Planned Maintenance System

1
Planned Maintenance System
3M 103 PQS Fundamentals
References (a) NAVSEAINST 4790.8 (series)
(b) OPNAVINST 4790.4(series) (c) OPNAVINST
5100.19(series) (d) COMNAVSURFORINST 4790.1
(series) (e) MOMSENINST
4790.1 (series) (f) CINCLANT/CINCPACFLTINST
4790.3 (series) (g) NAVEDTRA 43241-H 3M
PQS (h) NAVSUP P-485
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3M is the nucleus for managing maintenance
onboard ships.
Purpose
Providing maintenance and material managers the
means to plan, acquire, organize, direct, control
and evaluate the manpower and resources used for
the support of maintenance.
103.1
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Information collected on completed maintenance
and configuration changes provides the following
benefits
a. Standardization - achieve uniform maintenance
standards and criteria.
b. Efficiency - effective use of available
manpower and material resources in maintenance
and maintenance support efforts.
c. Documentation - recording of maintenance and
maintenance support actions to establish a
material history.
d. Analysis - provision to be used in the
improvement of maintainability and reliability of
systems and equipment, and the reduction of cost
of material ownership.
e. Configuration Status Accounting - a means of
reporting and recording changes in what equipment
is installed onboard, equipment configuration
specifications, and shipboard location.
f. Scheduling - standardized method for
scheduling, planning, managing, and tracking
maintenance required and accomplished.
103.1
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Duties, Responsibilities and the 3M chain of
Command
103.2
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TYCOMResponsibilities
Exercise primary responsibility for the effective
operation and support of their Ships' 3-M
Systems.
103.2 a
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Maintains staff to administer the 3M
system Provides training teams for 3M assists
assessments Reviews quality/quantity of ships 3M
data (CASREPs, Technical Feedback Reports, MDS
documents, etc.) Provides 3M system training for
maintenance and/or maintenance management. Reviews
Safety Advisory Mishap and Material Inspection
reports (INSURV, Propulsion Examining Board
(PEB), etc.). When deficiencies are evident,
corrective action is initiated
103.2 a
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SHIPBOARD ORGANIZATIONDUTIES AND RESPONSIBILITIES
103.2
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CO - overall responsible for ensuring ship
maintenance is accomplished following 3-M System
procedures and that the 3-M System functions
effectively within the command.
XO - Ships' 3-M System manager and responsible to
CO for overall management of the Ships 3-M
program.
3-M System Coordinator (3MC) - functional manager
of 3-M System and responsible to the XO for
coordination and direct supervision of all
administrative facets of the Ships 3-M System
program.
103.2 b-d
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DEPARTMENT HEAD

• Responsible for effective operation of the 3-M
  System within the department. Supervises
  scheduling all Maintenance Requirements (MRs)
  and is responsible for all budgetary expenses to
  support the 3M systems.

103.2e
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DIVISION OFFICER

• Trained in the 3-M System and responsible to the
  Department Head.
• Assists in managing the maintenance required for
  the divisions equipment, and is responsible for
  documentation accuracy.
• Conducts and manages divisional 3M training.

103.2 f
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DEPARTMENTAL 3M

• Responsible to 3MC and Department Head for
  preparation and submission of all departmental 3M
  reports (spot-checks, PMS, Equipment Validations,
  etc.).
• Maintains the EGL master copies for each MRC in
  the Department.
• Assists Division Officers in achieving required
  3M Systems training.

103.2 g
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Group and Work Center Supervisors
Division CPOs who are responsible for two or
more work centers shall be referred to as Group
Supervisors" Group Supervisors shall be
responsible for the proper performance of the 3-M
System functions within their work centers.
The Work Center Supervisor is responsible for the
effective operation of the 3-M System within the
work center This responsibility shall not be
delegated Work Center Supervisors receive
additional 3-M System training
103.2h i
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REPAIR PARTS PETTY OFFICER

• RPPO Interfaces with Supply for ordering parts
  and supplies required for all associated
  workcenters.
• Conducts monthly Material Obligation Validations
  (MOVs) with the Department Head to validate the
  continued need for parts ordered.

103.2 j
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You the Maintenance Personnel

• Responsible to Work Center Supervisor (WCS). Your
  3-M duties include, but are not limited to
• a. Perform assigned sheduled maintenance
  requirements using MRCs and Equipment Guide
  Lists (EGLs) as indicated by the 13 week
  accomplishment log and the weekly schedule.

