, and supervising required maintenance. Theinformation contained in this manual pertains only toequipment for which the department is responsible. TheDepartmental Master PMS Manual contains thefollowing:

1. Supplementary Information: Additionalinstructions, information, and data provided to

7-1

assist in implementation and accomplishmentof PMS.

2. List of Effective Pages (LOEP): TheDepartmental LOEP (fig. 7-1) provides alisting of the MIPs assigned to each

department, divided by workcenters, andcontains the following information:

a. Report date (date LOEP was produced).

b. FR (Force Revision).

7-2

Date: 08/23/00Time: 14:37:51

Planned Maintenance SystemList of Effective Pages (PMS 5)

Page: 1FR: 2-94

Unit: DDG 0053 UIC: R21313 Work Center: EA01 USS JOHN PAUL JONES

Adds/Changes MIP

1631/004-A22560/006-244431/002-635000/005-A25000/007-825140/011-C35161/001-C35312/002-325331/002-335332/001/C05511/010-445515/009-445600/016-445713/006-B15721/009-315811/020-445821/016-445831/013-935832/005-245833/047-835833/201-245833/202-245833/309-835931/016-436300/001-446331/002-446512/002-346512/027-636514/NMR6515/003-166517/006-34

SEA CHESTSCRCLT AND COOLING SW SYSVISUAL/AUDIO COMM SYSTEMSVALVES & VALVE OPERATORSENG REPAIR PROCEDURESAIR CONDTN SYSTEM (R-114)REFRD, SHIP SERVICE (R-12)DISTILLING PLANT VPR CPRSNWATER, POTABLE SERVICEDISTILLED WATER SERVICEAIR SYSTEM, HIGH PRESSURECOMPRESSORS, AIRSHIP CONTROL SYSTEMSRAS TRANSFER HEAD & SLIDINGSHIPS STORES HDLG EQPTANCHOR HANDLING & STOWAGEMOORING AND TOWING SYSTEMBOAT HANDLING & STOWAGELIFE SAVING EQUIP PRESVSMALL BOATS (ENGINE(CUMN))SMALL BOATS (EQUIPMENT)SMALL BOATS (STEERING SYS)SMALL BOAT (WILLARDRIB)SEW/WST WTR POLL CONT SYSPRESERVATION & COVERINGSZINCS (SACRIFICIAL ANODES)DISHWASHING MACHINEDISHWASHING MACHINEVEGETABLE PEELING MACHINEMEAT SLICING MACHINEGARBAGE DISPOSAL

Nomenclature

-

-

--

-

-

---

-

---

-

ABEf0701

-

-

Figure 7-1.—Departmental LOEP.

c. Type Commander (TYCOM).

d. Unit (ship's hull number, UIC, and name).Shore activity (UIC number).

e. Workcenter.

f. MIP number.

g. Nomenclature (brief description of thesystem/equipment).

h. Equipment status code.

3. Maintenance Index Pages (MIP): MIPs areprepared and issued for each installed systemor piece of equipment for which PMS supporthas been established. MIPs are basic PMSreference documents. Each MIP is an index ofa complete set of MRCs applicable to a shipsystem, subsystem, and equipment. MIPs (fig.7-2) contain the following information:

7-3

SHIP SYSTEM, SYSTEM, SUBSYSTEM, OR EQUIPMENT

Fire Extinguishing System, Fog, Foam, and AFFF5551

REFERENCE PUBLICATIONS

NAVSEA S8225-GY-MMA-010NAVSEA S9555-AN-MMO-010

DATEMay 2000

A scheduling aid; Review maintenance requirements. OmitMRC(s) which do not apply; no feedback report required.

# Mandatory scheduling required.

1. Inspect high-capacity AFFF injection station.

1. Inspect proportioner station FP-180.

1. Turn AFFF proportioner shaft by hand.2. Inspect oil level in AFFF proportioner.

1. Inspect high capacity AFFF injection station operation.2. Test AFFF concentrate for seawater contamination.

1. Test operate, inspect, and clean 1000 gpm AFFFproportioner station.

1. Test AFFF concentrate for seawater contamination atFP-180 station.

1. Clean and inspect hose reel stations.

1. Lubricate AFFF injection pump bearings.

1. Test operate, inspect, and clean AFFF FP-180 station.2. Lubricate FP-180 proportioner.NOTE: Accomplish quarterly or after each use,

whichever occurs first.

1. Accomplish liquid foam quantitative analysis at FP-180stations.

1. Change oil in AFFF injection station reducer.

1. Inspect AFFF bilge sprinkling system nozzles.

1. Accomplish AFFF concentration analysis

1. Lubricate high-capacity AFFF injection station flexiblecouplings.

1. Inspect and hydrostatically test AFFF station hose(s)..

46 6UMU N

42 8UNR N

42 8UNQ N

B4 6UMV N

80 6DAA N

16 6DAD N

88 8DRU N

44 6UMW N

54 C1TH N

97 8GMG N

44 6UMY N

38 8HQR N

39 6UMZ N

44 6UNA N

10 8NPR N

D-1

D-2

W-1

Q-1

Q-2

Q-3

Q-4

Q-5

Q-6R

S-2

S-3

S-4

A-1

A-2

A-3

HT2

HT2

HT/DC3

HT3FN

HT/DC3FN

HT3

HT/DC3

HT3EM3

HT/DC3FN

DCAHT1HG3

HT3

HT/DCHTFN/DCFN

HT/DCHG/DC2

HT3

HT/DC22FN

0.2

0.2

0.4

2.00.5

2.00.5

2.0

0.5

0.30.3

2.00.5

0.70.4

0.4

1.01.0

0.70.4

0.8

0.30.6

None

None

None

None

None

None

None

Q-1

None

D-2#Q-3#Q-4#orR-1#

None

None

D-1#Q-1#Q-4#orR-1#

None

None

4

4

4

4

MAINTENANCE REQUIREMENT DESCRIPTIONSYSCOM MRCCONTROL NO

OTHER

TEST

PERIO-DICITYCODE

RATESMAN

HOURS

RELATEDMAINT-

ENANCE

DISTRIBUTION STATEMENT DDistribution authorized to DOD components and DOD contractors only; critical technology; May 1994. Other requests for thisdocument shall be referred to Naval Sea Systems Command (SEA 04TD). Destroy by any method that will prevent disclosure ofcontents or reconstruction of the document.

MAINTENANCE INDEX PAGE (MIP)OPNAV 4790/85 (REV.2-82) PAGE 1 OF 2 SYSCOM MIP CONTROL NUMBER 5551/011-54

ABEf0702

Figure 7-2.—Maintenance Index Page (MIP).

a. Ship system, subsystem, or equipmentdescription of noun name.

b. Reference publications about the system,subsystem, or equipment.

c. Date: Preparation date of the MIP bymonth and year.

d. Test, Other, and SYSCOM MRC controlnumber columns.

7-4

Date: 08/23/00Time: 14:29:20

Planned Maintenance SystemMIP to Work Center by Dept (PMS 4A)

Page: 1FR: 2-94

Unit: DDG 0053 UIC: R21313 USS JOHN PAUL JONESDepartment: ENGINEERING

MIP Nomenclature

1230/001-54

1501/001-32

1631/004-A2

1671/003-33

1671/005-B1

1672/001-32

1681/002-32

1921/001-A9

2000/001-A2

2340/004-44

2400/013/-44

2411/015-44

2421/002-C2

2451/006-33

2513/007-34

2521/051-54

2560/006-24

2591/001-44

2610/059-54

2620/013-44

2640/012-44

3000/001-14

3001/002-C2

3002/001-24

3113/004-44

3131/005-24

3201/002-34

3241/051-34

3301/002-34

3431/002-44

Work CenterDistribution

TANKS, VOIDS, AND TRUNKS

SUPERSTRUCTURE & FITTINGS

SEA CHESTS

ARMORED DOORS & HATCHES

WTRTT, DR, TORPEDO MAGAZINE

ARMORED DOORS & HATCHES

DECKHOUSE STRUCT CLOSURES

COMPARTMENT TESTING

MACHINERY LUBRICATING OIL

MAIN PROPULSION GAS TURBIN

XMSN & PROPULSOR SYSTEMS

PRPLN REDUCTION GEARS

PROPULSION CLUTCH COUPLING

PROPELLERS AND PROPULSORS

COMBUSTION AIR SYSTEM

AUTO PROPULSION CTRL SYS

CRCLT AND COOLING SW SYS

UPTAKES AND BAFFLES

FUEL SERVICE SYSTEM

MAIN PROPULSION L O SYSTEM

L O FILLXFR PURIFICATION

MISC SHIPBOARD ELECT EQUIP

MISC CONTROLLERS

MISC AC/DC MOTORS

S/S GAS TURBINE GEN SET

BATTERY/SERV FACILITIES

POWER CABLES (CASUALTY)

SWITCHGEAR AND PANELS

LIGHTING AND DISTRIBUTION

SSGTG SUPPORT SYSTEMS

EM04

ER01

EA01

ER09

ER09

ER09

ER09

ER01

EM01

EM01

EM01

EM01

EM01

EM01

EM01

EM03

EA01

EM01

EM01

EM01

EM01

EE01

EE01

EE01

EM01

EE01

EE01

EE01

EE01

EM01

EM01

EM02

EM02

EM02

EM02

EM02

EM02

EM02

EM01

EM02

EM02

EM02

EM02

EM03

EM03

EM03

EM03

EM03

EM03

EM02

EM04

EM02

EM04

EM03

EM03

EM03

ABEf0703

Figure 7-3.—Example of an MIP to Workcenter File.

e. Maintenance requirement: A briefdescription of each maintenance require-ment.

f. Periodicity code: Shows how frequentlythe maintenance is to be performed.

g. Rate (skill level): Identifies therecommended skill level of the person(s)considered capable of performing themaintenance requirement. Qualifiedpersonnel other than the rate/ratingspecified may be assigned. When a NavyEnlisted Classification (NEC) is assigned,substitution of other personnel is notallowed.

h. Man-hours (MH): Total time required todo the maintenance.

i. Related maintenance.

(1) Mandatory

(2) Convenience

(3) None

j. Scheduling aids: Amplifying instructions,if needed, are located in the maintenancerequirement description block.

k. SYSCOM MIP control number.

l. Inactive equipment maintenance (IEM):Maintenance performed when specificequipment will remain inactive for 30 daysor longer and is not scheduled for repair,maintenance, or overhaul by either theship's force or an external repair activity.

4. The Departmental Master PMS Manual alsoincludes a MIP to Workcenter File (fig. 7-3).

WORKCENTER PMS MANUAL

The Workcenter PMS Manual contains only theplanned maintenance requirements applicable to aparticular workcenter. It is designed to provide a readyreference of planned maintenance requirements for theworkcenter supervisor and should be retained in theworking area, near the Weekly PMS Schedule, in theholder provided.

Maintenance Requirement Cards (MRCs)

Maintenance Requirement Cards (MRCs) (fig. 7-4)provide the detailed procedures used to perform a

maintenance action and state who is to perform themaintenance and what is to be done, and when, how,and with what resources a specific requirement is to beaccomplished. MRCs contain the followinginformation and instructions:

SHIP SYSTEM, SYSTEM, SUBSYSTEM,EQUIPMENT.—These blocks contains theidentification of the ship system (functional group),system, subsystem, or equipment involved.

MRC CODE.—The MRC code consists of twoparts. The first part of the MRC code is the MIP seriescode. MRCs applicable to more than one MIP serieswill have each MIP series entered in this block. If morethan four MIP series apply, reference will be made to anote in the Procedure block. The second part is themaintenance requirement periodicity code. The onlyauthorized periodicities are listed in Table 7-1.

