Chapter Objective: Upon completion of this chapter, you will have a working knowledge of procedures and equipment used for the Tool Control Program. You will have a basic knowledge of occupational awareness concepts, aircraft drawings, techniques for troubleshooting, aircraft lubrication requirements, aircraft weighing and balancing, aircraft hoisting and jacking, and fuel cell construction and repair.

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

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

The means by which tools can be rapidly inventoried and accounted for is accomplished by using silhouetted tool containers. All tools have individual silhouetted locations that highlight a missing tool. These containers are called "shadow boxes." A shadow (silhouette) of the tool identifies the place where the tool belongs. The TCP is based on the instant inventory concept and is accomplished, in part, through the use of shadow boxes. See figure 3-1. On containers where silhouetting is not feasible, a note with the inventory and a drawing of the container is included. Either system enables the work center supervisor or inspector to quickly ensure that all tools have been retrieved after a maintenance action.

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

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

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

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

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

4. That all equipment, in the work centers/tool control centers, requiring calibration is scheduled and cali- brated at the prescribed interval.

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

Figure 3-1.Typica1 silhouette toolbox.

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

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

8. That the departments tool control environment is maintained when work is to be performed by contractor maintenance teams or depot field teams. A QAR will brief field team/contractor supervisor/ leader(s) upon their arrival regarding the activitys TCP. Depot teams working in O- or I-level facilities will comply with the host activitys TCP.