103.2k
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You the Maintenance Personnel

• b. Performing PMS, promptly notify the WCS when
• (1) Anything on an MRC is not fully understood,
  appears to be incorrect or cannot be accomplished
  as written.
• (2) Tools, materials, etc., prescribed by the MRC
  are not available.
• (3) Any doubt exists about capability, training,
  or experience to properly perform the MR as
  prescribed.
• (4) Factors exist which would make performance of
  the MR unwise or dangerous (e.g., disassembly of
  equipment needed for operations, radiation when
  prohibited, situations causing safety hazard to
  exist, etc.).

103.2k
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Corrective and PreventiveMaintenance
3-M is a management tool designed to provide
efficient, uniform methods of conducting and
recording preventive and corrective maintenance.
Preventive maintenance actions intended to
prevent or discover functional failures.
Preventive maintenance includes actions taken to
prevent equipment from failing, such as changing
the oil, cleaning filters, calibrating, etc.
Corrective maintenance actions taken to fix
equipment that has failed or is not working to
design specifications. Included in the phrase
"corrective maintenance" are authorized changes
or modifications to installed equipment.
103.3
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Purpose of the 3M elements
Maintenance Requirement Card (MRC) step-by-step
procedures with safety precautions noted
describing who, what, how, and with what
resources an MR will be accomplished.
Equipment Guide List (EGL) - used when an MRC
applies to a number of identical items (i.e.,
valves, small arms, etc.). Each item will be
uniquely identified. Each ship prepares its own
EGLs.
Maintenance Index Page (MIP) Index of MRCs
prepared and issued for each system/equipment
onboard for which PMS exists. MRCs, EGLs,
MIPs are basic PMS documents.
103.4 a-c
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3M ELEMENTS (cont)
List of Effective Pages (LOEP) - lists MIPs and
system equipment not requiring PMS assigned to
each work center.
Change Page Historical Listing of all
authorized changes made to the Work Center Manual
(43P1) citing specific references authorizing
each change.
The LOEP, Change Page, MIPs are key elements
of the 43P1
103.4 d-e
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FEEDBACK REPORTS (FBR)
FBR notifies TYCOM FTSCs of PMS issues. Two
versions SKED and Hardcopy TWO types
Category A (for changes to LEOP) Category B
(Technical) Some Category B FBRs are Urgent.
Must be approved and transmitted within 4 days
of creation with a response time goal of 1
day. NOTE FBRs will provide initial PMS
coverage but Configuration Data needs to be
updated to initiate logistic support. This is
also referred to as submitting a 4790/CK
Configuration Change
103.4 f
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WORKCENTER PMS MANUAL(43P1)
The 43P1 reflects that portion of the PMS Master
File that contains only the planned maintenance
requirements applicable that work center. It
consists of the following Major Elements Change
Page, LOEP, MIPs, FBR file It is designed to
provide a ready reference of planned maintenance
requirements for the work center supervisor and
all Maintenance personnel.
103.4 g
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PMS SCHEDULES
Weekly displays MRCs and personnel assigned to
them for the week in a given work center.
Maintenance Personnel have access to view this in
SKED.
Quarterly displays maintenance to be performed
during a specific 3-month period. Updated weekly
by WCS, provides ready reference to the current
status of PMS. Represents departmental directive
and once finalized may only be changed with
department head approval.
103.4 h-i
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PMS SCHEDULES QUARTERLY FLIP PAGE
Flip Page cites justifiable reasons for all
unaccomplished or deleted maintenance. NOTE Lack
of Man-hours is not justifiable. Examples of
justifiable reasons are part on order with
JSNs and REQ s CASREP with Numbers
HAZMAT unavailable WITH JSN and REQ The Flip
page entry always starts with one of four
pro-words LOST - RESCHEDULED - DELETED - or
COMPLETED (with additional information
required).
103.4 i
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PMS SCHEDULES CYCLE
Cycle displays PMS to be performed during the
period between docking availabilities and/or
three interdeployment training cycles. Any checks
that have not been accomplished prior to
restarting a cycle will be scheduled during the
first quarter of the new cycle schedule. An
example of such an availability is Docking Phased
Maintenance Availability (DPMA).
103.4j
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13 Week Accountability Log
Signature documentation of personal
accomplishment of assigned MRs after WCS
notification and authorization. Documents
associated Tag-outs and is reviewed weekly by the
WCS DivO Maintained in the 43P1 for not less
than 13 weeks.
103.4 k
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Isolation Guide List (IGL)
Contains the information necessary for equipment
tag-out maintenance. Regulated by the Tag Out
Users Manual (TUMS) Created when existing
technical documentation (EOSS, CSOSS, etc.) is
insufficient to support tag-outs Signature
Verified by WCS, DivO, and DH and re-verified
when any one transfers
103.4 l
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SPMIG SCAT
Standard PMS Material Identification Guide
(SPMIG) - Database providing part numbers and
ordering information for MRC materials in the
Test Equipment, Materials, Parts and Tools Block.
This data accessible in SKED
Sub-category (SCAT) - Portable Electric/Electronic
Test Equipment listed in the Test Equipment
Index are assigned a SCAT code which groups
models having the same test capability and
tolerances.
103.4 m-n
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SYSCOM MRC Control Number
This is a 3-part four segment code used in
cataloging MRCs which is located at the lower
right side of the MRC Birthdate first 2 digits
103.4 o
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SYSCOM MIP Control Number
Three SYSCOM MIP control numbering systems have
been developed based on changing PMS philosophy
and are currently in use. (Conventional, Surface
Missile System, and Reliability Centered
Maintenance) Birthdate last 2 digits.
103.4 p
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Inactive Equipment Maintenance (IEM)
A modified maintenance program to prevent
equipment deterioration during inactive periods,
when complete PMS support is neither desirable
nor practical.
Objective reduce PMS to the minimum during a
prolonged inactive period without degrading
material condition, or jeopardizing future
operational reliability.
103.4 q
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MSDS