The periodicity code also includes a number forspecific identification. When more than one MRC ofthe same periodicity exists in the same MRC set, theMRCs, in most cases, will be numbered consecutively;for example, D-1, D-2, D-3, or M-1, M-2, M-3. Anexisting MRC may be reapplied to a revised MIP eventhough the periodicity code of the reapplied MRC maynot fall within the normally sequential numericperiodicity codes. For example, W-1, W-2, W-3, andW-6 may appear on a MIP, since W-6 was an existingMRC that was reapplied to this equipment. Technically,valid MRCs will not be reprinted merely to change theperiodicity code number. Nonsequential numbers willnot affect scheduling or management control.

Dual periodicity codes are used when con-figurations or utility differences of a permanent natureexist between installations of the samesystem/equipment. A dual periodicity may be assignedif no other aspect of the MRC requires modification tofit both periodicities. For example, equipment installedin an SSN or in a surface unit may see daily use, whilethe same equipment installed in an SSBN may be idlefor long periods of time because of the nature of theship's mission. This long period of idleness may resultin less frequently performed maintenancerequirements. In this case a dual periodicity, such asM-1/Q-I or Q-1/S-2, may be assigned. When dualperiodicities are assigned a note on the MIP and theMRC will specify the frequency of maintenance, forexample, "NOTE: SSBN, schedule quarterly; all othersschedule monthly." The unrequired periodicity shouldbe deleted by having a line drawn through it.

7-5

7-6

SHIP SYSTEM

Miscellaneous ShipboardElectrical Equip and InstalledReceptacles 3000

SUBSYSTEM

Miscellaneous Shipboard Electrical Equipand Installed Receptacles 3000

MRC CODE

3000 M-4/Q-2R

SYSTEM

Miscellaneous ShipboardElectrical Equip and InstalledReceptacles 3000

EQUIPMENT

Miscellaneous Shipboard ElectricalEquip and Installed Receptacles3000XY

MAINTENANCE REQUIREMENT DESCRIPTION

1. Inspect portable electrical tool/device equipped with two-prong plug.2. Measure Insulation resistance.

SAFETY PRECAUTIONS

1. Forces afloat comply with Navy Safety Precautions for Forces Afloat, OPNAVINST 5100 series.2. Ensure all tag-out procedures are in accordance with current shipboard instructions.3. Tool test set (SCAT 4547) can produce voltages dangerous to life. Wear rubber gloves.

TOOLS, PARTS, MATERIALS, TEST EQUIPMENT

1. [0399] Electrical tool testers, SCAT-4547,07239-235000

2. [0883] Megger, 500V, 100MOhm, SCAT-44523. [0901] Multimeter, AC/DC, SCAT-4245

TEST EQUIPMENT MISCELLANEOUS

1. [0526] Gloves, electrical workers,7500 volt maximum safeuse, size 9,rubber

1. [0096] Pen, ball-point2. [1144] Tag, safety3. [1657] Tag, safety check4. [2277] Pad, writing paper

MATERIALS

NOTE: Numbers in brackets can be referenced to Standard PMS Materials Identification Guide (SPMIC) for stocknumber identification.

PROCEDURE

NOTE 1: For equipment issued on permanent or semi-permanent loan to work centers,accomplish monthly, all other accomplish quarterly or before each issue. For repairlocker equipment, accomplish quarterly or after each use, whichever occurs first.

DISTRIBUTION STATEMENT DDistribution authorized to DOD components and DOD contractors only; critical technology; February 1994.Other requests for this document shall be referred to Naval Sea Systems Command (SEA 04TD). Destroy by anymethod that will prevent disclosure of contents or reconstruction of the document.

LOCATIONEquipment Guide List Recommended

DATEFebruary 2000

RATES

EM2EMFN

M/H

0.10.1

TOTAL M/H0.2

ELAPSED TIME0.1

PA

GE

1O

F3

244A

BG

N

MAINTENANCE REQUIREMENT CARD (MRC)OPNAV 4790 (REV. 2-82) ABEf0704

Figure 7-4.—Maintenance Requirement Card (MRC).

Situation requirement codes may be used with acalendar periodicity code in certain circumstances.These situations fall within two general categories:

• When the situation governs the scheduling of therequirement

• When the calendar periodicity governs thescheduling of the requirement

For example, consider the occasion of weeklymeasurement of values when a certain system is inoperation. The measurement of these values will not berequired when the equipment is not being operated,regardless of how prolonged the idle period may be.There are cases in which requirements must bescheduled with regard to the situation rather than thecalendar timing. The periodicity code will state the Rfor situation first, and after the hyphen and a uniquenumber, a letter will recognize the calendarcontingency. An example of a situation-calendarperiodicity code is that an R-IW requires you to

schedule equipment lubrication weekly when at sea.That means that the R-IW is entered into a daily columnof the weekly schedule only when the ship is at sea.During in-port times the R-IW will remain in theOutstanding Repairs and PM Checks Due In Next 4Weeks column.

When the periodicity code is of thecalendar-situation combination, the calendar controlsthe scheduling and is only occasionally overtaken bythe situation. The calendar periodicity is referred to firstin the code, for example, 18M-2R. In the example, the18M indicates that the longest time betweenaccomplishment is every 18 months, and the 2Rindicates that a situation could arise which wouldrequire it to be done more often. An explanation of suchsituations will appear on the MRC. When the situationno longer exists, scheduling reverts to the 18-monthperiod. Some examples of the combined calendar andsituation requirements are as follows:

7-7

PERIODICITY CODES

D - Daily S - Semiannually

2D - Every 2nd day 8M- - Every 8th month

3D - Every 3rd day A - Annually

W - Weekly 18M - Every 18 months

2W - Every 2nd week 24M - Every 24 months

3W - Every 3rd week 30M - Every 30 months

M - Monthly 36M - Every 36 months

2M - Every 2d month 48M - Every 48 months

Q - Quarterly 54M - Every 54 months

4M - Every 4th month 60M - Every 60 months

NON-CALENDAR PERIODICITY

R - Situation requirement

U - Unscheduled maintenance

INACTIVE EQUIPMENT MAINTENANCE (IEM)

LU - Lay-up

PM - Periodic maintenance

SU - Start-up

OT - Operational test

Table 7-1.—Periodicity Codes

M-1R: Monthly or every 600 hours, whicheveroccurs first.

W-3R: Weekly or after each use, whichever occursfirst.

S-1R: Semiannually or during each upkeep period,whichever occurs first.

Q1-1R: Quarterly or prior to getting underway,whichever occurs first.

When the periodicity code includes a situationrequirement (such as R-1 or Q-1R), a note ofexplanation is required in addition to the basic code.This note is the first entry in the Procedure block.

MAINTENANCE REQUIREMENT DE-SCRIPTION.—The maintenance requirementdescription is a brief definition of the PMS action to beperformed.

RATES.—The rate is the recommended skill levelof the person who should be qualified to do the work,identified by rate or NEC (Navy EnlistedClassification). Qualified personnel other than thosespecified may be assigned. When more than one personin the same rate is required, the appropriate number ofpersons precedes the rate. When more than one personin the same rate is required and time requirements arenot equal, each person is listed separately.

MAN-HOURS (M/H).—Man-hours is theaverage amount of time required of each rate listed inthe Rates block to perform the maintenance, on eachpiece of identical equipment, listed in hours and tenthsof an hour. When more than one person in the same rateis required and time requirements are equal, man-hourslisted are the sum of their requirements. When morethan one person in the same rate is required and timerequirements are not equal, man-hours are listed foreach person separately. Total man-hours are the sum ofall entries in the M/H block. Make ready and put awaytime, including removal and/or replacement ofanything that interferes with the maintenance (covers,other equipment, and so on) is not included.

SAFETY PRECAUTIONS.—This section of theMRC provides a listing of precautions and publicationsthat direct attention to possible hazards to personnel orequipment during maintenance. The word “NOTE”will precede procedural advisories. Specific categoriesof direction are as follows:

• Warning: Explains operating procedures,practices, and so forth, that, if not followed

correctly, may lead to injury or death. Warningsare listed in the Safety Precautions block and arerepeated preceding the procedure involved.

• Caution: Explains operating procedures,practices, and so forth that, if not correctlyfollowed, may lead to damage to equipment.Cautions are not listed in the Safety Precautionsblock; however, they do precede the instructionsfor the procedure involved.

TOOLS, PARTS, MATERIALS, TESTEQUIPMENT.—This section lists the test equipment,materials, parts, tools, and miscellaneous requirementsnecessary to perform the maintenance action. Each ofthe above categories may include both Standard PMSItem Name (SPIN) and non-SPIN items. Entries in thisblock can be cross-referenced to the Standard PMSMaterials Identification Guide (SPMIG) for stocknumber identification.

Equipment Guide List (EGL)

The EGL (OPNAV Form 4790/81) (fig. 7-5) is a5x8-inch card that is used with a controlling MRCwhen the MRC applies to a number of identical items,such as motors, controllers, life rafts, valves, testequipment, and small arms. Each ship prepares its ownEGLs.

The number of items included on an EGL isdirectly related to the time to do the maintenance oneach item. Each EGL normally contains no more than asingle day's work. If more than 1 day is required,separate EGL pages are prepared for each day and arenumbered consecutively.

In some instances it may be unnecessary orimpractical to list the equipment on EGLs. Forinstance, if the equipment is listed on aTYCOM-directed checklist or if an AutomatedCalibration Recall Program is in effect, a notation of theapplicable instruction in the Location block of theMRC is all that is required.

Tag Guide List (TGL)

The TGL (OPNAV Form 4790/107) (fig. 7-6)contains the information necessary for equipmenttag-out required during PMS actions. The TGLcontains the number of tags required, locations of thetags, position of each tagged item (open, shut, off, on,and so on) and permission or notification requirements.Each ship prepares its own TGLs.

7-8

7-9

EQUIPMENT GUIDE LISTOPNAV 4790/81 (2-76)S/N 0107-LF-047-9405

MIIP NO. (Less last 2 characters)

EQUIPMENT NAME NOMENCLATURESERIAL NO.QUANTITY

LOCATION APPLICABLE DATA AS REQUIRED BY MRC

PAGE OF

MRC PERIODICITY

ABEf0705

Figure 7-5.—Equipment Guide List (EGL).

TAG GUIDE LIST

ABEf0706

OPNAV 4790/107 (10-80) S/N 0107-LF-047-9545

MIP & MRC NO.

EQUIPMENT

EQUIPMENTSERIAL NO.

SERIAL NO.SWITCH / VALVE

LOCATION OFSWITCH / VALVE

POSITION OFTAGGED ITEM

AMPLIFICATION DATA

COLD IRONINPORT

STEAMING

NOTIFICATION DATA

UNDERWAY

NUMBER OF TAGS PER EQUIP

VERIFICATION / APPROVAL SIGNATURES

WCS DIV OFF DEPT HEAD CO

Figure 7-6.—Tag Guide List (TGL).

Location of MRCs, EGLs, and TGLs

A master MRC deck is maintained at thedepartmental level. Each departmental master deckcontains only one copy of applicable MRCs filed bySYSCOM control number. Applicable master EGLs

and TGLs are attached to related master MRCs. Inaddition, a complete working deck of applicableMRCs, EGLs, and TGLs is located in MRC holders ineach workcenter. Maintenance personnel use these toperform assigned planned maintenance.