Technical bulletins containing

Technical bulletins containing
information about the hazardous
information about the hazardous
material
Material (HAZMAT)

Shall be in English and contain at

Shall be in English and contain at
least the following information
least the following information

Identity of material

Identity of material

Hazardous ingredients

Hazardous ingredients

Physical and chemical characteristics

Physical and chemical characteristics
103.4 r
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MSDS (Cont)

Physical hazards (fire, explosion,

Physical hazards (fire, explosion,
reactivity)
reactivity)

Health hazards (routes of entry,

Health hazards (routes of entry,
exposure limits, and cancer potential)
exposure limits, and cancer potential)

Precautions for safe handling use

Precautions for safe handling use

Emergency first aid procedures

Emergency first aid procedures

MSDS preparation date

MSDS preparation date

Name, address phone number of

Name, address phone number of
chemical manufacturer, importer,
chemical manufacturer, importer,
employer who can provide additional
employer who can provide additional
information
information
103.4 r
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Hazardous Material Users Guide
(HMUG)
Divided into 22 groups
Each section contains information on
Control measures
Precautions
Health hazards
Spill controls
Disposal guidelines
103.4 s
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Unsafe condition in the performance of PMS
Accidents do not respect persons or rights.
Statistics show that a high percentage of
accidents or casualties could have been prevented
if specific precautionary measures had been taken.
Every effort has been made to indicate
hazards to personnel in the "Safety Precautions"
block and in the appropriate steps of the
procedure block of MRCs.
WARNINGS WILL BE INSERTED IMMEDIATELY PRIOR TO
THE APPROPRIATE PROCEDURAL STEP.
Common sense, thorough indoctrination, and
documented training of all personnel maintaining
and operating shipboard equipment is required.
Inadequacies in the MRC which might affect
the safety of personnel or equipment shall be
reported by an Urgent PMS FBR.
103.5
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Maintenance Requirement Card (MRC)
Provides detailed step-by-step procedures for
performing maintenance and describes who, what,
how, and with what resources a specific
requirements will be accomplished. 3 types
exist Technically Validated
(white)
Preliminary (Yellow)
Classified (Pink)
Most MRCs are Technically validated
103.6
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Preliminary (Yellow)
1. Provided via FTSCs to provide ships with
advance coverage while MIPs/MRCs are undergoing
final review.
2. Identified by a "P" code and number following
the slash of the SYSCOM MIP control number
reflecting the revision.
3. Preliminary MIPs/MRCs are technically
reviewed/approved by the cognizant SYSCOMs/BUMED.
103.6 b
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Classified (pink)
Unclassified locator card duplicates information
in all MRC blocks but procedures, and includes
one of the following statements
"Maintenance procedure with the requirement is
CONFIDENTIAL. Maintenance Requirement Card is
stowed in_________ . OR "Maintenance procedure
with the require-ment is SECRET. Maintenance
Requirement Card is stowed in __________________
."
103.6 c
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Periodicity codes
And the intervals of accomplishment
103.7
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Calendar Periodicities
The only authorized periodicities are as follows
103.7 a
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Non-Calendar Periodicities
R - Situation Requirement U - Unscheduled
Maintenance
Inactive Equipment Maintenance (IEM)
LU - Lay-Up PM - Periodic Maintenance SU -
Start-Up OT - Operational Test
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REPORTING DISCREPANCIES
No system starts perfect feedback can get it
there Three systems exist for process
improvement Feedback Reports (FBR) Technical
Manual Deficiency/Evaluation Report
(TMDER) Configuration Item or 4790/ck
Configuration Change
103.8
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Procedures for discrepancies/ deficiencies-Technic
al Feedback Reports (TFBR)
The PMS FBR or TFBR is used to notify Fleet
Technical Support Centers (FTSC) and/or the TYCOM
of matters related to PMS.
103.8
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FBR FORM

• Two versions SKED and Hardcopy
• SKED Instructions are available in the help
  file, with some specific Dos and Donts
• Hardcopy - composed of an original and four
  copies. Instructions for preparation and
  submission of the form are printed on the back of
  the last copy.

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There are three types of FBRs Category A,
Category B, and Urgent.
Category A -- This type of FBR is non-technical
in nature and is intended to meet PMS needs which
do not require technical review. Category A FBRs
are submitted to request classified or other PMS
documentation which cannot be obtained locally.
103.8
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Category B --
This type of FBR is technical in nature, and is
used to report
Technical discrepancies inhibiting PMS
performance.
Shift of maintenance responsibilities.
Requests for TYCOM assistance.
103.8
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URGENT Feedback Reports.
When the reason for submission of a PMS FBR
involves safety of personnel, ship, or equipment
and relates to the technical requirements of PMS,
the FBR will be considered URGENT.
The message shall describe the unsafe procedures
or conditions, and shall identify the MIP/MRC
involved.
103.8
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TMDER

• Used to correct Technical Manuals and
  Publications used in the maintenance of shipboard
  equipment.
• Accomplished either on-line via Distance Support
  or via Snail Mail using a form from the back of
  the Manual.

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CONFIGURATION

• Known as
• 4790/CK, Configuration Change, Configuration
  Items
• Used to get support for newly installed
  equipment. Will initiate all logistics
• PMS, Parts, Technical Documentation
• NOTE FBRs can be used to start and change PMS,
  but will do nothing for the other elements of
  logistic support.

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Definitions and Relationships of the following
MIP To MRC's
LOEP AND THE MIP
EGL's and MRC's
Change page to LOEP
TGL's and MRC's
103.9
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LOEPs And MIPs
Report No. PMS 5 (the LOEP) lists all MIPs and
system equipment not requiring PMS assigned to
each work center. The LOEP is a part of the PMS
Master file and contains
(1) Report Date (Date LOEP produced).
(2) Force Revision (FR) Number.
(3) Type Commander (TYCOM).
(4) Unit (Ship's hull number, Unit Identification
Code (UIC), and name).
(5) Work Center.
(6) MIP Numbers and Nomenclature (brief
description of the system/equipment).
103.9 a
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EGLs and MRCs
Specific EGLs are created for each MRC when it
applies to a number of identical items (i.e.
valves, small arms, etc.)
Each item on the EGL will have a unique
identifier/serial number assigned. Each ship
prepares its own EGLs.
103.9 b
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IGLs and MRCs
Contains specific equipment tag-out information
necessary for that MRC
Contains number, locations, and positions of the
tagged items and permission/notification
requirements
Each ship prepares its own TGLs
103.9 c
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MIPs and MRCs
MIPs are issued for each installed
system/equipment for which PMS support has been
established. MIPs are basic PMS reference
documents.
Each is an index of a complete set of MRCs
applicable to a ship system, subsystem, or
equipment.
103.9 d
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Change Page and LOEP
Change Page indicates all changes (FRs/CANs/DIT
s) to the WC referencing authorizing document.
(Force Revisions/Advance Change Notices/Document
Input Transmittals)
lists approved TFBRs submitted for LOEP
Corrections.
It must reflect the current FR
103.9 e
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SAFETY PRECAUTIONS
listed prior to applicable step on the
MRC Specific categories are
Warning Death or injury may result if the
operating/handling procedures and practices are
not correctly followed. Warning text may be
listed in the safety precautions block and will
be repeated preceding the procedure involved.
Caution Damage to equipment may result if the
operating procedures and practices, etc. are not
correctly followed. Cautions are not listed in
safety precautions block but will precede the
instruction for the procedure involved.
103.10
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This is the END of this lesson.