7-10

FROM (SHIP NAME AND HULL NUMBER)

SEE INSTRUCTIONS ON BACK OF GREEN PAGE

USS NEVERWAS

FFG 999

TONAVAL SEA SUPPORT CENTER (Category A)PACIFIC

TYPE COMMANDER (Category B)

X

SYSTEM, SUB-SYSTEM, OR COMPONENTSONAR RECEIVING SET

SYSCOM MIP CONTROL NUMBER4621/23-23

APL/CID/AN NO./MK. MODAN/SQR-18A (V) 1

SYSCOM MRC CONTROL NUMBERVARIOUS

MIP/MRC REPLACEMENTX TECHNICAL

TYCOM ASSISTANCE

OTHER (Specify)

CATEGORY A CATEGORY B

DESCRIPTION OF PROBLEM

REMARKS

REQUEST TWO COPIES EACH OF FOLLOWING CLASSIFIED MRCs:

72 EZV9 N

12 EZV0 N

20 EZW5 N

TOTAL OF 6 MRCs REQUESTED. ADEQUATE SECURE STORAGE PER OPNAVINST

5110.1H IS AVAILABLE.

ORIGINATOR & WORK CENTER CODE

DEPT. HEAD

DIV. OFFICER

3-M COORDINATOR

ET (SW) Boat EE01

I. M. Daboss, CDR, USN

LT Jay Gee

GMC (SW) Jack Frost

TYCOM CONCURDO NOTCONCUR

TAKESACTION

PASSES FORACTION

Originator do not write below. For TYCOM use only.

TYCOM REP SIGNATURE

OPNAV 4790/7B (Rev. 9-89)S/N 0107-LF-007-8000

DATE

ACTION COPYEDITION OF 3-84 MAY BE USED UNTIL EXHAUSTED

PAGE OF1 1

SUBJECT: PLANNED MAINTENANCE SYSTEM FEEDBACK REPORT

SERIAL #

DATE

1074-94

09 MAR 94

REPORT SYMBOL OPNAV 4790-4

ABEf0707

Figure 7-7.—PMS Feedback Report, category A.

PMS Feedback Report (FBR)

The PMS Feedback Report (FBR) (OPNAV4790/2B) is a form used by maintenance personnel tonotify NAVSEACEN, NAVAIRENGCEN, and

TYCOM, as applicable, of technical and nontechnicalmatters related to PMS. The FBR is a five-part formcomposed of an original and four copies. Figures 7-7and 7-8 provide examples of FBRs. Instructions for

7-11

FROM (SHIP NAME AND HULL NUMBER)

SEE INSTRUCTIONS ON BACK OF GREEN PAGE

USS NEVERWAS

FFG 999

TONAVAL SEA SUPPORT CENTER (Category A)

TYPE COMMANDER (Category B)X

SYSTEM, SUB-SYSTEM, OR COMPONENTAuto Ballast Comp Sys

SYSCOM MIP CONTROL NUMBERF-37/2-67

APL/CID/AN NO./MK. MOD

SYSCOM MRC CONTROL NUMBERT 44 E12F N

MIP/MRC REPLACEMENTX TECHNICAL

TYCOM ASSISTANCE

OTHER (Specify)

CATEGORY A CATEGORY B

DESCRIPTION OF PROBLEM

REMARKS

Before testing setting on relief valve, we need calibration steps

for Leslie-Matic controller. This step is not contained on the

present MRC. This ship does not have any pub or tech manual showing

the steps that should be taken in checking the Leslie-Matic

controller for accuracy.

ORIGINATOR & WORK CENTER CODE

DEPT. HEAD

DIV. OFFICER

3-M COORDINATOR

ET (SW) Boat EE01

I.M. Daboss, CDR, USN

Lt Jay Gee

GMC (SW) Jack Frost

TYCOM CONCURDO NOTCONCUR

TAKESACTION

PASSES FORACTION

Originator do not write below. For TYCOM use only.

TYCOM REP SIGNATURE

OPNAV 4790/7B (Rev. 9-89)S/N 0107-LF-007-8000

DATE

ACTION COPYEDITION OF 3-84 MAY BE USED UNTIL EXHAUSTED

PAGE OF1 1

SUBJECT: PLANNED MAINTENANCE SYSTEM FEEDBACK REPORT

SERIAL #

DATE

1074-94

04 MAR 94

REPORT SYMBOL OPNAV 4790-4

ABEf0708

Figure 7-8.—PMS Feedback Report, category B.

preparation and submission of the form are printed onthe back of the last copy (fig. 7-9).

PMS FBR Categories

There are two categories of FBRs-category A andcategory B-defined as follows:

1. Category A—This category (fig. 7-7) isnontechnical in nature and is intended to meetPMS needs that do not require technicalreview. Category A FBRs are submitted torequest classified or other PMS documentationwhich cannot be obtained locally. With theship’s master PMS requirements on compact

7-12

1. ORIGINATOR

a. Typewritten copies are preferred, however, handprinted copies are acceptable. Use ballpoint pen and ensure all copies are legible.

b. EQUIPMENT IDENTIFICATION: Fill in titled blocks that apply. Give as much information that can be determined. Ensure thatcorrect APL number is used for hull, mechanical or electrical equipment or electronic/weapons equipment which does not haveany Army-Navy number or mark/mod designation.

c. DESCRIPTION OF PROBLEM: Check the appropriate box.

Category A

(1) MIP/MRC REPLACEMENT: Ensure that PMS documentation request is current in accordance with latest SFR. For missingMIPs/MRCs, give SYSCOM control numbers when they can be determined. If SYSCOM control numbers cannot bedetermined, provide as much nameplate data as can be obtained. When ordering a variety of missing/worn MIPs/MRCs, thesubject section shall be left blank.

Category B

(2) TECHNICAL:

(a) Identify specific discrepancy discovered in PMS by MRC control number, step number, etc.

(b) For publication discrepancies identify publication by number, volume, revision date/number, change number, page,paragraph and or figure as appropriate.

(3) TYCOM ASSISTANCE: Includes clarification of 3-M instructions and other matters related to PMSadministration.

(4) OTHER: Identify in detail any problem not covered by (1) through (3) above. Shifts of maintenanceresponsibility will be reported under this item. Ensure that all work centers involved in the change areidentified by work center code. Approval by the Executive Officer will be shown in the "Remarks".

d. REMARKS: Provide brief, but complete, description of problem or requirement. Executive Officer indicateapproval of maintenance responsibility shift by endorsement. Use additional forms if more space is required.Mark additional forms, "page 2 of 2", "page 2 of 3", etc. Staple additional forms behind basic form.

e. ORIGINATOR IDENTIFICATION: Sign and insert work center code in appropriate space.

2.. DIVISION OFFICER: Review for accuracy and completeness and sign in the space provided.

3. DEPARTMENT HEAD: Review for accuracy and completeness and sign in the space provided.

4. 3-M COORDINATOR:

a. Serialize, date and sign in the appropriate spaces.

b. ROUTING INSTRUCTIONS: For Category "A" FBRs, forward the white and yellow copies to the appropriateNAVSEACEN and the pink copy to the TYCOM. For Category "B" FBRs, forward the white, yellow and pinkcopies to the TYCOM. Retain blue copy in suspense file. Return green copy to the originator.

THIS FORM WILL NOT BE USED TO ORDER PUBLICATIONS.

ABEf0709 OPNAVINST 4790/7B (BACK)

Figure 7-9.—Instructions for preparation of PMS Feedback Report.

disk, replacement copies will be generatedwith the print-on-demand capability.

2. Category B—This category (fig. 7-8) istechnical in nature. These FBRs are submittedby the ship's 3-M coordinator to the applicableTYCOM and pertain to the following:

a. Technical discrepancies that inhibit PMSperformance. These discrepancies canexist in documentation, equipment design,maintainability, reliability, or safetyprocedures as well as operationaldeficiencies in PMS support (parts, tools,and test equipment).

b. Shift of maintenance responsibilities.Individual ships sometimes desire or needto shift maintenance responsibility fromone workcenter to another, combine two ormore existing workcenters, or split anexisting workcenter. Such changes canonly be made with the approval of the typecommander. When changes inmaintenance responsibility are considerednecessary, ship's personnel should submit aPMS FBR (category B) via the applicableTYCOM, indicating from which work-center(s) equipment is to be deleted and towhich workcenter(s) it is to be transferred.All such FBRs are signed by the executiveofficer.

Preparation of the PMS FBR

The FBR is prepared and submitted according tothe instructions contained on its reverse side (fig. 7-9).

REVIEW QUESTIONS

Q1. What is Inactive Equipment Maintenance(IEM)?

Q2. The workcenter PMS manual contains whatrequirements?

Q3. What provide the detailed procedures used toperform a maintenance action?

PMS SCHEDULES

LEARNING OBJECTIVE: Describe thetypes of information displayed on each of thefollowing PMS schedules: Cycle, Quarterly,and Weekly. State the purpose of eachschedule.

PMS schedules are categorized as Cycle,Quarterly, and Weekly Schedules.

CYCLE PMS SCHEDULE

The Cycle PMS Schedule (fig. 7-10) displays theplanned maintenance requirements to be performedduring the period between major overhauls of the ship;that is, from the first quarter after overhaul to the nextfirst quarter after a ship's overhaul. For ships in phasedmaintenance or similar incremental overhaul programsand other short industrial availability programs, the firstquarter after overhaul is the quarter immediatelyfollowing completion of the docking availability. Cycleand multi-month requirements need to be scheduledduring this time period. Any checks that have not beenaccommodated in this cycle period are front loaded intothe new cycle schedule period.

Content of the Cycle PMS Schedule

The following information is found in theblock/column indicated in figure 3-10:

• Ship-The ship's name and hull number

• Workcenter-The applicable workcenter de-signator

• Schedule Quarter After Overhaul AsIndicated-The annual, semiannual, multiple-month (4M and greater) maintenancerequirements, and any related maintenancechecks to be completed during the quarterindicated

• Approval Signature/Date-The departmenthead's signature and the date the Cycle Schedulewas approved

• Each Quarter-Maintenance that is performedevery 2 weeks, monthly, every 2 months,quarterly maintenance requirements, and anyrelated maintenance checks and situationrequirements regardless of periodicity to becompleted during each quarter are listed in thiscolumn.

Preparation of the Cycle PMS Schedule

Cycle PMS Schedules are used to plan andschedule maintenance requirements to be conductedduring each calendar quarter. Department heads devoteconsiderable attention to the preparation of the CycleSchedule since these efforts directly affect long range

7-13

PMS scheduling. The materials required and theprocedures followed in schedule preparation aredetailed in the paragraphs that follow.

MATERIALS REQUIRED FOR PREPARA-TION.—The following materials are required:

• Blank Cycle Schedules (OPNAV 4790/13 orapproved automated form). Use of automatedforms generated from PMS schedulingprograms that have been approved by CNO andthe TYCOM are authorized for use in lieu ofpaper forms

• Workcenter PMS Manuals (List Of EffectivePages) (LOEP)

• Applicable MRCs (for general reference)

PROCEDURES.—The following are basicinstructions for filling out the cycle schedule (refer tofigure 7-10):

1. Neatly enter initial entries, either typed or inblack ink, on the Cycle Schedules. Changes

will be made in ink and initialed by thedepartment head.

2. From the LOEP (Report PMS 5), list each itemof equipment in MIP sequence. It is notnecessary for the Cycle Schedule to match theLOEP line for line.

a. Use the MIP column to list the MIP codewithout the date coding; for example,E-1/55, EL-2/80, and 4411/1.

b. Use the Component column to list thename of each system, subsystem, orequipment. Enter the item's serial numberor ship's numbering system number in theComponent column if more than one of theitems is located within a workcenter. Alsoenter EGL in this column when an EGL isapplicable. When multiple EGLs are used,they can either be scheduled on separatelines or be scheduled on the same line (orgroup of lines) using the EGL number asthe prefix to the scheduling code; that is, aquarterly check for MRC Q-1 would be

7-14

SHIP WORK CENTER SCHEDULE QUARTER AFTER OVERHAUL AS INDICATED

USS ROOSEVELTCVN-71

MACHINERY LUB OILNO. 1 AMR2000/001

MIP COMPONENT

MISC SHIPBOARDELECT EQUIPMENT3000/001

RECEPTACLES EGL-1

RUBBER GLOVES EGL-1

FIREMAIN & FLUSHING5210/009

COMPRESSED AIRSYSTEM EA07-0015510/018

02N2 SYSTEMFWD 1-30-65530/001

PUMP 27345

VALVES EGL-1

VALVES EGL-2

18M-1 (6) (18)

S-4R

A-2

EA07(pg 1 of 1)

S-3R

131721

159

141822

2610

151923

3711

162024

4812

APPROVAL SIGNATURE

DATEEACH QUARTER

B. A . Ol s o n LCDR, USN30 JA N 94

S-2

A-11

S-1#

A-13R

A-1

A-13R

S-2

A-5R#

S-1#

18M-1 (12) (24)

S-4R

S-3R

A-14#

2M-6, R-1

S-4RM-1, M-2, M-4R, R-2

2W-1, 3W-2

S-3R, R-1

Q-1, Q-5R#

A-5R#M-1, M-2, R-1, R-5W

M-1, M-2, Q-2#BA 0

Q-3, R-16D, R-17W

A-13R, R-11M, D-1R, W-1R

D-1R, W-1R, A-13R, R-11M

CYCLE PMS SCHEDULE (CONVENTIONAL)OPNAV FORM 4790/13 S/N 0107-LF-3220

ABEf0710

Figure 7-10.—Cycle PMS Schedule.

scheduled as 1-Q-1 on the same line with2-Q-1, 3-Q-1, and so on. These techniquespermit the use of a reasonably compactschedule for MIPs with large quantities ofEGLs that are normally found on largeships, such as aircraft carriers.

3. From the applicable MIP, list the periodicitycodes in the Schedule Quarter After OverhaulAs Indicated and Each Quarter columns asdescribed in the sections that follow. From theRelated Maintenance column of the MIPschedule all mandatory related maintenancerequirements which are to be completed duringthe quarter are indicated by the pound signsymbol “#”. The pound sign placed next to aprimary check, indicates that there ismandatory related maintenance associatedwith that maintenance requirement (e.g. S-1#).

a. In the Schedule Quarter After Overhaul AsIndicated column:

(1) List each semiannual (S) maintenancerequirement in one of the four col-umns, and then list it again 6 monthslater. For example, an S-1 requirementscheduled to occur in the 1st, 5th, and9th quarters is also scheduled in the 3d,7th, and 11th quarters.

(2) List each annual (A) maintenancerequirement in one of the fourcolumns.

(3) List each multiple month periodicityMR (18M, 24M, 30M, 36M, and soon). The quarter after overhaul must beindicated in parentheses. (Forexample, 18M-1(6) indicates an"every 18 months" periodicity MRscheduled to be accomplished in thesixth quarter after overhaul.) Table 7-2serves as an example for determiningthe quarter after overhaul. To use the

7-15

(NUMBERS INDICATE QUARTER AFTER OVERHAUL)

18M Scheduling Table

First Scheduling 1 2 3 4 5 6

Second Scheduling 7 8 9 10 11 12

Third Scheduling 13 14 15 16 17 18

Fourth Scheduling 19 20 21 22 23 24


First Scheduling 1 2 3 4 5 6 7 8

Second Scheduling 9 10 11 12 13 14 15 16

Third Scheduling 17 18 19 20 21 22 23 24


First Scheduling 1 2 3 4 5 6 7 8 9 10

Second Scheduling 11 12 13 14 15 16 17 18 19 20

Third Scheduling 21 22 23 24 25 26 27 28 29 30


First Scheduling 1 2 3 4 5 6 7 8 9 10 11 12

Second Scheduling 13 14 15 16 17 18 19 20 21 22 23 24

48M Scheduling

First scheduling in first 16 quarters and second scheduling 16 quarters later.

60M Scheduling

First scheduling in first 20 quarters and second scheduling 20 quarters later.

Table 7-2.—Multiple Month Periodicity Scheduling Table

table, first determine in which quarterafter overhaul the MR will be firstscheduled. Go to this quarter in thefirst row of the table. Then schedulethe MR for the quarters in that columnas applicable. For example, if an18M-1 is scheduled for the 4th quarterafter overhaul, it must also bescheduled for the 10th, l6th, and 22d,as applicable.

NOTE

Prior to scheduling 30M, 36M, 48M, or60M, review the MRC to see if a specificquarter after overhaul is indicated.

(4) Ships with overhaul cycles of less than24 quarters must schedule cyclerequirements within this operationaltime frame. Ships delayed beyond 24quarters must extend their Cycle PMSSchedule by adding quarter numbersin the Schedule Quarter After Over-haul As Indicated column. (Multiplemonth requirements needed beforeentering overhaul must be reviewedand rescheduled as necessary.)

b. In the Each Quarter column, list every 2weeks, monthly, every 2 months, andquarterly maintenance requirements(2W-1, M-1, 2M-1, Q-1, and so on), andsituation requirements (M-IR, Q-IR, S-IR,A-IR, 18M-IR, R-1, and so on). Daily,every 2d day, every 3d day, and weeklymaintenance requirements are not listedhere.

4. Have the completed Cycle PMS Schedulereviewed, signed, and dated by the departmenthead.

5. Once the Cycle Schedule has been completed,maintenance requirements listed are not to bemoved from one quarter to another. Ifrescheduling becomes necessary, reflect it onthe Quarterly PMS Schedules.

6. All superseded cycle schedules will be retainedfor 12 months.

QUARTERLY PMS SCHEDULE

The Quarterly PMS Schedule (OPNAV Form4790/14) (fig. 7-11) displays each workcenter's PMS

requirements to be performed during a specific3-month period. This schedule, when updated weekly,provides a ready reference to the current status of PMSfor each workcenter. This schedule represents adepartmental directive and, once completed, may bechanged only at the department head's discretion.Responsibility for changes is sometimes delegated todivision officers on carriers and cruisers.

Contents of the Quarterly PMS Schedule

The Quarterly PMS Schedule contains thefollowing:

• Space is provided for entering the workcenter,year, quarter after overhaul, department head'ssignature, date prepared, and months covered.

• Thirteen columns, one for each week in thequarter, are available to permit scheduling ofmaintenance requirements on a weekly basisthroughout the quarter. Additional columnsprovide space to enter the complete MIP codesand any PMS requirements that may be requiredto be rescheduled into the next quarter. Take careto ensure that rescheduling changes conform tothe periodicity specified for the requirement.

Preparation of the Quarterly PMS Schedule

Prepare OPNAV Forms 4790/14 or approvedautomated forms, in ink as follows:

1. Enter the workcenter code.

2. Enter the calendar year of the current quarter.

3. Enter the number of the quarter after overhaulas reflected on the Cycle PMS Schedule.

4. Enter the calendar months of the quarter asfollows:

JAN/FEB/MAR

APR/MAY/JUN

JUL/AUG/SEP

OCT/NOV/DEC

a. A ship ending a major overhaul,conversion, or construction in Augustwould use the months of July, August, andSeptember as the first quarter afteroverhaul. If the ship finished a majoroverhaul, conversion, or constructionduring the last 2 weeks in September, thefirst Quarterly PMS Schedule prepared

7-16

would include the months of October,November, and December as the firstquarter.

b. Ships completing overhaul late in thequarter are not expected to do all plannedmaintenance scheduled during that quarter,but should do a certain amount based onthe time remaining in the quarter. In thisinstance, the maintenance done and theeffective dates are recorded on the back ofthe Quarterly PMS Schedule, and theschedule is marked to show that it is only apartial quarterly PMS record.

5. Each column represents a week and is dividedinto 7 days by the use of tick marks across thetop. The first tick marked space within acolumn represents Monday. Place Monday'sdate for each week in the quarter on thepedestal between each column.

6. Lightly shade in across the tick marks the daysthat the ship expects to be underway.

7. Using both the LOEP and the Cycle PMSSchedule, enter the MIP number including thedate code in the MIP column in a space on linewith the subject equipment on the CycleSchedule.

8. From the Cycle PMS Schedule, select theSchedule Quarter After Overhaul As Indicatedcolumn corresponding to the quarter beingscheduled. Each of the maintenance re-quirements listed in this column and the EachQuarter column will be transcribed to anappropriate weekly column of the QuarterlyPMS Schedule. If possible, do not schedule inthe last 2 weeks of the quarter. These 2 weeksmay then be used for rescheduled maintenancerequirements.

9. Refer to the MIPs and the departmental masterdeck of MRCs for a brief description of themaintenance actions represented by theperiodicity codes on the Cycle PMS Scheduleto determine if the actions should be performedin port or at sea. Schedule the requirements on

7-17

2000/001-A2

QUARTERLY PMS SCHEDULE (CONVENTIONAL)OPNAV FORM 4790/14 (REV 6-73) S/N 0107-LF-3241

WORK CENTER YEAR QUARTER AFTER OVERHAUL APPROVAL SIGNATURE DATE

RESCHEDULEMONTH

3000/001-73

5210/009-C1

5510/018-82

5530/001-13

5530/001-13

4924/RHD-82

R-1 2M-6

M-1SAR

2W-1 3W-1 2W-1

M4RM-2

3W-22W-1

M-1

A-2

M-2M-4R

2W-1

S-3R

18M-1

3W-2 2W-1

M-1

2M-6

M-2M-4R3W-22W-1

S-2Q-5R( Q1)

M-1M-2M-1M-2

2W-1

M-1M-1

M-1

Q-3A-1

Q-2

M-2 M-2M-1

(M-1)

M-1

R1TM

R1TM

M-4

M-2R

M-4M-4

M-2RM-1

M-4

M-4

M-1M-2R

A-13R

Q-3

Q-2( M-1)S-1( R-1)

4 11 18 25 2 9 16 23 30 6 13 20 27

30MAR94JUNE

M. M. RodentMONTHMAYMONTH

6APRIL

94EA07

MIP

A-13R

M-4

M-4

A-2

S-1

M-1M-2R

ABEf0711

Figure 7-11.—Quarterly PMS Schedule.

the Quarterly PMS Schedule in the week mostappropriate for accomplishment. With theexception of related daily and weekly PMSrequirements, ensure that all mandatory relatedmaintenance are scheduled within parentheseson the same line and during the same week asthe primary maintenance requirement.

10. From the Cycle PMS Schedule column titledEach Quarter, schedule monthly, quarterly, andapplicable situation requirements into theappropriate weeks of the Quarterly PMSSchedule. All calendar situation requirements(24M-2R, A-2R, S-IR, Q-3R, M-IR) must beaccomplished at least once during theperiodicity specified and also each additionaltime the situation arises. Schedule 2M( )periodicity as indicated by a number inparentheses. For example, 2M(2) occur twicein the quarter (7 to 10 weeks apart).

11. From the Cycle PMS Schedule column, titledSchedule Quarter After Overhaul As Indicated,schedule the annual, semiannual, and multiplemonth requirements. Schedule the cyclerequirements for which the number inparentheses matches the quarter after overhaulbeing scheduled.

12. Be sure that any PMS requirement listed in theReschedule column of the previous QuarterlyPMS Schedule is brought forward to theQuarterly PMS Schedule you are preparing.

13. The complete Quarterly PMS Schedule shouldbe reviewed and then signed and dated by thedepartment head in the appropriate block. If theship's operating schedule changessignificantly, PMS requirements scheduled inthe affected periods may need to be reviewedand rescheduled as necessary to coincide withthe new operating schedule.

Use of the Quarterly PMS Schedule

The Quarterly PMS Schedule serves as a directiveto workcenter supervisors for scheduling weeklymaintenance. Quarterly PMS Schedules are used asfollows:

1. Each Monday, the division officer updates theprevious week's column of the Quarterly PMSSchedule, using the following symbols:

X = Completed maintenance. The symbol Xindicates completion of a maintenance

requirement. Fully accomplished MRs areaddressed and X'd off separately on theQuarterly Schedule. Pay particular attention tomake sure situation requirements that wereaccomplished are added and X'd off separately.

0 = Maintenance not completed. A circledrequirement indicates a requirement that wasnot accomplished according to the applicableMRC.

¢ = Satisfied by higher authority test. Thissymbol is used to mark scheduled equipmentmaintenance or lower level MRC requirementsthat have been satisfied by the completion ofthe parent system test. A brief explanation ofthe parent system test (including the MIP, whoperformed the maintenance, and when) isrequired on the reverse side of the QuarterlySchedule. An X marked over the higher leveltest symbol indicates that the lower level testrequirement annotated with the ¢ has beensatisfied. (MRCs that are so satisfied areidentified on the applicable system level testMIP.)

2. The division officer is responsible forrescheduling circled requirements still withinperiodicity and for determining the reason fornonaccomplishment.

3. From the Quarterly PMS Schedule, theworkcenter supervisor schedules therequirements for the following week on theWeekly PMS Schedule and updates theinformation in the Outstanding Repairs andPMS Requirements Due In The Next 4 Weekscolumn.

4. Any requirement that was not completed instrict accordance with the applicable MRCwithin its periodicity during the quarter must(in addition to being circled on the front of theQuarterly PMS Schedule) be identified on theback of the schedule by the complete MIPnumber and MRC code, followed by a briefreason for noncompletion. Example:

C-2/1 - 11 M-1 Unable to accomplish step I.J.,"Test operate transmitter," due to antennacasualty. (This is an indication of a partialcompletion.) G-58/3-72 Q-1 Heavy seaspreclude accomplishment as scheduled.

Unaccomplished S, A, or multiple-monthperiodicity requirements should be added to

7-18

the Reschedule column for accomplishment inthe next quarter, if they are within theirassigned periodicities. At the end of the quarterthe department head should indicate awarenessof the maintenance actions which were notaccomplished by reviewing, signing, anddating the back of the schedule for the quarterjust completed. The department head shouldalso take positive steps to ensure that priority isgiven to completing maintenance requirementsrescheduled from the previous quarter andthose not accomplished within their assignedperiodicities.

5. The completed Quarterly PMS Schedule isremoved from the holder after the close of eachquarter and retained as a planned maintenancerecord. The four previously completedquarterly schedules will be retained.

6. The recopying of Quarterly Schedules tofacilitate legibility is discouraged, and shouldonly be done with the division officer's writtenapproval.

WEEKLY PMS SCHEDULE

The Weekly PMS Schedule (fig. 7-12) displays theplanned maintenance scheduled for accomplishment in

7-19

Figure 7-12.—Weekly PMS Schedule.

a given workcenter during a specific week. A WeeklyPMS Schedule is posted in each workcenter and usedby the workcenter supervisor to assign and monitor theaccomplishment of required PMS tasks by workcenterpersonnel.

Content of the Weekly PMS Schedule

The Weekly PMS Schedule contains the followinginformation:

1. Workcenter code

2. Date of current week

3. Division officer's approval signature

4. MIP number (minus the date code)

5. A list of applicable components/equipment

6. Maintenance responsibilities assigned, byname, to each line item of equipment

7. The periodicity codes of maintenancerequirements to be performed, listed bycolumns for each day

8. Outstanding major repairs, applicable PMSrequirements, and all situation requirements

Preparation of Weekly PMS Schedule

Prepare the Weekly PMS Schedule as follows:

1. Using OPNAV Form 4790/15 or approvedautomated form, type in or neatly enter in inkthe following basic (permanent) informationfrom the Cycle PMS Schedule, the LOEP, andapplicable MIPs:

a. Workcenter identification.

b. MIP codes and component nomenclature,line for line, to match the Cycle PMSSchedule. (Include serial or identifyingnumbers and EGL information ifapplicable.)

c. Daily and weekly PMS requirements asindicated in the MIPs for each workcenter.List all weekly requirements in theMONDAY column and daily requirementsonce in each day of the week column andtwice in the SAT.-SUN. column. Schedule2D periodicity on Monday, Wednesday,

Friday, and once in the SAT.-SUN. period.Schedule 3D periodicity on Monday,Thursday, and once in the SAT.-SUN.period.

d. List all situation requirements in the NextFour Weeks column, and schedule them, asthe situation requires. Also list the 2Wperiodicity requirements in the Next FourWeeks column.

e. Now, either laminated or covered withplastic so that it can be cleared and updatedeach week.

2. The following information is not permanent innature and is written in after the schedule islaminated.

a. Using the Quarterly PMS Schedule, theworkcenter supervisor transposes all PMSrequirements from the column for theweek being scheduled to the Weekly PMSSchedule. MIPs/MRCs must be reviewedto ensure that related maintenance actionsare scheduled for the same day and thatappropriate consideration is given to theweek's operating schedule.

b. Using information from the QuarterlyPMS Schedule, the workcenter supervisorlists in the Next Four Weeks column of theWeekly PMS Schedule all PMSrequirements due in the next 4 weeks.

c. The workcenter supervisor assignspersonnel, by name, to specific line entries.

d. The Weekly PMS Schedule is signed anddated by the division officer prior to itsposting in the holder in the workcenter.

Use of the Weekly PMS Schedule

The Weekly PMS Schedule is used by theworkcenter as follows:

1. Maintenance personnel obtain PMSassignments from the Weekly PMS Scheduleand report completed and uncompletedmaintenance actions to the workcentersupervisor.

7-20

2. When satisfied that the work has been properlycompleted, the workcenter supervisor crossesoff, with an X, the maintenance requirement. Ifthe maintenance is not completed, themaintenance requirement is circled andrescheduled. However, if material deficienciesor casualties that are unrelated to themaintenance requirement are discovered, themaintenance requirement can be X'd off, butthe discrepancy must be reported to theworkcenter supervisor. PMS requirements(other than daily checks) accomplished duringthe prescribed week but not on the dayspecified are considered completed onschedule and X'd off.

3. Each Monday morning, the division officercompares the preceding week's Weekly PMSSchedule with the Quarterly Schedule andensures that the Quarterly Schedule is properlyupdated as follows:

a. Scheduled requirements that werecompleted are X'd out.

b. Scheduled requirements that were notcompleted are circled.

c. Situation requirements that occurred andwere completed are entered and X'd off.

d. Requirements that were completed aheadof schedule are circled, back scheduled andX'd out.

4. Each Monday morning, the division officerreviews the current week's Weekly PMSSchedule, ensures that it is properly made outaccording to the Quarterly Schedule, and signsand dates the Weekly Schedule in theappropriate block.

REVIEW QUESTIONS

Q4. What maintenance requirements do the cycleschedules display?

Q5. All superseded cycle schedules are retainedfor how many months?

Q6. How often is the quarterly schedule updated?

THE MAINTENANCE DATA SYSTEM

LEARNING OBJECTIVES: State thepurpose of the Maintenance Data System anddescribe the types of maintenance actionsreported on the following OPNAV forms:4790/2K, 4790/CK, 4790/2P.

The Maintenance Data System is used to recordinformation considered necessary for workloadplanning and coordination and to provide a data basefor evaluating and improving equipment installed in thefleet. Much of the data collected by MDS returns to theship in the form of a material history known as theCurrent Ship's Maintenance Project (CSMP).

Nearly all the reporting of maintenance actionsother than normal PMS actions is done on a singlemultipurpose form, the Ship's Maintenance ActionForm, OPNAV 4790/2K. Personnel completing amaintenance action fill out the appropriate sections ofthe form and send it via the ship's data collection centerto an ADP (automatic data processing) facility to beprocessed. The 4790/2K contain information on thereporter's ship, workcenter, equipment worked on, andinitial symptoms observed. In other sections, space isprovided to record completion information, deferral ofthe work for various reasons, remarks, and specialinformation for work requests. A space also exists forrecording time meter and counter readings where theyare required.

Normally, the following types of maintenanceactions will be reported on the 4790/2K: system orequipment repairs or improvements; maintenanceactions that require the use of parts or materialsspecifically requisitioned for the job; actions thatcannot be completed in the usual amount of time due tothe ship's operations; requirements for outsideassistance, or unavailability of parts or material;assistance received from nonreporting activities, suchas mobile technical training units (MOTUs) ortechnical representatives; major work associated withcorrosion control and preservation of the ship; andcertain PMS actions listed in the 3-M Manual,OPNAVINST 4790.4.

7-21

To prevent the loss of significant data when it isrecorded on several forms, each maintenance actionmust be assigned a unique identifier. Under MDS, thisidentifier is known as the job control number (JCN). Itconsists of a five-character unit identification code(UIC), a four-character workcenter code, and afour-character serial number called the job sequencenumber (JSN). Figure 7-13 shows an example of a JCNlog used to record the JSNs. This system gives aworkcenter at least 9,999 JCNs. If additional JCNs aredesired, letters can be substituted for the first numeral.In any event, take care to make sure that two differentjobs are not assigned the same JCN.

There are many different situations that could becovered by the MDS documents. This text will coveronly the basic actions.

SHIP'S MAINTENANCE ACTION FORM(OPNAV 4790/2K)

The ship's maintenance action form (OPNAV4790/2k) (fig. 7-14), printed on a single sheet of"no-carbon-required" paper, is the basic MDSdocument. If multiple copies are needed, the necessarynumber of forms may be fastened together and filled inat one time. The form may also be reproduced onelectrostatic (Xerox-type) copying machines.

This form contains six sections that require entriesto describe the type of maintenance action beingreported. Entries should be printed in capital letters. Allentries must be legible and should be inserted withinthe tic marks. If an error is made, it should be lined outusing a single line, and the correct information entered.

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Figure 7-13.—Example of an job control number log.

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Figure 7-14.—Ship's Maintenance Action Form (OPNAV 4790/2K).

The OPNAV 4790/2K is used to report all deferredmaintenance actions and the completion ofmaintenance actions that do not result in configurationchanges. Partially completed maintenance actions thatwill result in configuration changes and complete orpartial accomplishment of alterations are reported onOPNAV 4790/CK. A description of the OPNAV4790/2K information sections is presented in thefollowing paragraphs.

Section I-Identification

This section identifies the equipment or system onwhich maintenance actions are being performed.

Section II-Deferral Action

This section filled in when reporting the deferral ofa maintenance action. Indicates ship's force man-hoursexpended up to the time of deferral, the date of thedeferral, ship's force man-hours remaining, and if thework must be completed by a certain date.

Section III-Completed Action

This section is filled in to report the completion of amaintenance action.

Section IV-Remarks/Description

This section must be filled in when the deferral of amaintenance action is reported. It is filled in when thecompletion of a maintenance action is reported, onlywhen such remarks are considered important to themaintenance action. This section must also be filled into report maintenance actions on selected equipmentrequiring second level reporting, and to describesituations that are safety related.

Section V-Supplementary Information

This section contains helpful information aboutdeferred maintenance actions, such as what technicalmanuals and blueprints are available and whether or notthey are retained on board the requesting ship.

Section VI-Repair Activity Planning Action

The repair activity may use this section for internalplanning and scheduling of the workload.

Block G, Completed By

This block contains the signature and rate/rank ofthe senior person actively engaged on the job in the leadworkcenter. For maintenance actions not requiringassistance from an outside workcenter, the seniorperson working on the job signs this block and indicateshis or her rate.

Block H, Accepted By

This block contains the signature and rate/rank ofthe individual authorized by the tended ship to verifythe acceptability of the work performed. Completion ofthis block is mandatory when an OPNAV 4790/2K isused to report completion of a previously deferredmaintenance action. For maintenance actions notrequiring assistance from an outside workcenter, theworkcenter supervisor will sign this block and indicatehis or her rate/rank.

The commanding officer, or his/her authorizedrepresentative, places his/her signature on all originaldeferrals in block E. Two copies are held in a deferralsuspense file in the workcenter until the JCN appears onthe automated CSMP report, at which time the copiesare transferred to the active suspense file held in theworkcenter

MAINTENANCE PLANNING ANDESTIMATING FORM (OPNAV4790/2P)

The maintenance planning and estimating form(OPNAV 4790/2P) (fig. 7-15) is used along with theOPNAV 4790/2K form for deferring maintenance to bedone by an intermediate maintenance activity (IMA).Attached to the original 2K at the intermediatemaintenance activity, it is used by the IMA to screenand plan the job in detail.

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Figure 7-15.—Maintenance Planning and Estimating Form (OPNAV 4790/2P).

SUPPLEMENTAL FORM (OPNAV 4790/2L)

The supplemental form (OPNAV 4790/2L) (fig.7-16) is used by maintenance personnel to provideamplifying information (such as drawings and listings)related to a maintenance action reported on an OPNAV4790/2K. The information on this form will never beentered into the computer. The form is prepared in thefollowing manner:

1. The ship's name and hull number are entered inblocks A and B.

2. If the form is a continuation of a maintenancedata form or another supplemental report form,the appropriate form is checked in block F andthe JCN assigned to the basic form is entered inblocks C, D, and E.

3. Section II will contain comments, sketches, orother supplemental information.

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Figure 7-16.—Supplemental Form (OPNAV 4790/2L).

4. Section III (blocks H, I, J, and K) will containthe names of the person and the supervisorsubmitting the report.

REPORTING CHANGES TO EQUIPMENTCONFIGURATION

One of the major objectives of the MDS is toprovide the capability for reporting configurationchanges. The importance of configuration change

reporting cannot be overemphasized. Whenever anysystem, equipment, component, or unit within the shipis installed, removed, modified, or relocated, thechange must be reported. This action will ensure properaccounting of configuration changes, and will improvesupply and maintenance support such as technicalmanuals, PMS coverage, and COSAL to the fleet. TheConfiguration Change Form (ONNAV 4790/CK) (fig.7-17) is used to provide this service.

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Figure 7-17.—Ship's Configuration Change Form (OPNAV 4790/CK).

The OPNAV 4790/CK form is completed to themaximum extent possible by the accomplishingactivity and provided to the ship or activity 3-Mcoordinator.

The 3-M coordinator then reviews the forms forlegibility (all copies) and ompleteness and provides theforms to the applicable workcenter supervisor, whoensures that the proper documentation is completed andprocessed when a configuration change isaccomplished, including required signatures to indicateverification of all reported configuration changes.

The ship is also responsible for reporting andmonitoring all changes accomplished by ship's forceduring any type of availability, and for providing theConfiguration Change Form to the overhauling activity.The ship is not responsible for reporting configurationchanges accomplished by an overhauling activityduring availabilities.

A configuration change is either (1) theaccomplishment of any action prescribed by analteration directive (SHIPALT or equipment alteration)or (2) the installation, removal, or modification of anysystem, equipment, component, or unit. Thereplacement of repair parts (such as nuts, bolts, wires,0-rings, gaskets, resistors, and capacitors) with likeparts, does not constitute a configuration change.

The OPNAV 4790/CK form is used to report aconfiguration change or to report the completion of aprevious deferral that resulted in a configurationchange. Deferred maintenance actions and completedmaintenance actions that do not result in configurationchanges are reported on OPNAV 4790/2K. TheOPNAV 4790/2K form will never be used to reportaccomplishment of any maintenance action that resultsin configuration changes.

A configuration change occurs whenever theaccomplishment of a maintenance action results in thefollowing:

• Addition or installation of any new equipment.

• Deletion, removal, or turn-in of any installedequipment.

• Replacement or exchange of any equipment. Areplacement or exchange is reported as theremoval of an installed item of equipment andthe installation of a new item of equipment.

• Modification of any installed or in-useequipment. A modification occurs when amaintenance action alters the design oroperating characteristics of the equipment orwhen nonstandard replacement parts (notidentified on the APL or in the technical manual)are used.

• Relocation of any equipment to a new deck, newframe, or new compartment.

• Accomplishment of any alteration directive,such as a field change or SHIPALT.

CAUTIONS ON ERRORS

Since the data entered on the MDS forms is used bydata processing equipment to provide information to aship in the form of the CSMP report, it is essential thateach form be filled in completely and accurately. Acomputer cannot recognize anything that it is told doesnot exist. It will reject incorrect and incomplete entriesand the data will not be available for use. To prevent thisfrom happening, it is important that the completedforms be reviewed at all levels. Some of the commonerrors that workcenter supervisors, division officers,department heads, and 3-M coordinators should be alertfor are

• omission of slash marks through zeros and Z's;

• incorrect EICs;

• use of improper codes for alterations and fieldchanges;

• too many or not enough spaces between wordsin the Remarks section;

• incorrect dates; and

• incorrect entries.

These are only a few of the many errors detectedeach day by a typical TYCOM 3-M staff section.

Some areas on the 4790/2K require specialmention. Alterations and field changes are identified inblock 18 by a two-letter code in the first two spaces,followed by the identification number of the change. Atitle code, such as A, D, F, or K may be shown in theauthorizing directive of SHIPALTs. This title code, ifassigned, must be entered in the extreme right handposition of the block.

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In block 18, the first two letters identify SHIPALT(SA), ORDALT (OA), field change (FC), or any otherappropriate instruction. Electronic equipment is alwaysidentified by serial number, and only one piece ofequipment may be reported under a given JCN. Ifseveral pieces of the same type of equipment are alteredby field changes, there must be one document for eachpiece of equipment. Example:

A ship has four C-13 Mod 1 catapults, and field change17 is to be installed in all of them. Each catapult will bechanged, and the changes will be reported on separatedocuments showing a specific JSN and equipmentserial number. This will enable the computers toidentify which items of equipment have been changedand which have not. It also will be reflected on thereadouts returned to the ship as part of its materialhistory.

Another problem is the use of the noun name inblock 5. For electronic equipment the "AN"designation is the best entry for the noun name. If thereis no "AN" designation, the name from the nameplateshould be used. Up to 16 characters of a name may beentered.

In block 35, a space follows each word, and wordsthat cannot be completed on a line are continued on thenext line with no spaces or hyphens inserted. Ondeferred actions, the XXX's used to separate the troublefrom the desired corrective action must not beseparated. If they cannot be fitted in on one line, extraspaces will be left blank on that line and the XXX's willbe put in the first spaces of the next line.

REVIEW QUESTIONS

Q7. Maintenance Data System is used to recordwhat type of information?

Q8. Under the maintenance Data System, what isa Job Control Number?

Q9. What is the OPNAV 4790/2K used to report?

Q10. The OPNAV 4790/2P provide what type ofinformation?

SUPPLY

LEARNING OBJECTIVES: Recognize thedifferent types of stock and control numbers.Recall the purpose of cognizance symbols.Recognize sources of identifying materialwhen a stock number is not available.Recognize the uses of the following supply

publications: FED LOG, ML–C, MCRL,MRIL, ASG, and GSA.

One of the duties of an ABE is to identify andrequisition material. This section provides basicinformation to help you develop the knowledge youneed to perform these duties. Proper materialidentification is essential to the requisitioning andreceipt of the correct item. You must understand theterminology used in material identification.

GENERAL INFORMATION

Material is managed according to category(Federal Supply Classification) and its intended use.An inventory manager is assigned for each category ofmaterial, and has overall responsibility for all itemswithin the category. All items in the supply system havean assigned two-position cognizance symbol code.This code identifies the inventory manager and thestores account in which the material is carried. Theitems assigned to bureau, office, or systems commandfor inventory management includes the followingmaterial:

• Material in the research and development stage

• Material that requires continuing logistics,engineering, or fiscal administration and controlat the department level.

• Material recognized as a onetime installationthat was bought and issued for a specific use

Naval Supply System Command (NAVSUP)Inventory Control point (ICP) items are those for whichbureau, office, or systems command management is notessential. The NAVSUP ICP provides stocks of theseitems to its segment of the supply system. This group ofitems includes equipment, repair parts, andconsumables. It also includes those items for whichstocking determination, quality control, funding, andissue control can be accomplished by the ICP ifrequired, the ICP ensure that these items are availablefrom commercial sources and other governmentagencies. NAVSUP selects the items assigned to ICPfor inventory management with the advice of theappropriate bureau, office, or systems command.

The Navy Retail Office items are items for whichjoint military supply management responsibility isvested to the Defense Logistics Agency (DLA). Theseitems include components, repair parts, consumables,and other material. The requirement determination andprocurement of these items can be accomplished by the

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defense supply center on a combined basis for allmilitary services.

MATERIAL CATALOGING ANDCLASSIFICATION

LEARNING OBJECTIVE: Recognize thedifferent types of stock and control numbers.Recall the purpose of cognizance symbols.Recognize sources of identifying materialwhen a stock number is not available.Recognize the uses of the following supplypublications: MCRL, ML-C, MRIL, ASG, andGSA.

This will help you understand the information usedin material identification. There are ore than 4 millionsupply items in the Department of Defense (DOD)supply system. The Navy supply system alone stocksmore than 1 million items. Each item must be identifiedto make buying, stocking, and issuing easier. Toaccomplish this, each item must be listed in differentgroups or categories.

FEDERAL CATALOG SYSTEM

The Federal Catalog System encompasses thenaming, description, and numbering of all items carriedunder centralized inventory control by the Departmentof Defense (DOD) and civil agencies of the FederalGovernment as well as the publication of relatedidentification data. Only one identification may be usedfor each item in all supply functions from purchase tofinal disposal. The North Atlantic Treaty Organization(NATO) countries also use the Federal Catalog System.The Defense Logistics Agency (DLA) administers theFederal Cataloging System under the direction of theAssistant Secretary of Defense (Installation andLogistics).

FEDERAL SUPPLY CLASSIFICATIONSYSTEM

The Federal Supply Classification (FSC) Systemwas designed to permit the classification of all items ofsupply used by the Federal Government. Each item ofsupply is classified in only one four-digit FederalSupply Classification class. The first two digits denotethe group or major division of commodities within thegroup. Currently, there are 76 groups assigned. Groupnumbers start from 10 and end at 99. Table 7-3 is anexample list of federal supply groups and titles.

Table 7-3.—Example List of Federal Supply Groups

GROUP TITLE

17 Aircraft launching, land-ing, and ground handlingequipment

48 Valves

53 Hardware and abrasives

The number of classes within each group varies.Each class covers a particular area of commoditiesaccording to physical or performance characteristics.The items in the class are usually requisitioned orissued together. This is used as a basis for includingitems in the same area of commodities. Examples ofhow classes are used to divide types of material within astock group are shown in figure 7-18. The stock groupand class together make the Federal SupplyClassification (FSC).

GROUPS CLASSES

Group 17

Aircraft launching,landing, and groundhandling equipment

1710 Arresting gear andbarricade equipment

1720 Catapult launchingequipment

Group 48

Valves

4810 Valve solenoid

4820 Valve angle

Group 53

Hardware andabrasives

5305 Screws

5306 Bolts

5307 Studs

5310 Nuts and washers

5320 Rivets

Figure 7-18.—Examples of supply classes within a stockgroup.

The Navy uses groups 01 through 09 for forms andpublications that are not included in the FederalCatalog System. The forms and publications arenumbered according to the following system:

01 Navy Department forms

02-08 Publications

09 District and fleet forms

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NATIONAL STOCK NUMBER (NSN)

All items of supply that are centrally managed orbought for system stock are required to have a NationalStock Number (NSN) assigned to them. National StockNumbers are used in all supply management functionsand publications that mention the items. The NSN is a13-digit number assigned by Defense LogisticsInformation Service (DLIS) to identify an item ofmaterial in the supply distribution system. Thefollowing paragraph discusses the breakdown of anNSN. Figure 7-19 is an example of an NSN.

Federal Supply Classification (FSC)

The Federal Supply Classification (FSC) is afour-digit number that occupies the first part of anNSN. The Defense Logistics Agency CatalogingHandbook H2 (in book form) lists the groups andclasses in use today.

National Codification Bureau (NCB) Code

The National Codification Bureau (NCB) code is atwo-digit code that occupies the fifth and sixth positionof a NATO stock number. These code identities theNATO country that originally cataloged the item ofsupply. The NCB codes currently assigned are listed inAfloat Supply Procedures, NAVSUP P-485. The NSNassigned by United States uses NCB codes “00” and“01.”

National Item Identification Number (NIIN)

The National Item Identification Number (NIIN)consists of a two digit National Codification Bureau(NCB) code and seven digits which in conjunction withthe NCB code, uniquely identify each NSN item in thefederal supply distribution system. In the examplegiven in figure 3-2, the “00-1234567” is the NIIN.Although part of the NSN, NIINs are usedindependently for material identification. Except foridentification list, most federal supply catalogs arearranged in NIIN order.

In addition to the 13-digit NSN, the Navy usesother codes for material identification. These codesmay be prefixes or suffixes to the NSN. The followingparagraphs describe these codes.

Cognizant (COG) Symbol

The cognizant (COG) symbol consists of atwo-character code that identifies the stores accountand cognizant inventory manager of an item. Thecognizant symbols are listed in table 7-4. To understandcognizant symbols, you must understand the followingterms:

Stores Account: This is an account reflecting thevalue of material, supplies, and similar property onhand. The accounts are the Appropriation StoresAccount (APA) and the Navy Stock Account (NSA).

Appropriations Purchase Account (APA): Thisaccount is for all stock material paid for out ofappropriations. This material is not charged to theuser’s operating funds. If the material was ought for apurpose other than its original appropriation, thematerial is chargeable to the user’s fund.

Navy Stock Account (NSA): The NSA consists ofall material paid from the Defense Business OperatingFund (DBOF). NSA material is always charged to theuser’s allotment, operating budget, or operating targetfunds.

Inventory manager: This is an organizational unitor activity within the Department of Defense. Theinventory manager has the primary responsibility forcontrolling the functions of cataloging, identification,determination of requirements, procurement,inspection, storage, and distribution of categories ofmaterial.

Technical responsibility: This is the systemscommand or office that determines the technicalcharacteristics of equipment. For example, theelectronics equipment characteristics include itemssuch as circuitry and the types and arrangement ofcomponents.

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1710 00 1234567

Federal Supply ClassificationCode Number

National Codification BureauCode

National Item IdentificationNumber

Figure 7-19.—Example of an NSN.

Expense type item: This term identifies stock itemsthat are financed by the Defense Business OperatingFund, and is the same as NSA items.

Consumable: Consumable material is material thatis consumed in normal use. Some of the examples ofthese materials are paints, cleaning supplies, officesupplies, and common tools.

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COGSYMBOL

COGNIZANTINVENTORYMANAGER

STORESACCOUNT

TECHNICALRESPONSIBILITY

DEFINITION

0I Naval Publication andForms Directorate

None Navy Publication andPrinting Service

Publications

1I Naval Publication andForms Directorate

NSA Navy Publication andPrinting Service

Forms

1R Naval InventoryControl PointPhiladelphia(NAVICP PHIL)

NSA Naval Air SystemCommand

Aeronautical,photographic, andmeteorological 1material(consumable orexpense typematerial).


APA Naval Air SystemCommand

Catapult andarresting gearmaterial (repairableor investment typematerial).

4V Naval Air SystemCommand


Aircraft engines.

4Z Naval InventoryControl PointPhiladelphia(NAVICP PHIL)


Airbornearmament.



Catapult andarresting gearmaterial(consumable orexpense typematerial).



Aviation groundsupport equipment(repairable orinvestment typematerial.

6V Naval Air SystemCommand


Technical directivechange kits.



Depot-levelrepairable aviationmaterial.

Table 7-4.—Cognizance (COG) Symbols

Cognizance symbols are two-character,alphanumeric codes prefixed to national stocknumbers. Cognizance symbols are listed in Table 7-4.The first character of the cognizance symbol identifiesthe stores account. The following information refers tothe first character of the cognizance symbol:

• Cognizance symbols 0 (zero), 2A and 8A is notcarried in the stores account and is issuedwithout charge to the requisitioner.

• Even numbers 2, 4, 6, and 8 are carried in theAppropriation Stores Account (APA).

• Odd numbers 1, 3, 5, and 7 are carried in theNavy Stock Account (NSA).

• Number 9 is Navy-owned material carried inNSA and managed-by the Naval InventoryControl Point Mechanicsburg.

The second position of the cognizance symbolidentifies the item manager. The item managerexercises supply management over specified categoriesof material.

Material Control Codes

A Material Control Code (MCC) is a singlealphabetic character assigned by the inventorymanager. It is used to segregate items into manageablegroupings (fast, medium, or slow movers) or to relate tofield activities special reporting and control

requirements. Table 7-5 contains a list of MCCscommonly encountered.

NAVY ITEM CONTROL NUMBER (NICN)

As we have discussed in a previous paragraph,NSNs are required for all items centrally managed orbought for supply system stock. With changes ofequipment and products, the Navy buys new items fromthe suppliers. New items entering the Navy supplysystem are identified in time to permit assignment ofNSNs before shipment. In numerous instances, theNavy Item Control Number (NICN) is used to identifythe items before an NSN can be assigned. Some itemsare permanently identified by the NICN because of thenature of the items. The NICN designation includes thefollowing:

• Inventory Control Point ICP control numbers

• Kit numbers

• Publications and forms ordering numbers

• Local Navy Activity Control (NAC) numbers

• Other locally assigned numbers

The NICN is a 13-digit number that identifies anitem of supply. It is composed of the following parts:

• Federal Supply Classification (FSC) code(numbers that occupy the first four digits of theNICN)

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CODE DEFINITION

D Field level repairable.

E (1) Depot-level repairables.

(2) Material (expendable ordnance) requiring lot and serialnumber control, but is reported by serial number only.

H Depot-level repairables.

L Items of local stock or items pending NSN assignment.

M Medium demand velocity items (consumables).

S Slow demand velocity items.

T Terminal items.

W Ground support equipment.

X Special program repairables.

Z Special program consumables.

Table 7-5.—Material Control Codes

• Navy Item Control Number (NICN) code(letters that occupy the 5th and 6th position)

• Serial number (alphanumeric and occupies the7th through the 13th position)

The NIC numbers that you must be familiar withare listed in Table 7-6. These codes differentiate thetypes of NICN.

Permanent LL Coded NICNs

The NICNs with “LL” in the 5th and 6th positionsand a “C” in the 7th position mean that the ICPs or otherNavy item managers (including field activities)assigned them. Its purpose is to identify and monitornonstocked items that are not expected to have enoughdemand to qualify for NSN assignment. The NICNs areassigned to permit the maintenance of a complete anduniform inventory control point weapons system file. Itis also used to ensure that selected items are consideredfor inclusion in future allowance lists. Stock pointsmust purchase items identified by this type of NICN.Stock points currently do not have the capability totranslate permanent LL coded NICNs to applicableCAGES and part numbers. The items are requisitioned

by using the DD 1348-6 format (part numberrequisition).

Temporary LL Coded NICNs

The NICNs with “LL” in the 5th and 6th positionsand any letter except “C” in the 7th position areassigned by ICPs or other Navy inventory managers fortemporary identification. These NICNs enables theitem manager to establish and maintain automated filerecords, to ease procurement action, and to maximizeautomated processing of requisitions. The cognizantitem managers review the temporary NICNsperiodically to convert them to NSN or to delete theones that are no longer required. When a requisitionidentifies an item by a temporary NICN that has beenconverted to an NSN the status card will include thenew NSN. A NICN to NIIN cross-reference list ispublished monthly by the Defense LogisticsInformation Service (DLIS) on the FED LOGCD-ROM.

LOCAL ITEM CONTROL NUMBER (LICN)

The LICN (fig. 7-20) is an identification numberassigned by an activity for its own use. However,

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NIC NUMBERCODES

USED TO DESIGNATE

LD Directive ordering number (COG 0I).

Example:1234-LD-123-4567

LF Form ordering number (COG 1I).

Example:1234-LF-123-4567

LK Aircraft change kit number.

Example:1234-LK-123-4567

LP Publication ordering number (COG 0I and 0P).

Example:1234-LP-123-4567

LX Control number assigned by NAVICO PHIL field activities tocertain items under their inventory control.

Example:1234-LX-123-4567

Table 7-6.—Navy Item Control Codes

1710 LL 0000123

Appropriate Federal SupplyClassification Code Number

Designation for locally assignedidentification number

Serially assignedidentification number

Figure 7-20.—Example of an LICN.

LICNs are not authorized in supply transactiondocuments. LICNs are for local use only and may beassigned to shipboard stocked consumable items thatare not identified by and NSN or another type of NICN.A LICN consists of 13 characters. The first four will benumbers corresponding to the federal supplyclassification (FSC) of a similar NSN items, the fifthand sixth will be LL and the remaining seven alphanumeric.

SOURCES OF MATERIAL IDENTIFICATION

This chapter presents different sources ofinformation that is needed in performing technicalresearch. Material identification does not end with theassignment of the NSN. Some means of identifyingother particular needs by the stock number must beprovided to the customers. This includes the means ofdetermining the correct quantities of these items tocarry in stock. Identification of needs maybedetermined by using the lists described in the followingparagraphs.

FEDERAL LOGISTICS (FED LOG)

The FED LOG on Compact Disc Read-OnlyMemory (CD-ROM) (fig.7-21) is the access to DODlogistics data. The FED LOG includes the basicmanagement data necessary for preparing requisitionsand it includes an integrated historical record of deletedand superseded NIINs with appropriate codes toindicate disposition action.

PART NUMBER

The part number, also called reference number, isan identification number assigned to an item by themanufacture. It is made up of letters, numbers, orcombinations of both. When used with the CommercialAnd Government Entity (CAGE) code, it identifies theitem. It is used with other technical data (for example,model, series, and end-use application) to requisitionan item when an NSN is not assigned. Part number toNSN cross-reference is provided in FED-LOG.

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Figure 7-21.—Example of FED LOG query.

COMMERCIAL AND GOVERNMENT ENTITYCODE

The Commercial And Government Entity (CAGE)(fig. 7-22) Code is a five-digit, numeric identificationcode assigned to manufacturers which have previouslyor are currently producing items used by the FederalGovernment. The CAGE is used in conjunction withpart number, item number, symbol, or trade nameassigned by the manufacturer to his product. TheCAGE catalog handbook is published the DefenseLogistics Information Service (DLIS) on the FED LOGCD-ROM.

MANAGEMENT LIST-CONSOLIDATED (ML-C)

The Management-List Consolidated (ML-C) is aconsolidated, cumulative listing of National StockNumbers for all branches of the armed services. EachNSN is listed one time only. The integrated materialmanager and service or agency is listed separately. TheML-C is a tool used for determining management dataapplicable to items used or managed by other militaryactivities.

MASTER CROSS-REFERENCE LIST(MCRL)

The Master Cross-Reference List (MCRL) (fig.7-23) Part I, provides a cross-reference from areference number (manufacturer’s part number,drawing number, design control number, etc.) to itsassigned National Stock Numbers (NSN). The MCRL,Part II, provides a cross-reference from an NSN to areference number. The MCRL is published on the FEDLOG CD-ROM.

MASTER REPAIRABLE ITEM LIST(MRIL)

The Master Repairable Item List (MRIL) (fig. 7-24and 7-25) is a catalog of selected Navy-managed itemswhich, when are unserviceable and not locallyrepairable, are required to be turned in to a DesignatedOverhaul Point (DOP) for repair and return to systemstock. The MRIL is part of the FED LOG that isdistributed in compact disc format. The MRIL ispublished on the FED LOG CD-ROM and is made upof two parts as shown in figures 7-24 and 7-25.

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Figure 7-22.—Example of CAGE from FED LOG.

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Figure 7-23.—MCRL from FED LOG.

Figure 7-24.—MRIL Part I from FED LOG.

AFLOAT SHOPPING GUIDE

The Afloat Shopping Guide (ASG) (fig. 7-26) isdesigned to assist the fleet personnel in identifying theNSNs for items that are frequently requested by ships.It includes a detailed description of each item, and(when applicable) the stock number for substituteitems. The ASG is distributed in CD-ROM format andin printed form.

GENERAL SERVICES ADMINISTRATIONFEDERAL SUPPLY CATALOG

The General Services Administration (GSA)Federal Supply Catalog lists approximately 20,000 lineitems that are stocked in GSA supply distributionfacilities. The items listed in this catalog are assignedcognizance 9Q. The GSA supply catalog series servesas the major merchandising instrument of the FederalSupply Service (FSS) Stock Program. Since they areprepared for civilian agencies, the FED LOG must be

referred to for supply management data. The GSAsupply catalog series consists of the following:

The GSA Supply Catalog Guide containsconsolidated alphabetical and NSN indexes to all stockitems. These are items listed in the four commoditycatalogs and other items available through the FSSprogram. It provides detailed information concerningthe program and requisitioning procedures.

The GSA Supply Catalog (Tools) contains listingsof common and special use tools. It includesalphabetical and numerical indexes and a price list.

The GSA Supply Catalog (Office Products) lists awide variety of items for office use, including papersupplies, standard and optional forms, and many itemsof equipment. It includes alphabetical and numericalindexes and a price list.

The GSA Supply Catalog (Industrial Products)contains descriptive listings of a broad range of items,such as hardware, paints, adhesives, and cleaning

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Figure 7-25.—MRIL Part II from FED LOG.

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Figure 7-26.—Page from Afloat Shopping Guide.

equipment and supplies. It includes alphabetical andnumerical indexes and a price list.

The GSA Supply Catalog (Furniture) provides asingle source of information for all furniture itemsstocked by the FSS.

NAVY STOCK LIST OF PUBLICATIONS,FORMS, AND DIRECTIVES

The Navy Stock List of Publications, Forms, andDirectives, NAVSUP P-2002, contains requisitioningprocedures and sources of supply to assist in thedetermination of how and where material may beobtained.

HAZARDOUS MATERIAL INFORMATIONSYSTEM

The DOD Hazardous Material Information System(HMIS) provides information concerning the use,procurement, receipt, storage, and expenditure ofhazardous material. The NAVSUPSYSCOM maintainsand distributes the HMIS hazardous item list. This listincludes information concerning hazardousingredients, use of hazardous material, protectiveclothing, and emergency treatment.

ILLUSTRATED PARTS BREAKDOWN

An illustrated Parts Breakdown (IPB) is preparedby the manufacturer for each model aircraft, engine,accessory, electronic equipment, support equipment, orother equipment considered advisable by NAVAIR.The IPB is printed and issued by the authority ofNAVAIR. It is used as reference for identifying andordering replacement items. Each item of equipment islisted in assembly breakdown order, with theillustration placed as close as possible to its appropriatelisting. Some IPBs have a different format from others

The TABLE OF CONTENTS shows thebreakdown of publication into sections. It alsofurnishes an alphabetical listing of the variousassemblies and lists the page, work package, or figureswhere they are illustrated.

The GROUP ASSEMBLY PARTS LIST is themain text of the publication. It consists of series ofillustrations and parts list in which parts of the aircraftor equipment are shown in assembly breakdown order.The items in the illustration pages are identified byindex numbers. These index numbers match thenumbers listed in the parts list of the assemblybreakdown. The parts list is arranged in numerical

sequence by index number to make it easier to use. Theinformation in the parts list include index number, partnumber, description, units per assembly, Usable Oncode, and the Source, Maintenance, and Recoverability(SM&R) code. Each major assembly in the parts list isfollowed immediately by its component parts orsubassemblies. Component parts listed in thedescription column may be prefixed with a dot orindented to show their relationship. You should use thisinformation to identify and obtain the required materialin accordance with the SM&R code. The numericalindex of the IPB lists all parts in reference/part numbersequence. Each reference/part number iscross-referenced to the figure and index number or thework package where the item is listed in the text.

SOURCE, MAINTENANCE, ANDRECOVERABILITY CODES

The SM&R code consists of two-position sourcecode, two single-position maintenance codes,single-position recoverability code, and if applicable, asingle-position service option code. Table 7-7 breaksdown the SM&R code by position and defines thesource, maintenance level, and reparability level of thecomponent.

Source Code: The source code is a two-charactercode that occupies the first two positions of the SM&Rcode format. This code shows the manner of getting thematerial needed for maintenance, repair, or rework ofitems.

Maintenance Code: The maintenance codes areindicated in the third and fourth positions of the SM&Rcode. Levels of maintenance authorized to replace andrepair an assembly or part are given. The code shown inthe third position provides the lowest level ofmaintenance authorized to remove or replace theassembly or part. The fourth position indicates if theitem is to e repaired and identifies the lowestmaintenance level authorized to perform the repair.

Recoverability Code: The Recoverability Code isindicated in the fifth position, this code defines theapproved disposition of unserviceable items.

CASUALTY REPORTING (CASREP)

The casualty report (CASREP) us designed tosupport the Chief of Naval Operations (CNO) and fleetcommanders in the management of assigned forces.The effective use and support of Navy forces requiresan up-to-date, accurate operational status for each unit.An important part of operational status is casualty

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information. The CASREP system contains four typesof reports: Initial, Update, Correct, and Cancel. Thesereports are described in general in the followingparagraphs.

Initial Casualty Report (INITIAL)

An initial casrep identifies the status of the casualtyand any parts or assistance needed. Operational andstaff authorities use this information to set priorities forthe use of resources.

Update Casualty Report (UPDATE)

An update casrep is used to submit changes topreviously submitted information.

Correction Casualty Report (CORRECT)

A correct casrep is submitted when equipment thathas been the subject of casualty reporting is repairedand is back in operational condition.

Cancellation Casualty Report (CANCEL)

A cancel casrep is submitted when equipment thathas been the subject of casualty reporting is scheduledto be repaired during an overhaul or some otheravailability. Outstanding casualties that will not berepaired during such availability will not be canceledand will be subject to normal follow-up casualtyreporting procedures as specified.

REVIEW QUESTIONS

Q11. National Stock Numbers are made up of howmany digits?

Q12. What occupies the first part of a NationalStock Number?

Q13. What does the Cognizant Symbol identify?

Q14. The Afloat Shopping Guide is designed forwhat purpose?

Q15. List the different types of casualty reports.

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Table 7-7.—SM&R Code Format

ADMINISTRATION

LEARNING OBJECTIVE: Describe the useand maintenance of various logs and reportsused to record details of catapult and arrestinggear operations and maintenance

Record keeping in relation to launch and recoveryequipment is as important as the operation of themachinery or maintenance procedures. Because of themany 3-M maintenance requirements that must beadhered to and periodic reports that must be made, theimportant of accurate logs, reports, and records shouldbe emphasized.

CATAPULT WORK CENTER MAINTENANCELOG

The work center maintenance log (fig. 7-27) is themost important record kept on the catapult systems.Each catapult workcenter supervisor shall maintain aseparate maintenance log for each catapult. Sufficientpages in the front of the log should be reserved forentering data of a historical or permanent nature, whichwill provide a read reference when required. Dailyentries should be made listing all maintenanceperformed during a 24-hour period. This will provide acontinuous record of maintenance actions performed

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Figure 7-27.—Catapult maintenance log entries.

on each catapult. When a logbook is filled, thehistorical or permanent data shall be transferred into anew maintenance log and the completed log retainedfor a minimum of two years.

STEAM CATAPULT LOG

The steam catapult log (fig. 7-28) is maintainedduring all catapult operations by a catapult recorderstationed at the central charging panel (CCP) or maincontrol console (MCC).

ARRESTING GEAR WORK CENTERMAINTENANCE LOG

The work center maintenance log (fig. 7-29) is themost important record kept on the arresting gear

system. The arresting gear supervisor shall maintain aseparate maintenance log for each arresting engine.Sufficient pages in the front of the log should bereserved for entering data of a historical or permanentnature. Daily entries should be made listing allmaintenance performed during a 24-hour period. Whena log is filled, the historical or permanent data shall betransferred into a new maintenance log and thecompleted log retained for a minimum of two years.

RECOVERY LOG

The Recovery Log (fig. 7-30) is maintained duringall aircraft recovery operations by the Pri-fly controlpane operator to provide a uniform system of recordingpertinent arresting gear data.

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Figure 7-28.—Steam catapult log.

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Figure 7-29.—Arresting gear maintenance log entries.

Figure 7-30.—Recovery Log sheet (NAVAIR Form 13810/4).

WIRE ROPE HISTORY REPORT

The wire rope history chart (fig. 7-31) provides auniform system for recording arresting gear wire ropedata. Engine operators shall maintain this for eachspecific engine, with the last recovery number beingobtained from pri-fly. A new sheet shall be used at thebeginning of each month.

FLIGHT DECK OPERATIONS (NAVAIR FORM13810/1 AND 138/1A)

The flight operation report (fig. 7-32) and (fig. -33)is a two part form and is compiled from informationcontained in the catapult shot logs and the arrestinggear recovery logs.

ALRE AUTO SHOT RECOVERY LOGPROGRAM

The Auto shot and recovery log program provides acomputerized program for the collection anddissemination of launch and recovery log data. Theautomated program has been developed to record theShot Log, Recovery Log, and the Wire Rope History

Report on computer disc. These discs would then besent to NAWC Lakehurst vice the paper forms.

REVIEW QUESTIONS

Q16. The work center maintenance logs areretained for what minimum period of time?

SUMMARY

In this chapter, you learned that the PlannedMaintenance System is a means for accomplishingpreventive maintenance aboard ship. You also learnedthat PMS procedures for a specific piece of equipmentare based on good engineering practices, practicalexperience, and technical standards. You studied therole the Maintenance Data System has in planningworkloads and providing a database for evaluating andimproving equipment installed in the fleet. The supplyinformation in this chapter is not intended to make youan expert in supply matters. Rather, this section wasdeveloped to give you a basic understanding andprovide you with some of the information needed forordering supplies. You also studied the maintenancelogs and reports for recording the details of catapult andarresting gear operations and maintenance.

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Figure 7-31.—Recovery Wire Rope History chart (NAVAIR Form 13810/5).

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Figure 7-32.—Flight Deck Operations (Part I) (NAVAIR Form 13810/1).

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Figure 7-33.—Flight Deck Operations (Part II) (NAVAIR Form 13810/1A).

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